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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography
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Hybrid Additive and Subtractive Manufacturing Method Using Pulsed Arc Plasma.

Xiaoming Duan1, Ruirui Cui1, Haiou Yang2

  • 1Department of Mechanical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China.

Materials (Basel, Switzerland)
|July 14, 2023
PubMed
Summary
This summary is machine-generated.

A new hybrid additive and subtractive manufacturing (PAP-HASM) process integrates pulsed arc plasma wire arc additive manufacturing and dry electrical discharge machining milling. This method achieves excellent tensile properties and improved surface roughness in 316L stainless steel without detrimental effects from the recast layer.

Keywords:
316Lelectrical discharge machininghybrid additive and subtractive manufacturingstrengthsurface roughness

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Technology
  • Additive and Subtractive Manufacturing

Background:

  • Integrating additive and subtractive manufacturing processes is crucial for advanced component fabrication.
  • Pulsed arc plasma (PAP) offers a versatile thermal source for both additive and subtractive techniques.
  • Dry machining processes are desirable to eliminate working fluids and associated environmental concerns.

Purpose of the Study:

  • To develop and validate a novel hybrid additive and subtractive manufacturing (PAP-HASM) method.
  • To investigate the integration of pulsed arc plasma wire arc additive manufacturing (PAP-WAAM) and dry electrical discharge machining (EDM) milling.
  • To assess the impact of the recast layer from dry EDM milling on the mechanical properties and surface quality of fabricated components.

Main Methods:

  • Development of the PAP-HASM process by combining PAP-WAAM (additive) and dry EDM milling (subtractive).
  • Utilized a flexible pulsed arc plasma power supply and interchangeable tool electrodes for process switching.
  • Fabricated and tested 316L stainless steel specimens using the developed PAP-HASM method.

Main Results:

  • PAP-HASM specimens demonstrated excellent tensile properties, comparable to PAP-WAAM specimens (UTS: 539 ± 8 MPa, Elongation: 46 ± 4%).
  • The recast layer formed during dry EDM milling did not significantly degrade the mechanical properties of the 316L stainless steel components.
  • Components fabricated by PAP-HASM exhibited significantly improved surface roughness compared to those made solely by PAP-WAAM.

Conclusions:

  • The developed PAP-HASM process effectively integrates additive and subtractive manufacturing using pulsed arc plasma.
  • The hybrid method produces components with high tensile properties and superior surface finish.
  • PAP-HASM is a promising dry machining technique for fabricating high-performance components without adverse effects from the recast layer.