Multi-material Additive Manufacturing: Processing and Heterogeneous Materials Design: Recent Progress in Multi-Material AM
Sponsored by: TMS Additive Manufacturing Committee
Program Organizers: Hang Yu, Virginia Polytechnic Institute And State University; Steven Boles, Hong Kong Polytechnic University; Michael Gibson, Desktop Metal; Lonnie Love, Oak Ridge National Laboratory; Leon Prentice, SDI Ltd
Thursday 8:00 AM
November 5, 2020
Room: Virtual Meeting Room 5
Location: MS&T Virtual
8:00 AM Invited
Aluminum Powders for Additive Manufacturing: Yoshiki Hashizume1; 1TOYO Alunimium K.K.
As aluminum alloys are key materials for automotive, aerospace and other industries, attempts to build them by additive manufacturing (AM) are being done extensively. However, performances of aluminum alloys by AM are not satisfactory because of difficulty to get spherical powders, limited alloy selections and restriction of machines. Here we introduce recent developments of aluminum alloy powders for AM, which include those of spherical powders, aluminum alloys and powders for electron beam melting (EBM). Spherical aluminum alloy powders have given manufactured bodies with low porosity and high reliability. Developments of alloys for AM include a high strength Al-Mg-Sc alloy, Scalmalloy®, heat resistant alloys and alloys without strength loss by over aging of AM. Technologies for eliminating hot cracks in wrought aluminum alloys are also reviewed. Spherical powders with very low oxygen contents have realized additive manufacturing of aluminum alloys by EBM that has been thought to be difficult.
8:30 AM Invited
NEW PRESENTATION: 3D Printing of Multi-functional Structures with Multiple Materials: Eric MacDonald1; 1University of Texas El Paso
3D printing has been historically relegated to fabricating conceptual models and prototypes; however, increasingly, research is now focusing on fabricating functional end-use products. As patents for 3D printing expire, new low-cost desktop systems are being adopted more widely and this trend is leading to a diversity of new products, processes, and available materials. However, currently, the technology is generally confined to fabricating single material static structures. For additively manufactured products to be economically meaningful, additional functionalities are required to be incorporated in terms of electronic, electromechanical, electromagnetic, thermodynamic, biological, chemical and optical content. By interrupting the 3D printing and employing complementary manufacturing processes, additional functional content can be included in mass-customized structures. This presentation will review work in multi-process 3D printing for creating structures with consumer-anatomy-specific wearable electronics, electromechanical actuation, electromagnetics, propulsion, embedded sensors in soft tooling and even in metal and ceramic structures.
9:00 AM
Multimaterial Additive Manufacturing at Penn State’s CIMP-3D: Edward Reutzel1; Jayme Keist1; Frederick Lia1; Wesley Mitchell1; Allison Beese2; Zi-Kui Liu2; 1ARL Penn State / CIMP-3D; 2Penn State University
The potential to produce fully fused, metal components comprising multiple materials is widely recognized as one of the great untapped benefits that Directed Energy Deposition Additive Manufacturing may offer. The ability to vary alloy content within prescribed regions of a single, solid component promises potential to produce components that have locally tailored properties, for example: high strength bulk properties with locally enhanced corrosion protection; or continually varying coefficient of thermal expansion to reduce interfacial stress during temperature excursions. However, process parameters may need to be adjusted to ensure a robust deposition throughout the graded deposition, and alloy content may need to be controlled to minimize formation of undesirable phases that can lead to cracking. This presentation will discuss recent projects at Penn State’s CIMP-3D that have explored these issues in a variety of alloy systems.