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Solid-Based Additive Manufacturing Systems
Published in G.K. Awari, C.S. Thorat, Vishwjeet Ambade, D.P. Kothari, Additive Manufacturing and 3D Printing Technology, 2021
G.K. Awari, C.S. Thorat, Vishwjeet Ambade, D.P. Kothari
The advantage of this technology is the combination of different types of materials including aluminum and fiber optics. The disadvantage is that the process is limited to malleable metals that can be ultrasonically welded. The decision tree for this process is shown in Figure 4.11. Ultrasonic consolidation is a developing process for hybrid manufacturing and provides good capability for the combination of malleable materials and embedded electronics and fiber optics.
Additive manufacturing technology review From prototyping to production
Published in Adedeji B. Badiru, Vhance V. Valencia, David Liu, Additive Manufacturing Handbook, 2017
Larry Dosser, Kevin Hartke, Ron Jacobsen, Sarah Payne
Ultrasonic consolidation is a process that uses an ultrasonic welding process to build up a part a layer-by-layer. The process is combined with CNC machining to remove the unwanted material and generate the desired part shape. Solidica (www.solidica.com) is the inventor of ultrasonic consolidation and sells capital equipment to support the technology. A schematic of the process and a sample part is shown in Figure 24.33.
Topology optimization for metal additive manufacturing: current trends, challenges, and future outlook
Published in Virtual and Physical Prototyping, 2023
Osezua Ibhadode, Zhidong Zhang, Jeffrey Sixt, Ken M. Nsiempba, Joseph Orakwe, Alexander Martinez-Marchese, Osazee Ero, Shahriar Imani Shahabad, Ali Bonakdar, Ehsan Toyserkani
While Powder Bed Fusion (PBF), Direct Energy Deposition (DED), and Binder Jetting (BJ) form the most popular MAM technologies as pointed out by Toyserkani et al. (2021), in this study, most MAM technologies are first broadly classified as either powder-bed, directed energy deposition, or sheet lamination. MAM processes can also be identified or classified by their working mechanisms such as lasers, electron beams, optical systems, material delivery, etc. The classifications in Figure 1 are according to how the feedstock material is being consolidated. Within powder bed processes, Laser Fusion (LF) often called Laser Powder Bed Fusion (LPBF) and Electron Beam Melting (EBM) are popular fusion processes while Binder Jetting (BJ) is a unique metal powder bed process that requires a binder to consolidate powder particles to form a ‘green’ part which needs to be heat treated for binder removal and curing. For DED processes, feedstock materials are either powder-fed or wire-fed. While materials that are powder-fed cannot be consolidated by electron beams because vacuum conditions will be required, wire-fed materials can be worked upon by either lasers or electron beams. Direct Metal Deposition (DMD) and Electron Free-Form Fabrication (EF3) are popular laser and electron beam DED technologies respectively. In sheet lamination, thin sheets of metal are joined together in a solid-state manner usually by ultrasonic consolidation (Toyserkani et al. 2021). Sheet lamination can be beneficial because joining is done at much lower temperatures than the material’s melting temperature, consequently, the microstructure of the final part closely matches that of the parent material. However, there are limitations on compatible materials possible and design complexities.