Additive Manufacturing Technologies by Ian Gibson David Rosen & Brent Stucker

Author:Ian Gibson, David Rosen & Brent Stucker
Language: eng
Format: epub
Publisher: Springer New York, New York, NY

Defects strongly affect the strength of UAM parts. Process parameter optimization (including optimization of width settings) to maximize LWD and minimize Type-3 defects is the most effective means to increase bond strength. With optimized parameters, Type-1 and Type-3 defects are minimized and Type-2 defects do not occur.

Type-1 defects can be reduced by surface machining a small amount of metal (~10 μm, or the largest roughness observed at the upper-most deposited surface, as in Fig. 9.9) after depositing each layer. Post-process heat treatment can also be used to significantly reduce all types of defects.

The degradation of part mechanical properties due to Type-3 defects can be reduced by designed arrangement of successive layers. Successive layers in a UAM part can be arranged so that 50 % overlap across layers is obtained, as shown in Fig. 9.13. Although somewhat counter-intuitive, it has been shown that better tensile properties result from a 50 % overlap than when random foil arrangements are used.

Fig. 9.13Schematic illustrating (a) 50 % foil overlap and (b) random foil overlap in UAM

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