International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 10 Issue: 04 | Apr 2023
p-ISSN: 2395-0072
www.irjet.net
Metal Additive Manufacturing: Processes, Applications in Aerospace, and Anticipated Hurdles - A Comprehensive Review A.K. Madan1, Parth Singh2, Aman Mishra2, Naman Tanwar2 1Professor, Department of Mechanical Engineering, Delhi Technological University, India 2 Student, Department of Mechanical Engineering, Delhi Technological University, India
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Abstract - Additive manufacturing has emerged as a
One of the main advantages of metal LBM is its ability to produce complex geometries that are difficult or impossible to achieve with traditional manufacturing techniques. This process enables the creation of intricate designs with internal structures, such as lattices and honeycombs, that can improve the mechanical properties of the final component. Furthermore, metal LBM allows for the fabrication of custom components with minimal material waste, which makes it a more cost-effective and sustainable manufacturing process compared to traditional methods. However, metal LBM does have some limitations, such as the need for post-processing to achieve the desired surface finish and the relatively slow build time for larger components. Additionally, the quality of the final product can be affected by factors such as powder quality, laser power, and process parameters, which require careful monitoring and optimization to ensure consistent and high-quality parts.
game-changing technology in the manufacturing industry, particularly in the aerospace sector. Metal additive manufacturing, in particular, has garnered considerable attention due to its unique ability to produce complex geometries with high precision and accuracy. This review paper focuses to provide a comprehensive overview of the common metal additive manufacturing processes, their applications in the aerospace industry, and the challenges that lie ahead. The study begins with a brief introduction to metal additive manufacturing, followed by a detailed analysis of the most commonly used processes, such as laser bed melting, powder bed fusion, directed energy deposition, and binder jetting. Next, the paper explores the various aerospace applications of metal additive manufacturing, including engine components, structural parts, and tooling. Finally, the review concludes by discussing the current limitations and future challenges of metal additive manufacturing, such as the need for improved material properties, cost reduction, and standardisation. Overall, this paper provides valuable insights for researchers, practitioners, and policymakers interested in the potential of metal additive manufacturing in aerospace and beyond.
In summary, metal LBM is a powerful additive manufacturing technique that enables the production of complex geometries with improved mechanical properties. The ability to make custom components along with minimal waste makes it an attractive option for various industrial applications. Despite its limitations, metal LBM continues to be an area of active research and development, with ongoing efforts to improve the process efficiency, scalability, and reliability to expand its potential applications in various fields, including the aerospace, medical, and automotive industries.
Key Words: Additive Manufacturing, Ti-6Al-4V, EBM, LBM, Post Processing, Aerospace, Microstructure, etc.
1.INTRODUCTION Additive manufacturing methods: 1.1. Laser beam melting (LBM)Metal laser beam melting (LBM) is a widely used additive manufacturing technique that employs a high-power laser to selectively melt metal powder layers to create threedimensional (3D) components. The process typically involves the deposition of metal powder in thin layers onto a build platform, followed by the melting of the powder layer using a laser beam. The melted metal solidifies rapidly upon cooling to form a solid layer. The build platform is then lowered to allow for the deposition of the next layer of powder, which is selectively melted using the laser. This layer-by-layer process continues until the 3D component is complete.
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Fig 1: Schematics of LBM system.
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