Light-weight structures are in massive demand in automotive, biomedical implants, and aerospace industries. Usually, these industries use components with complicated shapes and manufacturing difficulties. The challenges can be addressed with the implementation of metal additive manufacturing (AM) processes like laser powder bed fusion (LPBF) and direct energy deposition (DED). To manufacture lightweight components, the outer shell should be fully solid and semisolid within, due to which manufacturing of these types of components becomes even more complicated. Infill patterns may be utilized to reduce the material usage to manufacture a lightweight metal component. However, existing metal AM processes entrap powder inside the cavity, which makes the components bulky and overweight. However, these components can be easily manufactured using extrusion-based metal AM, which does not involve loose powder while printing components. Current work discusses AM of lightweight components using extrusion-based metal AM using Gyroid and Concentric infills with 20% infill. The AM components’ tensile, flexural behavior and microstructural characterization were studied using the universal testing machine and scanning electron microscope.

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Manufacturing of Lightweight Metallic Components Using Extrusion-Based Metal Additive Manufacturing

  • Naveen Kumar Bankapalli,
  • Prateek Saxena

摘要

Light-weight structures are in massive demand in automotive, biomedical implants, and aerospace industries. Usually, these industries use components with complicated shapes and manufacturing difficulties. The challenges can be addressed with the implementation of metal additive manufacturing (AM) processes like laser powder bed fusion (LPBF) and direct energy deposition (DED). To manufacture lightweight components, the outer shell should be fully solid and semisolid within, due to which manufacturing of these types of components becomes even more complicated. Infill patterns may be utilized to reduce the material usage to manufacture a lightweight metal component. However, existing metal AM processes entrap powder inside the cavity, which makes the components bulky and overweight. However, these components can be easily manufactured using extrusion-based metal AM, which does not involve loose powder while printing components. Current work discusses AM of lightweight components using extrusion-based metal AM using Gyroid and Concentric infills with 20% infill. The AM components’ tensile, flexural behavior and microstructural characterization were studied using the universal testing machine and scanning electron microscope.