A review of computational modeling in powder-based additive manufacturing for metallic part qualification
ISSN: 1355-2546
Article publication date: 23 October 2018
Issue publication date: 14 November 2018
Abstract
Purpose
Additive manufacturing (AM) is revolutionizing the manufacturing industry due to several advantages and capabilities, including use of rapid prototyping, fabrication of complex geometries, reduction of product development cycles and minimization of material waste. As metal AM becomes increasingly popular for aerospace and defense original equipment manufacturers (OEMs), a major barrier that remains is rapid qualification of components. Several potential defects (such as porosity, residual stress and microstructural inhomogeneity) occur during layer-by-layer processing. Current methods to qualify AM parts heavily rely on experimental testing, which is economically inefficient and technically insufficient to comprehensively evaluate components. Approaches for high fidelity qualification of AM parts are necessary.
Design/methodology/approach
This review summarizes the existing powder-based fusion computational models and their feasibility in AM processes through discrete aspects, including process and microstructure modeling.
Findings
Current progresses and challenges in high fidelity modeling of AM processes are presented.
Originality/value
Potential opportunities are discussed toward high-level assurance of AM component quality through a comprehensive computational tool.
Keywords
Acknowledgements
This work was partially supported by Department of Energy Award No. DE-SC0013223. Authors would like to express their appreciation to Department of Energy for its support.
Citation
Liu, J., Jalalahmadi, B., Guo, Y.B., Sealy, M.P. and Bolander, N. (2018), "A review of computational modeling in powder-based additive manufacturing for metallic part qualification", Rapid Prototyping Journal, Vol. 24 No. 8, pp. 1245-1264. https://doi.org/10.1108/RPJ-04-2017-0058
Publisher
:Emerald Publishing Limited
Copyright © 2018, Emerald Publishing Limited