Additive manufacturing of materials: Opportunities and challenges
Abstract
Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.
- Authors:
-
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- SABIC Americas (United States)
- Publication Date:
- Research Org.:
- Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)
- Sponsoring Org.:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- OSTI Identifier:
- 1286848
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- MRS Bulletin
- Additional Journal Information:
- Journal Volume: 40; Journal Issue: 12; Journal ID: ISSN 0883-7694
- Publisher:
- Materials Research Society
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; metal; crystallographic structure; neutron scattering; simulation; joining
Citation Formats
Babu, Sudarsanam Suresh, Love, Lonnie J., Dehoff, Ryan R., Peter, William H., Watkins, Thomas R., and Pannala, Sreekanth. Additive manufacturing of materials: Opportunities and challenges. United States: N. p., 2015.
Web. doi:10.1557/mrs.2015.234.
Babu, Sudarsanam Suresh, Love, Lonnie J., Dehoff, Ryan R., Peter, William H., Watkins, Thomas R., & Pannala, Sreekanth. Additive manufacturing of materials: Opportunities and challenges. United States. https://doi.org/10.1557/mrs.2015.234
Babu, Sudarsanam Suresh, Love, Lonnie J., Dehoff, Ryan R., Peter, William H., Watkins, Thomas R., and Pannala, Sreekanth. Sun .
"Additive manufacturing of materials: Opportunities and challenges". United States. https://doi.org/10.1557/mrs.2015.234. https://www.osti.gov/servlets/purl/1286848.
@article{osti_1286848,
title = {Additive manufacturing of materials: Opportunities and challenges},
author = {Babu, Sudarsanam Suresh and Love, Lonnie J. and Dehoff, Ryan R. and Peter, William H. and Watkins, Thomas R. and Pannala, Sreekanth},
abstractNote = {Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.},
doi = {10.1557/mrs.2015.234},
journal = {MRS Bulletin},
number = 12,
volume = 40,
place = {United States},
year = {Sun Nov 01 00:00:00 EDT 2015},
month = {Sun Nov 01 00:00:00 EDT 2015}
}
Web of Science
Works referenced in this record:
Correlation between solidification parameters and weld microstructures
journal, January 1989
- David, S. A.; Vitek, J. M.
- International Materials Reviews, Vol. 34, Issue 1
Thermomechanical Modeling of Additive Manufacturing Large Parts
journal, October 2014
- Denlinger, Erik R.; Irwin, Jeff; Michaleris, Pan
- Journal of Manufacturing Science and Engineering, Vol. 136, Issue 6
Development and Application of on-Line Weld Modelling Tool
journal, January 2009
- Zhang, W.; Yang, Y-P.
- Welding in the World, Vol. 53, Issue 1-2
Thermal effects on microstructural heterogeneity of Inconel 718 materials fabricated by electron beam melting
journal, July 2014
- Sames, William J.; Unocic, Kinga A.; Dehoff, Ryan R.
- Journal of Materials Research, Vol. 29, Issue 17
Spatial variation of melt pool geometry, peak temperature and solidification parameters during laser assisted additive manufacturing process
journal, November 2014
- Manvatkar, V.; De, A.; DebRoy, T.
- Materials Science and Technology, Vol. 31, Issue 8
Fatigue crack path prediction in UDIMET 720 nickel-based alloy single crystals
journal, January 2000
- Reed, P. A. S.; Sinclair, I.; Wu, X. D.
- Metallurgical and Materials Transactions A, Vol. 31, Issue 1
Three-Dimensional Printing: Rapid Tooling and Prototypes Directly from a CAD Model
journal, January 1990
- Sachs, E.; Cima, M.; Cornie, J.
- CIRP Annals, Vol. 39, Issue 1
Crystallographic texture engineering through novel melt strategies via electron beam melting: Inconel 718
journal, October 2014
- Dehoff, R. R.; Kirka, M. M.; List, F. A.
- Materials Science and Technology, Vol. 31, Issue 8
Joining of nickel base superalloy single crystals
journal, February 2004
- Babu, S. S.; David, S. A.; Park, J. W.
- Science and Technology of Welding and Joining, Vol. 9, Issue 1
Heat transfer and material flow during laser assisted multi-layer additive manufacturing
journal, September 2014
- Manvatkar, V.; De, A.; DebRoy, T.
- Journal of Applied Physics, Vol. 116, Issue 12
Overview of modelling and simulation of metal powder bed fusion process at Lawrence Livermore National Laboratory
journal, November 2014
- King, W.; Anderson, A. T.; Ferencz, R. M.
- Materials Science and Technology, Vol. 31, Issue 8
In situ quality control of the selective laser melting process using a high-speed, real-time melt pool monitoring system
journal, August 2014
- Clijsters, S.; Craeghs, T.; Buls, S.
- The International Journal of Advanced Manufacturing Technology, Vol. 75, Issue 5-8
Determination of Bulk Residual Stresses in Electron Beam Additive-Manufactured Aluminum
journal, June 2013
- Brice, Craig A.; Hofmeister, William H.
- Metallurgical and Materials Transactions A, Vol. 44, Issue 11
The effect of welding conditions on stray grain formation in single crystal welds – theoretical analysis
journal, January 2005
- Vitek, J. M.
- Acta Materialia, Vol. 53, Issue 1
Additive manufacturing: rapid prototyping comes of age
journal, June 2012
- Campbell, Ian; Bourell, David; Gibson, Ian
- Rapid Prototyping Journal, Vol. 18, Issue 4
Investigation of the benefits of plasma deposition for the additive layer manufacture of Ti–6Al–4V
journal, June 2012
- Martina, F.; Mehnen, J.; Williams, S. W.
- Journal of Materials Processing Technology, Vol. 212, Issue 6
Thermodynamic and kinetic models for describing microstructure evolution during joining of metals and alloys
journal, November 2009
- Babu, S. S.
- International Materials Reviews, Vol. 54, Issue 6
Microstructure and Mechanical Properties of Wire and Arc Additive Manufactured Ti-6Al-4V
journal, September 2012
- Wang, Fude; Williams, Stewart; Colegrove, Paul
- Metallurgical and Materials Transactions A, Vol. 44, Issue 2
Truchas – a multi-physics tool for casting simulation
journal, August 2009
- Korzekwa, D. A.
- International Journal of Cast Metals Research, Vol. 22, Issue 1-4
Transmission Bragg edge spectroscopy measurements at ORNL Spallation Neutron Source
journal, November 2010
- Tremsin, A. S.; McPhate, J. B.; Vallerga, J. V.
- Journal of Physics: Conference Series, Vol. 251
Study on threshold fatigue crack growth characteristics of electron beam welding in AISI 4130 steel
journal, July 1993
- Hwang, Jiun-Ren; Chang, Hsiu-Hung
- Engineering Fracture Mechanics, Vol. 45, Issue 4, p. 519-527
Additive manufactured Ti-6Al-4V using welding wire: comparison of laser and arc beam deposition and evaluation with respect to aerospace material specifications
journal, January 2010
- Brandl, E.; Baufeld, B.; Leyens, C.
- Physics Procedia, Vol. 5
Rationalization of Microstructure Heterogeneity in INCONEL 718 Builds Made by the Direct Laser Additive Manufacturing Process
journal, June 2014
- Tian, Yuan; McAllister, Donald; Colijn, Hendrik
- Metallurgical and Materials Transactions A, Vol. 45, Issue 10
A Review of Additive Manufacturing
journal, January 2012
- Wong, Kaufui V.; Hernandez, Aldo
- ISRN Mechanical Engineering, Vol. 2012
Single-crystal laser deposition of superalloys: processing–microstructure maps
journal, April 2001
- Gäumann, M.; Bezençon, C.; Canalis, P.
- Acta Materialia, Vol. 49, Issue 6
Metal Additive Manufacturing: A Review
journal, April 2014
- Frazier, William E.
- Journal of Materials Engineering and Performance, Vol. 23, Issue 6
Time-of-flight neutron imaging for spatially resolved strain investigations based on Bragg edge transmission at a reactor source
journal, July 2012
- Strobl, M.; Woracek, R.; Kardjilov, N.
- Nuclear Instruments and Methods in Physics Research Section A: Accelerators, Spectrometers, Detectors and Associated Equipment, Vol. 680
Modeling of grain refinement in aluminum and copper subjected to cutting
journal, August 2011
- Ding, Hongtao; Shen, Ninggang; Shin, Yung C.
- Computational Materials Science, Vol. 50, Issue 10
A Review on Process Monitoring and Control in Metal-Based Additive Manufacturing
journal, October 2014
- Tapia, Gustavo; Elwany, Alaa
- Journal of Manufacturing Science and Engineering, Vol. 136, Issue 6
Progress in Additive Manufacturing and Rapid Prototyping
journal, January 1998
- Kruth, J. -P.; Leu, M. C.; Nakagawa, T.
- CIRP Annals, Vol. 47, Issue 2
Comparison of Residual Stresses in Inconel 718 Simple Parts Made by Electron Beam Melting and Direct Laser Metal Sintering
journal, January 2015
- Sochalski-Kolbus, L. M.; Payzant, E. A.; Cornwell, P. A.
- Metallurgical and Materials Transactions A, Vol. 46, Issue 3
Fundamental consolidation mechanisms during selective beam melting of powders
journal, November 2013
- Körner, Carolin; Bauereiß, Andreas; Attar, Elham
- Modelling and Simulation in Materials Science and Engineering, Vol. 21, Issue 8
Sensing, modeling and control for laser-based additive manufacturing
journal, January 2003
- Hu, Dongming; Kovacevic, Radovan
- International Journal of Machine Tools and Manufacture, Vol. 43, Issue 1
Three-Dimensional Printing: The Physics and Implications of Additive Manufacturing
journal, January 1993
- Sachs, Emanuel; Cima, Michael; Cornie, James
- CIRP Annals - Manufacturing Technology, Vol. 42, Issue 1
A review of rapid prototyping technologies and systems
journal, April 1996
- Yan, Xue; Gu, P.
- Computer-Aided Design, Vol. 28, Issue 4
Consolidation phenomena in laser and powder-bed based layered manufacturing
journal, January 2007
- Kruth, J. -P.; Levy, G.; Klocke, F.
- CIRP Annals, Vol. 56, Issue 2
Reconstruction of axisymmetric strain distributions via neutron strain tomography
journal, January 2012
- Abbey, Brian; Zhang, Shu Yan; Vorster, Wim
- Nuclear Instruments and Methods in Physics Research Section B: Beam Interactions with Materials and Atoms, Vol. 270
Introduction to the Characterization of Residual Stress by Neutron Diffraction
book, January 2005
- Hutchings, M. T.; Withers, P. J.; Holden, T. M.
Investigation of the austenite-bainite transformation in gray iron using real time neutron transmission
journal, November 1994
- Meggers, Kay; Priesmeyer, Hans G.; Trela, Walter J.
- Materials Science and Engineering: A, Vol. 188, Issue 1-2
In situ velocity measurements of very high power ultrasonic additive manufacturing using a photonic Doppler velocimeter
journal, December 2013
- Foster, D. R.; Taber, G. A.; Babu, S. S.
- Science and Technology of Welding and Joining, Vol. 19, Issue 2
Speed and accuracy evaluation of additive manufacturing machines
journal, January 2011
- Brajlih, Tomaz; Valentan, Bogdan; Balic, Joze
- Rapid Prototyping Journal, Vol. 17, Issue 1
Works referencing / citing this record:
A Subtractive Photoresist Platform for Micro- and Macroscopic 3D Printed Structures
journal, May 2018
- Zieger, Markus M.; Müller, Patrick; Blasco, Eva
- Advanced Functional Materials, Vol. 28, Issue 29
The Influence of Annealing Temperature and Time on the Formation of δ-Phase in Additively-Manufactured Inconel 625
journal, May 2018
- Stoudt, M. R.; Lass, E. A.; Ng, D. S.
- Metallurgical and Materials Transactions A, Vol. 49, Issue 7
Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification
journal, June 2018
- Babu, S. S.; Raghavan, N.; Raplee, J.
- Metallurgical and Materials Transactions A, Vol. 49, Issue 9
Overview of Materials Qualification Needs for Metal Additive Manufacturing
journal, January 2016
- Seifi, Mohsen; Salem, Ayman; Beuth, Jack
- JOM, Vol. 68, Issue 3
Alloy design for aircraft engines
journal, July 2016
- Pollock, Tresa M.
- Nature Materials, Vol. 15, Issue 8
Correlation of Microstructure and Mechanical Properties of Metal Big Area Additive Manufacturing
journal, February 2019
- Shassere, Benjamin; Nycz, Andrzej; Noakes, Mark
- Applied Sciences, Vol. 9, Issue 4