Metal Additive Manufacturing: A Review

J. Alcisto, A. Enriquez, H. Garcia, S. Hinkson, T. Steelman, E. Silverman, P. Valdovino, H. Gigerenzer, J. Foyos, J. Ogren, J. Dorey, K. Karg, T. McDonald, and O.S. Es-Said, Tensile Properties and Microstructures of Laser-Formed Ti-6Al-4V, JMEP, 2011, 20(2), p 203–212

D.L. Bourell, M.C. Leu, and D.W. Rosen, Ed., Roadmap for Additive Manufacturing, University of Texas at Austin, Austin TX, 2009

W.E. Frazier, “Digital Manufacturing of Metallic Components: Vision and Roadmap”, Solid Free Form Fabrication Proceedings, University of Texas at Austin, Austin TX, 2010, p 717–732

E. Herderick, Additive Manufacturing of Metals: A Review, Proceedings of MS&T’11, Additive Manufacturing of Metals, Columbus, OH, 2011

NIST, “Measurement Science Roadmap for Metal-Based Additive Manufacturing,” US Department of Commerce, National Institute of Standards and Technology, Prepared by Energetics Incorporated, May 2013

J. Scott, N. Gupta, C. Weber, S. Newsome, T. Wohlers, and T. Caffrey, Additive Manufacturing: Status and Opportunities, IDA, Science and Technology Policy Institute, Washington, DC, 2012

DoD SBIR/STTR Database ( https://www.dodsbir.net , Contracts N00014-12-C-0411, N00014-12-C-0221, N00014-13-C-0057, Nov 2013

S.M. Kelly and S.L. Kampe, Microstructural Evolution in Laser-Deposited Multilayer Ti-6Al-4V Builds: Part II. Thermal Modeling, Metall. Trans. A., 2004, 35A, p 1869–1879

F. Wang, S. Williams, P. Colegrove, and A.A. Antonysamy, Microstructure and Mechanical Properties of Wire and Arc Additive Manufactured Ti-6Al-4V, Metall. Trans. A., 2013, 44A, p 968–977

B. Zheng, Y. Zhou, J.E. Smugeresky, J.M. Schoenung, and E.J. Lavernia, Thermal Behavior and Microstructural Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part I. Numerical Calculations, Metall. Trans. A., 2013, 39A, p 2237–2245

T. Vilaro, C. Colin, and J.D. Bartout, As-fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting, Metall. Trans. A., 2011, 42A, p 3190–3199

B. Zheng, Y. Zhou, J.E. Smugeresky, J.M. Schoenung, and E.J. Lavernia, Thermal Behavior and Microstructure Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part II. Experimental Investigation and Discussion, Metall. Trans. A., 2008, 39A, p 2228

P.A. Kobryn and S.L. Semiatin, The Laser Additive Manufacturing of Ti-6Al-4V, JOM, 2011, 53, p 40–43

L.E. Murr, E. Martinez, S.M. Gaytan, D.A. Ramirez, B.I. Machado, P.W. Shindo, J.L. Martinez, F. Medina, J. Wooten, D. Ciscel, U. Ackelid, and R.B. Wicker, Microstructural Architecture, Microstructures, and Mechanical Properties of a Nickel-Base Superalloy Fabricated by Electron Beam Melting, Metall. Trans. A., 2011, 42A, p 3491–3508

S.G. Lambrakos and K.P. Cooper, An Algorithm for Inverse Modeling of Layer-by-Layer Deposition Processes, JMEP, 2009, 18(3), p 221–230

S.G. Lambrakos and K.P. Cooper, A General Algorithm for Inverse Modeling of Layer-by-Layer Deposition Processes, JMEP, 2010, 19(3), p 314–324

F. Wang, S. Williams, P. Colegrove, and A.A. Antonysamy, Microstructure and Mechanical Properties of Wire and Arc Additive Manufactured Ti-6Al-4V, Metall. Trans. A., 2013, 44A, p 968–977

AMS 4999 Specification, Titanium Alloy Laser Deposited Products 6Al-4V Annealed, SAE, Warrendale, PA 2002

S. Rengers, Electron Beam Melting [EBM] vs. Direct Metal Laser Sintering [DMLS], Presented at SAMPE Midwest Chapter, Direct Part Manufacturing Workshop, Wright State University, Nov 2012

M. Svensson, Ti6Al4V manufactured with Electron Beam Melting (EBM): Mechanical and Chemical Properties, Presented at Aeromat 2009, Dayton OH, Jun 2009

M.K.E. Ramosoeu, G. Booysen, T.N. Ngonda, and H.K. Chikwanda, Mechanical Properties of Direct Laser Sintered Ti-6Al-V4, MS&T’11, Columbus, OH, 2011

B. Baufeld, Mechanical Properties of INCONEL 718 Parts Manufactured by Shaped Metal Deposition (SMD), JMEP, 2012, 21(7), p 1416–1421

K.S. Chan, M. Koike, R.L. Mason, and T. Okabe, Fatigue Life of Titanium Alloys Fabricated by Additive Layer Manufacturing Techniques for Dental Implants, Metall. Trans. A., 2013, 44A, p 1010–1022

D. Greitemeir, K. Schmidtke, V. Holzinger, and C. D. Donne, Additive Layer Manufacturing of Ti-6Al-4V and Scalmalloyrp© Fatigue and Fracture, 27th ICAF Symposium, Jerusalem, June 2013

R. Martukanitz and T. Simpson, The Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D), Brief at the Technology Showcase, ARL Penn State, State College, PA Jan 2013

C. Charles, “Modeling microstructure evolution of weld deposited Ti-6Al-4V,” Ph.D. thesis, Lulea University of Technology, Lulea, Sweden, 2008

S.M. Kelly, “Thermal and Microstructure Modeling of Metal Deposition Processes with Application to Ti-6Al-4V,” Ph.D. thesis, Virginia Polytechnic Institute, VA, 2004

J. Beuth and N. Klingbeil, The Role of Process Variables in Laser-Based Direct Metal Solid Freeform Fabrication, JOM, 2001, 53, p 36–39

W.E. Frazier, D. Polakovics, and W. Koegel, Qualifying of Metallic Materials and Structures for Aerospace Applications, JOM, 2001, 53, p 16–18

Metallic Materials Properties Development and Standardization (MMPDS-02). FAA, Battelle Memorial Institute, Atlantic City, NJ, 2005

ASTM F2921-11, Standard Terminology for Additive Manufacturing-Coordinate Systems and Test Methodologies, ASTM International, West Conshohocken, PA, 2011

ASTM F2792-12a, Standard Terminology for Additive Manufacturing Technologies, ASTM International, West Conshohocken, PA, 2012

ASTM F2915-12, Standard Specification for Additive Manufacturing File Format (AFM) Version 1.1., ASTM International, West Conshohocken, PA, 2012

ASTM F2924-12, Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium with Powder Bed Fusion, ASTM International, West Conshohocken, PA, 2012

M. Maher, Open Manufacturing, Brief Presented at the SAMPE Direct Part Manufacturing Workshop, Dayton OH, 2012

T.H. Benson Tolle, and G.A. Shoeppner, Accelerating Materials Insertion by Evolving the DoD Materials Qualification-Transition Paradigm, AMMITAC Q., 2002, 6(1), p 3–6

M. Ruffo, C. Tuck, and R. Hague, Cost Estimation for Rapid Manufacturing: Laser Sintering Production for Low to Medium Volumes, J. Eng. Manuf. Proc. IMech E, 2006, 220B, p 1417–1427

A. Gunasekaran, Design of Activity-Based Costing in a Small Company: A Case Study, Comput. Ind. Eng., 1999, 37, p 413–416

T. Wen-Hsien, Activity-Based Costing Model for Joint Products, Proc. 18th International Conference on Computers and Industrial Engineering, Vol. 31(3/4), Computers Industrial Engineering, 1996, p. 725–729

A. Gunaesekaran, R. McNeil, and D. Singh, Activity Based Management in a Small Company: A Case Study, Prod. Plan. Control, 2000, 11(4), p 391–399

Materials KTN, Shaping Our National Competency in Additive Manufacturing, 27th ed., Additive Manufacturing Special Interest Group for the Technology Strategy Board, UK, 2012

M. Gnam, R. Plourde, and T. McDonald, “Laser Engineered Net Shaping (LENS),” Paper Presented at the National Center for Manufacturing Sciences, JTEG Business Meeting, 2000

S.M. Kelly, Cost Benefit Analysis of Direct Digital Manufacturing, Private Communications, ARL Penn State University, 2010

S. Phinazee, Efficiencies: Saving Time and Money with Electron Beam Free Form Fabrication, Fabricator, 2007, p 15–20

M.E. Kinsella, Additive Manufacturing of Superalloys for Aerospace Applications, WPAFB AFRL, Report Number AFRL-RX-WP-TP-2008-4318, Dayton OH 2008

C.A. Brice, S.D. Needler, and B.T. Rosenberger, Direct Manufacturing at Lockheed Martin Aeronautics Co., Paper Presented at AeroMat Conference, Seattle Washington, 2010

A. Drizo and J. Pegna, Environmental Impacts of Rapid Prototyping: An Overview of Research to Date, Rapid Prototyp. J., 2006, 12(2), p 64–71

W.R. Morrow, H. Qi, I. Kim, J. Mazumder, and S.J. Skerlos, Environmental Aspects of Laser-Based and Conventional Tool and Die Manufacturing, J. Clean. Prod., 2007, 15, p 932–943

Y. Luo, Z. Ji, M.C. Leu, and R. Caudill, Environmental Performance Analysis of Solid Freeform Fabrication Processes, IEEE 0-7803-5495-8/99, 1999

K. Kellens, E. Yasa, Renaldi, W. Dewulf, J.P. Kruth, and J.R. Duflou, Energy and Resource Efficiency of SLS/SLM Processes, Proceedings Twenty-Second Annual International Solid Freeform Fabrication Symposium, 2011

M. Goedkoop, R. Heijungs, M. Huijbregts, A. De Schryver, J. Struijs, and R. van Zelm, ReCiPe 2008 A Life Cycle Impact Assessment Method Which Comprises Harmonised Category Indicators at the Midpoint and the Endpoint Level, Ruimte en Milieu Ministerie van Volkshuisvesting, Ruimtelijke Ordening en Milieubeheer, http://www.mech.kuleuven.be/co2pe , 2013

R.R. Unocic and J.N. DuPont, Process Efficiency Measurements in the Laser Engineered Net Shaping Process, Metall. Trans. B, 2004, 35B, p 143–152

R. Sreenivasan and D. Bourell, Sustainability Study in Selective Laser Sinterin: An Energy Perspective, Conference Proceedings, University of Texas at Austin, Austin TX, 2009, p 257–265

ATKINS, Manufacturing a Low Carbon Footprint, Loughborough University Project No: N0012J, 2007