Metal Additive Manufacturing Failure

ABSTRACT:

Metal Additive manufacturing is added layer by layer, and it is also challenging for some of the critical reasons such as Surface Roughness, Porosity, Residual Stress, Distortion and Microstructure on the surface. In this review paper, we have discussed about detail explanation of Metal Additive manufacturing and its different types of techniques. In all metal, their will be a common fatigue failure, due to its surface roughness, Residual stress, and Porosity which occurs on the surface of the material. To overcome this failure method, we are using the method called Metal Additive manufacturing, to reduce the failure process in metal. Now a day in all industries, they are using Metal Additive manufacturing to over come this failure

Using thermal energy, we use to join the two materials together. Additive manufacturing is a common technique for developing a rapid prototype of good dimensional accuracy and it also finishes quickly in time[10]. The metal additive manufacturing is widely classified into six types, they are: State of fusion, material feedstock, material distribution, Basic additive manufacturing principle, source of fusion, process category[7]. In Additive manufacturing techniques there are many mechanical component applications such as electronic, corrosion resistant protective coatings etc. In metal Additive manufacturing we use many process such as Electron Beam Melting(EBM), Laser beam melting(LBM), direct metal laser sintering(DMLS), the process of Laser beam melting is also called as Selective laser melting(SLM) [2-4-6]. The Wire and arc additive manufacturing(WAAM) process has good accuracy of surface quality and manufacturing cost is very low. The LENS (Laser engineered Net shaping) process widely using in additively manufactured process, which is used to manufacture stainless steel and Vanadium Carbide[11]. Almost all metal parts are manufactured by Laser powder bed fusion Additive manufacturing (LPBFAM)[1]. Manufacturing of the metals it will leads to crack initiation and distortion. When stress reaches maximum, cooling process is done by simplifying layer by layer at finite element analysis[6]. The

Surface roughness is identified on the surface of the material, it is one of the major disadvantage in Metal Additive Manufacturing[38]. Surface finishing is very challenging part in Additive Manufacturing process. The benefits of surface finish such as (i) Increasing in resistance to the bending stress fatigue, (ii) Increasing in Tensile strength, (iii) It will reduce in Turbulence of the material component. The result in surface finishing are completely removal of roughness and waviness on the material and removal of all supports such as internal and external component. One of the most important features in surface roughness is intricate fabricated components using Additive Manufacturing[6]. The Reduction and optimizing of surface roughness is belong to process conditions and input parameters. Selective laser Melting and Electron Beam Melting are the process used in Additive manufacturing technique to improve the surface quality of the material component[8]. In surface Roughness, achieving for meeting the specifications or improving the properties, by means of surface quality, geometric dimensional accuracy and mechanical properties of the materials. The common value of the surface roughness for SLM process is varying between 15(micrometre) to 40(micrometre). With the help of the Additive