Metal Additive Manufacturing Failure

Introduction Quenching is one of the most important heat treatment process to attain desirable properties, for example strength and hardness. Quenching means to rapidly cool a material. But this rapid cooling can cause some serious distortions in the material. In steels, the transformation phases and thermal gradients are the main causes of this distortion. It has become an industry objective to reduce this distortion caused by heat treatments.

The table below shows how the additives affect the mechanical properties. The number of additives are numerous and show the versatility of Poly (ether sulphone) to incorporate new materials in making composites. The different additives are added as per requirement of application. For example, addition of Graphene oxide to improve the thermal and mechanical properties. The mechanical properties effect is shown through the comparison of Poly (ether sulphone) with 30% Carbon fibre and with 40% Glass fibre.

Powder metallurgy is defined as the process of mixing of powder materials in some desired ratio, compacting the powder mixture to some higher pressures in a compaction die so that the bond formation would takes place followed by the sintering process at higher temperatures (nearly around melting temperatures) so as to achieve sufficient strength. The resulting parts are solid bodies of material with sufficient strength and density for use in diverse fields. Highly porous parts, precise high performance components and composite materials can be produced by P/M route. P/M offers compositional flexibility, minimized segregation and ability to produce graded microstructures with varying physical and mechanical properties. P/M also offers advantages

The heat of each electrical spark, estimated at around 15,000° to 21,000° Fahrenheit. This process has been widely used in aerospace, nuclear and automotive industries, to machine precise, complex and irregular shapes in various difficult-to-machine electrically conductive materials. Recently, WEDM process is also being used to machine a wide variety of miniature and micro-parts in metals, alloys, sintered materials, cemented carbides, ceramics and silicon. These characteristics makes WEDM a process which has remained as a competitive and economical machining option fulfilling the demanding machining requirements imposed by the short product development cycles and the growing cost

Hardening is carried out by quenching steel, which consists of cooling it rapidly from a temperature above the transformation temperature (A?). The quenching is necessary to suppress the normal breakdown of austenite into ferrite and cementite (pearlite), and to cause a partial decomposition at such a low temperature to produce the new phase called martensite. To achieve this, steel requires a critical cooling velocity, which is greatly reduced by the presence of alloying elements. In such case hardening of steel occurs with mild quenching. Martensite is a supersaturated metastable phase and has body centered tetragonal lattice (bct) instead of bcc.

To recognize the most straightforward course to grow high caliber in Al alloys from pieces of assembling businesses. 2. To evaluate the effect of machining parameters i.e. cutting speed, cutting angle and depth of cut on microstructure, mechanical and tribology properties. 3.

For example strain hardening, as the ductile material is deformed more and more its strength and its hardness increases because of the generation of more and more dislocations, so, in engineering applications, especially the ones which have safety concerns involved, ductile materials are the obvious choice. Safety and dependability are the main concern in a material design, but in order to attain these goals, there needs to be a thorough understanding of the fracture both brittle and ductile. Understanding fracture and failure of materials will lead the materials engineer to develop a safer and more dependable materials and