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Metal powder bed fusion: an overview on processes, materials, and challenges

Metal powder bed fusion: an overview on processes, materials, and challenges

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Additive manufacturing (AM) is one of the key pillars of the fourth industrial revolution. AM technology is developing rapidly in the industry for manufacturing custom industry, functional or finished machined parts. Printed parts, either semifinished or finished, are widely used in the medical, automotive, and aerospace industries. AM technology has more competitive advantages than subtractive processes. The advantages include the capability of producing small and complex parts. Among the available AM technologies, powder bed fusion is promising for metal parts production. This chapter presents an overview of the four metal powder bed fusion processes, namely, direct metal laser sintering, selective laser sintering, selective laser melting, and electron beam melting. Metal materials commonly used and the key challenges of these processes are presented with the size of the global market.

Chapter Contents:

  • 10.1 Introduction
  • 10.2 Metal powder bed fusion process
  • 10.2.1 Direct metal laser sintering (DMLS) and selective laser sintering (SLS)
  • 10.2.2 Selective laser melting (SLM)
  • 10.2.3 Electron beam melting (EBM)
  • 10.3 Materials used in metal powder bed fusion processes
  • 10.3.1 Steel
  • 10.3.2 Titanium alloys
  • 10.3.3 Aluminum alloys
  • 10.3.4 Nickel-chromium alloys
  • 10.3.5 Cobalt-chromium alloys
  • 10.4 Key challenges
  • 10.5 Size of the global market and future trend
  • 10.6 Conclusion
  • References

Inspec keywords: laser sintering; aerospace industry; rapid prototyping (industrial); laser materials processing; production engineering computing; melting; powders; three-dimensional printing

Other keywords: direct metal laser sintering; additive manufacturing; selective laser sintering; selective laser melting; metal powder bed fusion processes; available AM technologies; automotive, aerospace industries; metal parts production; printed parts; fourth industrial revolution; key pillars; medical aerospace industries; functional parts; finished machined parts; custom industry; metal materials; subtractive processes; competitive advantages

Subjects: Production engineering computing; Powder techniques, compaction and sintering; Laser materials processing; Industrial applications of IT; Manufacturing systems; Design; Engineering materials; Production management; Inspection and quality control; Powder technology; Other manufacturing processes

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