Additive Manufacturing Post Processing Techniques
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Additive Manufacturing Post Processing Techniques

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Questions and Answers

What is the primary purpose of electroplating?

  • To prevent corrosion (correct)
  • To improve thermal resistance
  • To enhance electrical conductivity
  • To provide a decorative finish

    • Which process shares similarities with anodizing?

  • Welding
  • Electroplating (correct)
  • Painting
  • Casting

    • What is a potential outcome of using laser polishing on metallic components?

  • Decreased thermal conductivity
  • Increased brittleness
  • Surface integrity enhancement (correct)
  • Formation of surface oxidation

    • Why is post-processing important in manufacturing?

    <p>It helps achieve a final product with fewer defects</p> Signup and view all the answers

    Which of the following is NOT considered a major post-processing technique to remove defects?

    <p>Anodizing</p> Signup and view all the answers

    What defect is commonly associated with metal additive manufacturing?

    <p>Porosity</p> Signup and view all the answers

    What is one of the solutions for addressing defects in metal additive manufacturing?

    <p>Reducing layer height during printing</p> Signup and view all the answers

    Which statement best describes laser polishing?

    <p>A process that enhances surface smoothness</p> Signup and view all the answers

    What is the primary focus of in-out and out-in scanning strategies in powder bed-based AM methods?

    <p>Enhancing material properties</p> Signup and view all the answers

    Which particle properties directly influence flowability in additive manufacturing?

    <p>Sphericity and surface roughness</p> Signup and view all the answers

    How does decreasing particle size affect electrostatic interactions in powder systems?

    <p>It reduces flowability</p> Signup and view all the answers

    What characteristics contribute to better flow in a powder system?

    <p>Spherical particles with a smooth surface</p> Signup and view all the answers

    What is a consequence of using coarser particles with uniform sizes in a powder bed?

    <p>Increased porosity</p> Signup and view all the answers

    What particle size range is preferred for powder bed-based systems?

    <p>100 &lt; µm</p> Signup and view all the answers

    What does an increase in blade energy during powder flow testing indicate?

    <p>More cohesive powder</p> Signup and view all the answers

    Which factor is crucial for ensuring good layer density in powder systems?

    <p>Ideal particle shape and size distribution</p> Signup and view all the answers

    What determines the maximum layer thickness in a melt pool?

    <p>Distance between the surface and the lowest point of overlap</p> Signup and view all the answers

    Which factors influence the choice of layer thickness for the BJ process?

    <p>Droplet nozzle spacing and binder viscosity</p> Signup and view all the answers

    How does build chamber temperature affect printed components?

    <p>It affects the microstructure and mechanical characteristics.</p> Signup and view all the answers

    What is a consequence of having low powder bed temperature and high power?

    <p>Concentration of residual stress leading to distortion</p> Signup and view all the answers

    What effect might increasing the powder bed temperature have?

    <p>It can cause geometrical integrity issues due to fusing.</p> Signup and view all the answers

    Which of the following is crucial for monitoring ambient characteristics during metal processing?

    <p>Build chamber temperature and shield gas system</p> Signup and view all the answers

    What happens to printed components with a high powder bed temperature gradient?

    <p>It can initiate and accelerate crack formation.</p> Signup and view all the answers

    What equipment is essential for in-situ monitoring of the powder bed temperature profile?

    <p>Infrared cameras and thermo-couple embedded build beds</p> Signup and view all the answers

    What can cause the instability of the melt pool in additive manufacturing?

    <p>Excessive energy input</p> Signup and view all the answers

    How do trapped gas pores primarily form during the additive manufacturing process?

    <p>Inter gas and material evaporation</p> Signup and view all the answers

    What is the significance of optimizing parameters in additive manufacturing?

    <p>To maximize density by reducing porosities</p> Signup and view all the answers

    What relationship describes the microhardness of AM-processed alloys?

    <p>Hall-Petch relationship</p> Signup and view all the answers

    How does the thermal history of layers in AM affect their hardness?

    <p>Inconsistencies arise due to heating and cooling rates</p> Signup and view all the answers

    What happens to micro-hardness in multilayer deposited steels during the additive manufacturing process?

    <p>It drops and then rises</p> Signup and view all the answers

    Which factor primarily influences the hardness of AM-processed ferrous alloys?

    <p>Alloying components and carbon effect</p> Signup and view all the answers

    What is a consequence of the liquid melt’s time-dependent cooling rate in AM?

    <p>Inconsistent hardness variation between layers</p> Signup and view all the answers

    What is the primary function of support structures in additive manufacturing?

    <p>To dissipate heat and facilitate cooling</p> Signup and view all the answers

    Which of the following describes the importance of density in additive manufacturing?

    <p>Density below 99.5% can impact cracking and mechanical properties.</p> Signup and view all the answers

    What affects the density of AM parts during production?

    <p>Energy volume given to the material</p> Signup and view all the answers

    Which type of support structure is characterized by a high density?

    <p>Solid supports</p> Signup and view all the answers

    What is one of the common defects found in AM printed alloys?

    <p>Porosity</p> Signup and view all the answers

    How do support structures in Powder Bed Fusion (PBF) processes contribute to print quality?

    <p>They aid in heat conduction to minimize residual stress.</p> Signup and view all the answers

    What parameter is crucial for optimizing the mechanical properties of AM printed parts, especially for critical applications?

    <p>Energy flux provided during printing</p> Signup and view all the answers

    What effect does insufficient energy flux have on additive manufacturing?

    <p>Formation of unmelted material and voids</p> Signup and view all the answers

    Study Notes

    AM Processing

    • Printing defects can be reduced through post processing
    • Common post processing techniques:
      • Electropolishing
      • Anodizing
      • Laser polishing
    • Post processing is important for removing defects from metal printed parts and improving their surface finish
    • Defects in metal printed parts can be caused by many factors:
      • Poor powder flow
      • Incorrect laser settings
      • Improper build chamber temperature
    • Scanning patterns in AM:
      • In-out scanning
      • Out-in scanning
      • Spiral scanning
    • Powder bed-based AM methods use powdered materials for printing
    • Powder properties affect print quality:
      • Particle size distribution
      • Sphericity
      • Surface roughness
    • Cohesive powder reduces flowability
    • Powder flowability affects print quality
    • Particle size range should be large enough for smaller particles to fill gaps between coarser particles and improve layer density
    • Particle size range should not be too wide, as this can limit flowability
    • Powder bed-based systems prefer a particle size smaller than 100 µm
    • Build chamber temperature significantly affects printed parts
    • Temperature, in conjunction with beam power, affect melt pool size and type
    • High powder bed temperature gradient can cause crack formation
    • Sensors like infrared cameras and thermocouples are necessary for in-situ monitoring of the powder bed temperature profile
    • Supporting structures are necessary in some AM processes for providing thermal stability and preventing part distortion
    • Density and dispersion of supporting structures significantly affect print quality
    • Several AM processes exist, each with unique process parameters that affect print quality

    Mechanical Properties of AM Printed Parts

    • Density above 99.5% is a priority for AM-made parts in critical applications
    • AM-made parts now have mechanical properties comparable to conventionally made parts
    • Porosity affects cracking and mechanical properties
    • AM product density depends on the energy volume given to the material
    • Insufficient energy flux can cause unmelted material, resulting in irregular voids that reduce density
    • Excessive energy input may cause melt pool dynamic instability, which may lead to a keyhole mode that decreases density due to trapped gas pores
    • Optimizing parameters to maximize density by reducing porosities is crucial to improving part quality
    • Optimizing parameters to maximize density by reducing porosities is done because pore size and distribution affect mechanical properties
    • Hardness is a measure of a material's resistance to indentation
    • The microhardness of AM-processed alloys follows the Hall-Petch relationship
    • The microstructure coarsens with a larger cross-sectional area causing the hardness to drop
    • The thermal history of each layer affects its hardness
    • Using different process parameters for the cross-sectional area may improve hardness heterogeneity
    • The development of hardness in AM-processed ferrous alloys is influenced by process input parameters
    • In multilayer deposited steels, microhardness drops from the initially deposited layers and then increases
    • This inconsistency is due to the liquid melt's time-dependent cooling rate and the middle area's slow solidification rate
    • Top and bottom AM parts have higher hardness than the middle
    • In low alloy steels, such as 41XX series steels, alloying components and carbon effect phase formation and hardness
    • Tensile strength and static strength refers to a material's ability to withstand tensile stress without failing
    • Fatigue behavior refers to a material's ability to withstand repeated loading cycles without failing
    • Common defects in AM printed parts include porosity, cracking, and surface roughness
    • These defects can significantly affect the mechanical properties of AM printed parts

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    Description

    This quiz explores various post processing techniques used in additive manufacturing to reduce printing defects. Learn about common methods like electropolishing and anodizing, the impact of powder properties on print quality, and the importance of scanning patterns. It is essential for improving the surface finish of metal printed parts.

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