Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing
Hybrid manufacturing is often used to describe a combination of additive and subtractive processes in the same build envelope. In this research study, hybrid manufacturing of 18Ni-300 maraging steel was investigated using a Matsuura LUMEX Avance-25 system that integrates metal additive manufacturing...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-10-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/5/4/107 |
| _version_ | 1797503333420761088 |
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| author | Sheida Sarafan Priti Wanjara Javad Gholipour Fabrice Bernier Mahmoud Osman Fatih Sikan Marjan Molavi-Zarandi Josh Soost Mathieu Brochu |
| author_facet | Sheida Sarafan Priti Wanjara Javad Gholipour Fabrice Bernier Mahmoud Osman Fatih Sikan Marjan Molavi-Zarandi Josh Soost Mathieu Brochu |
| author_sort | Sheida Sarafan |
| collection | DOAJ |
| description | Hybrid manufacturing is often used to describe a combination of additive and subtractive processes in the same build envelope. In this research study, hybrid manufacturing of 18Ni-300 maraging steel was investigated using a Matsuura LUMEX Avance-25 system that integrates metal additive manufacturing using laser powder bed fusion (LPBF) processing with high-speed machining. A series of benchmarking coupons were additively printed at four different power levels (160 W, 240 W, 320 W, 380 W) and with the integration of sequential machining passes after every 10 deposited layers, as well as final finishing of selected surfaces. Using non-contact three-dimensional laser scanning, inspection of the final geometry of the 18Ni-300 maraging steel coupons against the computer-aided design (CAD) model indicated the good capability of the Matsuura LUMEX Avance-25 system for net-shape manufacturing. Linear and areal roughness measurements of the surfaces showed average Ra/Sa values of 8.02–14.64 µm for the as-printed walls versus 0.32–0.80 µm for the machined walls/faces. Using Archimedes and helium (He) gas pycnometry methods, the part density was measured to be lowest for coupons produced at 160 W (relative density of 93.3–98.5%) relative to those at high power levels of 240 W to 380 W (relative density of 99.0–99.8%). This finding agreed well with the results of the porosity size distribution determined through X-ray micro-computed tomography (µCT). Evaluation of the static tensile properties indicated that the coupons manufactured at the lowest power of 160 W were ~30% lower in strength, 24% lower in stiffness, and more than 80% lower in ductility relative to higher power conditions (240 W to 380 W) due to the lower density at 160 W. |
| first_indexed | 2024-03-10T03:49:06Z |
| format | Article |
| id | doaj.art-c72500221f044b5ebc8d43ebaecc26b4 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-10T03:49:06Z |
| publishDate | 2021-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-c72500221f044b5ebc8d43ebaecc26b42023-11-23T09:01:24ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942021-10-015410710.3390/jmmp5040107Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive ManufacturingSheida Sarafan0Priti Wanjara1Javad Gholipour2Fabrice Bernier3Mahmoud Osman4Fatih Sikan5Marjan Molavi-Zarandi6Josh Soost7Mathieu Brochu8National Research Council Canada, Montréal, QC H3T 1J4, CanadaNational Research Council Canada, Montréal, QC H3T 1J4, CanadaNational Research Council Canada, Montréal, QC H3T 1J4, CanadaNational Research Council Canada, Montréal, QC H3T 1J4, CanadaNational Research Council Canada, Montréal, QC H3T 1J4, CanadaNational Research Council Canada, Montréal, QC H3T 1J4, CanadaNational Research Council Canada, Montréal, QC H3T 1J4, CanadaMatsuura Machinery USA Inc., St. Paul, MN 55102, USADepartment of Mining and Materials Engineering, McGill University, Montréal, QC H3A 0C5, CanadaHybrid manufacturing is often used to describe a combination of additive and subtractive processes in the same build envelope. In this research study, hybrid manufacturing of 18Ni-300 maraging steel was investigated using a Matsuura LUMEX Avance-25 system that integrates metal additive manufacturing using laser powder bed fusion (LPBF) processing with high-speed machining. A series of benchmarking coupons were additively printed at four different power levels (160 W, 240 W, 320 W, 380 W) and with the integration of sequential machining passes after every 10 deposited layers, as well as final finishing of selected surfaces. Using non-contact three-dimensional laser scanning, inspection of the final geometry of the 18Ni-300 maraging steel coupons against the computer-aided design (CAD) model indicated the good capability of the Matsuura LUMEX Avance-25 system for net-shape manufacturing. Linear and areal roughness measurements of the surfaces showed average Ra/Sa values of 8.02–14.64 µm for the as-printed walls versus 0.32–0.80 µm for the machined walls/faces. Using Archimedes and helium (He) gas pycnometry methods, the part density was measured to be lowest for coupons produced at 160 W (relative density of 93.3–98.5%) relative to those at high power levels of 240 W to 380 W (relative density of 99.0–99.8%). This finding agreed well with the results of the porosity size distribution determined through X-ray micro-computed tomography (µCT). Evaluation of the static tensile properties indicated that the coupons manufactured at the lowest power of 160 W were ~30% lower in strength, 24% lower in stiffness, and more than 80% lower in ductility relative to higher power conditions (240 W to 380 W) due to the lower density at 160 W.https://www.mdpi.com/2504-4494/5/4/107hybrid manufacturinglaser powder bed fusionmaraging steeldensitysurface qualityX-ray micro-computed tomography |
| spellingShingle | Sheida Sarafan Priti Wanjara Javad Gholipour Fabrice Bernier Mahmoud Osman Fatih Sikan Marjan Molavi-Zarandi Josh Soost Mathieu Brochu Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing Journal of Manufacturing and Materials Processing hybrid manufacturing laser powder bed fusion maraging steel density surface quality X-ray micro-computed tomography |
| title | Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing |
| title_full | Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing |
| title_fullStr | Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing |
| title_full_unstemmed | Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing |
| title_short | Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing |
| title_sort | evaluation of maraging steel produced using hybrid additive subtractive manufacturing |
| topic | hybrid manufacturing laser powder bed fusion maraging steel density surface quality X-ray micro-computed tomography |
| url | https://www.mdpi.com/2504-4494/5/4/107 |
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