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From Art-to-Part: Multidisciplinary Virtual Toolset for Laser Power-Bed Fusion Additive Manufacturing and Multi-Step Post Processing Certification

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Technical Report

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GE Global Research NISKAYUNA United States

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Powder-bed Fusion Additive Manufacturing processes PBFAM combine precision powder bed formation for materials deposition with high resolution micro-welding for direct materials consolidation. It enables on-demand bespoke manufacturing and radically disruptive supply chains. Structured methods to matureand certify PBFAM are in their infancy meaning that numerous process iterations are required to achieve the requisite form and fit tolerances, surface finish, and material integrity. Thermal distortion, feature dependent surface roughness, shrinkage, cracking, and porosity are known artifacts in the PBFAM process. While prior efforts have focused on optimizing the PBFAM process, this team took a holistic look at optimizing a substantial subset of the manufacturing process chain used to take a design from concept to the final part. This includes the analysis and optimization of part geometry and material state through PBFAM, heat treatments and bulk machining.

Subject Categories:

  • Manufacturing and Industrial Engineering and Control of Production Systems

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