Preprint Article Version 3 NOT YET PEER-REVIEWED

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Version 1 : Received: 27 March 2017 / Approved: 27 March 2017 / Online: 27 March 2017 (12:13:38 CEST)
Version 2 : Received: 29 March 2017 / Approved: 30 March 2017 / Online: 30 March 2017 (04:04:47 CEST)
Version 3 : Received: 4 April 2017 / Approved: 4 April 2017 / Online: 4 April 2017 (07:56:07 CEST)

A peer-reviewed article of this Preprint also exists.

Patterson, A.E.; Messimer, S.L.; Farrington, P.A. Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need. Technologies 2017, 5, 15. Patterson, A.E.; Messimer, S.L.; Farrington, P.A. Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need. Technologies 2017, 5, 15.

Journal reference: Technologies 2017, 5, 15
DOI: 10.3390/technologies5020015

Abstract

A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

Subject Areas

additive manufacturing; 3-D printing; metal additive manufacturing; selective laser melting; SLM; direct metal laser sintering; DMLS; metal powder processing

Readers' Comments and Ratings (2)

Comment 1
Received: 4 April 2017
Commenter: Albert E Patterson (Click to see Publons profile: )
Commenter's Affiliation: University of Illinois at Urbana-Champaign
The commenter has declared there is no conflict of interests.
Comment: Version 3 updates:

1. Elsevier journal "Materials & Design" title corrected from originally-stated "Materials and Design" (References 21, 23, 37, 51, 59, and 84 updated)

2. Error in study title of Reference 108 corrected

3. Two additional references added (109 & 116) highlighting two additional studies in heat treatment and shot-peening for residual stress management

4. Improvements made to in-text description of Figure 3

Thanks to Dr. Bandar AlMangour (one of the authors cited in this study) from Department of Materials Science and Engineering at University of California - Los Angeles (UCLA) for the detailed informal review and comments provided on the paper.

- Albert E. Patterson (Author 1)
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Comment 2
Received: 12 April 2017
Commenter: Albert E Patterson (Click to see Publons profile: )
Commenter's Affiliation: University of Illinois at Urbana-Champaign
The commenter has declared there is no conflict of interests.
Comment: This paper has been published in Technologies (ISSN: 2227-7080) in Special Issue: Additive Manufacturing Technologies and Applications. Official link will be posted soon.

10.3390/technologies5020015
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