Material incorporation in powder sheet additive manufacturing toward lightweight designs for future mobility

Author:

Zhang Wenyou1ORCID,Pullini Daniele2ORCID,Alberghini Matteo3ORCID,Bertinetti Andrea3ORCID,Tommasi Alessio3ORCID,Coban Asli4ORCID,McConnell Seán5ORCID,Naesstroem Himani6ORCID,Babu Ramesh Padamati4ORCID,Volpp Joerg6ORCID,Lupoi Rocco1

Affiliation:

1. Department of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin 1 , Dublin D02PN60, Ireland

2. Centro Ricerche Fiat Scpa 2 , Strada Torino 50, 10043 Orbassano, Italy

3. Gemmate Technologies Srl 3 , via Reano 31, 10090 Buttigliera Alta, Italy

4. School of Chemistry, CRANN, & AMBER, Trinity College Dublin, The University of Dublin 4 , Dublin D02PN60, Ireland

5. 3CPT 5 , Dublin A92R2T6, Ireland

6. Department of Engineering Sciences and Mathematics, Luleå University of Technology 6 , 97187 Luleå, Sweden

Abstract

Additive manufacturing of AlSi10Mg has obtained increased attention due to its lightweight feature. However, handling of loose powder, efficient usage of feedstock, and powder recycling still remain major open challenges. Herein, a novel additive manufacturing method based on metal additive manufacturing using powder sheet (MAPS) is proposed, which leverages composite flexible films made of the feedstock of metal powder and a polymeric binder, aiming to extend the range of applicability of AlSi10Mg-based additive manufacturing technologies, for example, vehicle components. In situ high-speed imaging is used to explore the underlying manufacturing mechanisms of the proposed MAPS concept and investigate the laser–powder sheet interaction. In addition, a representative computational thermo-mechanical model was used to evaluate the substrate deformation due to the printing process, a critical aspect that must be minimized in order to transfer this technology to larger scale applications.

Funder

EIT RawMaterials

Science Foundation Ireland

Publisher

Laser Institute of America

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