Lawrence Livermore National Laboratory (LLNL) recently launched a strategic initiative called "3D Printing Metal Innovation Accelerated Certification" (ACAMM) to improve metal 3D printing and promote its application in a wider range of industries. Plans to combine technologies such as physical modeling, data mining, and uncertainty analysis to optimize 3D printing components and accelerate the certification process, ultimately developing the full potential of 3D printing.
Four years ago, the professional consultancy Woehlers released an influential report that some metal 3D printed parts are comparable in strength to cast or forged parts, so this technology is expected to be the most conventional and important in the future. Strategic technology.
Xiaobian strongly agrees with this view. It is important to know that metal 3D printing technology is not what it used to be. It has grown rapidly and has become a qualified manufacturing technology from the original rapid prototyping tools. But at present, there are not many institutions or enterprises that adopt this technology. So what is the reason behind this?
According to LLNL researchers, this is primarily due to our lack of understanding of the basic principles of complex 3D printing techniques such as selective laser melting (SLM); secondly, the certification of 3D printed metal materials takes a long time. Therefore, ACAMM sets two main objectives: first, development process modeling, process optimization simulation and modeling capabilities; second, streamlining material certification procedures to provide near net shape metal for critical applications at significantly reduced cost Parts certification.
“If we want to put components into critical applications, they must meet quality standards. Our focus is on getting people to truly understand 3D printing technology scientifically, and to build confidence in the quality of 3D printed parts.†ACAMM director Wayne King said, “We want to speed up the certification and inspection process to make better use of the flexibility of metal 3D printing. Ideally, if the quality of the 3D printed parts of the factory the day before is factory-qualified, then the next day’s parts will also be qualified."
According to China's 3D printer network, King and his team have prepared a variety of physical models including powder particles and integral parts for the SLM process. With them, researchers can better understand how each of the possible factors (including laser power, print speed, beam size and shape) will affect different materials during metal 3D printing.
This information can be reversed for developing new materials, improving predictions of deformations and stresses that can cause print failures, improving the overall 3D printing process and optimizing finished metal parts—all with a small amount of inexpensive experimentation.
ACAMM powder model
"These models will help us get rid of our dependence on experience," King said. "What we want to achieve is 'just press the start button to achieve metal printing'. If successful, this will result in people using metal 3D printing. Tremendous influence"
Although some improved metal 3D printing processes and materials have appeared so far, for example, Northwestern University has developed a better-performing metal powder material that can achieve complex structures that have never been seen before, but in the eyes of LLNL, There is progress in improving the consistency and reliability of metal 3D printed components, and the industry and aerospace industries have the confidence to use them. The only viable way is their more scientific approach.
ACAMM has published the physical model mentioned above in the January issue of Applied Physics Reviews. In addition, this three-year study has also received financial support from the LLNL Laboratory Guided Research and Development (LDRD) program.
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