This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

FEASIBILITY ANALYSIS OF UTILIZING MARAGING STEEL IN A WIRE ARC ADDITIVE PROCESS FOR HIGH-STRENGTH TOOLING APPLICATIONS

Christopher Masuo*, Andrzej Nycz*, Mark W. Noakes*, Derek Vaughan*, and Niyanth Sridharan*

*Manufacturing Demonstration Facility, Oak Ridge National Laboratory, Knoxville, TN 37932,USA

Abstract

Traditional tool and die development require skilled labor, long lead time, and is highly expensive to produce. Metal Big Area Additive Manufacturing (mBAAM) is a wire-arc additive process that utilizes a metal inert gas (MIG) welding robot to print large-scale parts layer-by-layer. By using mBAAM, tooling can be manufactured rapidly with low costs. For cold work tooling applications, a high hardness level is desired to increase the life-time of the tool. A promising material that can achieve this is maraging steel. Maraging steel is known to have good weldability; however, further testing must be conducted to ensure it is feasible for printing using mBAAM. In this paper, initial process parameters were obtained by printing single bead welds. Multi-bead walls were then printed with some refinement of process parameters to construct homogenous outer features of the walls. Lastly, the walls were heat-treated, and hardness data was gathered through Rockwell Hardness tests.

Introduction

Metal Big Area Additive Manufacturing (mBAAM) utilizes a robotic welding arm to print metal layer-by-layer, similar to Fused Filament Fabrication (FFF). Unlike traditional robotic welding, welded beads are used to form complex geometry. In mBAAM, medium- to large-scale metal objects are additively produced using a Direct Energy Deposition (DED) process. Large-scale additive systems are considered to have a print envelope of one to two meters on its longest axis [1]. The challenges that arise when printing in large-scale are uneven layer height error accumulation and warp distortion caused by heat. This relies on a closed-loop control [2] that tracks the height of the layer in real-time to ensure the printed part is near-net shape. The mBAAM system developed by Wolf Robotics and Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) is a gas metal arc welding (GMAW) robotic system that incorporates this closed-loop control feature and has successfully printed metal parts used for tooling and other industrial applications (e.g., excavator stick, propeller). This system is also equipped with two welding torches for multi-material metal printing. Currently, metals used for printing with this system are mild steel and 410 stainless steel. This means that tools and dies printed with the mBAAM system comprised of these metals.

When developing high performance tooling for metal forming, a high hardness level is necessary for the tool to maintain long production cycles. This is important in cold work tooling applications as the materials for forming can be particularly hard, which leads to deforming and wearing of the tool [3]. When dealing with steel sheet metal, a Hardness Rockwell C (HRC) above 50 is the minimum preferred hardness. This introduces some difficulties when using mild steel and stainless steel, as they have an HRC below 50. For printed mild steel, Shassere et al.

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determined that mild steel has an HVN of 170 [4], which is below the value of HRC. Printed 410 stainless steel has an HRC of 41; however, it is at least 10 values below the recommended hardness. The advantage of mBAAM is that these tools and dies can be printed in a matter of days. These parts can be quickly replaced; however, they would have to undergo post-process machining to get the proper surface finishes and tolerances required. Increasing the tool-life of these parts would decrease the need to produce these tools and dies, thus effectively decreasing cost.

When considering an HRC above 50, machining becomes a concern, as high hardness would result in wearing out the machine tool quickly. In contemplation of this situation, the material should have the characteristics of a soft metal for machining but have the capability of post-process hardening. Due to the process used in the mBAAM system, materials used for printing should have weldable characteristics while in the form of a filler wire. For this reason, the material selected to achieve these characteristics is maraging steel.

Maraging steel is known as a high-strength steel, having a tensile strength ranging from 1000 MPa to 3000 MPa [5]. It also has a hardness value of HRC 52-54 [6]. These properties occur when heat treating the metal to 480-500°C for 4 to 12 hours [6, 7]. Prior to heat treatment, maraging steel is rather ductile and soft allowing it to be easily machined. These characteristics make this material highly applicable for tooling purposes. Other applications of maraging steel are seen in the aerospace industry [7], as it is used for landing gears and rocket motor cases. Maraging steel also comes in different grades of filler wire. MAR 250 filler wire was selected as the material used in this paper.

The objective of this paper is to determine if MAR 250 can be used for mBAAM and maintain a similar hardness level seen in pure maraging steel. The methodology used to analyze this material began with observing the weldability of MAR 250 and developing process parameters that were used to test its printability. After printing samples, they underwent a Vickers Hardness test to obtain the HRC of this material. Results were shown for weldability, printability, and hardness, and the paper concluded with future experiments and applications.

Methodology

A. WeldabilityThe purpose of testing weldability is to understand the characteristics of a welded bead

made of MAR 250. In addition to finding the characteristics of the bead, initial welding parameters were developed and used as a baseline for the printability test. The welder equipped in the mBAAM system was an R500 Lincoln electric welder. This welder consisted of hundreds of weld modes that changed the welding waveform. For welding parameters, Lincoln Electric’s Power Mode Waveform was used for its ability to use any metal and gas type [8]. In Power Mode, welding power and pinch current can be controlled. For all waveforms, wire feed speed and welding speed (i.e., travel speed of the robot) are necessary variables for welding parameter development.

In this experiment, 203.2 mm long weld beads were printed on a 203.2mm x 609.6mm x 6.35mm (l x w x t) low-carbon steel plate shown in Figure 1. Wire feed speed and pinch current were held constant. Weld speed, power, and shielding gas were variables that were changed throughout the experiment. The beads were grouped by the welding speed used. The shielding gases used were Ar-CO2 and Trimix (90% He-7.5% Ar-2.5% CO2).

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Figure 1. Welded bead test setup

B. PrintabilityThis test consisted of printing one- and two-bead thick walls. The reason for printing

walls was for simplicity and their correlation to the geometry seen in a complex part. Figure 2 shows the comparison between a wall and a more complex part in terms of print path. Walls are considered a perimeter and inset feature seen in complex parts, and thus are beneficial for the conduction of these experiments.

Figure 2. Print path of a wall and a stamping tool

In the printability test, surface finish and geometric conformity were the main characteristics that were observed. Parameters that affect these characteristics are bead spacing and welding parameters (e.g., weld mode, wire feed speed, weld speed). Walls were printed with the same bead spacing of 3.0mm and a constant wire feed speed of 95.25mm/sec. Weld speed and weld mode were changed for every wall printed.

C. Hardness TestVickers hardness tests were conducted on a two-bead thick wall printed in MAR 250.

The wall was cut into sections and were hardness tested in three locations, as shown in Figure 3. Hardness was measured from sections with different heat treatment temperatures including one section without heat treatment. The temperatures ranged from 420 C to 1115 C. For 420 C to 520 C, isothermal temperatures were kept for three hours. For 815 C to 1115 C, the temperatures were kept for one hour and were then dropped to 420 C for three hours.

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Results

Regarding the weldability test, there were no apparent issues welding with MAR 250 using the Power Mode Waveform. A wire feed speed of 95.25mm/sec was used, and a power of 3.3 kW was used. 2.5 kW was originally used for the power; however, this produced a colder weld with minimal wetting. Visible ripples in the weld and non-uniform melting of the metal droplets occurred as well. In Figure 4, it was observed that using Trimix gas improved the surface quality of the welded beads, which was caused by the additional heat added to the system. Since Trimix mainly consisted of Helium gas, it has a higher thermal conductivity than Ar-CO2 gas mixture. Different welding speeds were used, and improvements were seen using a faster weld speed of 16 in/min (6.77 mm/sec) compared to using 10 in/min (4.23 mm/sec).

Figure 4. Single bead welds of MAR 250 with different welding speeds and shielding gas mixtures

Using the welding parameters obtained from the weldability test, a single bead wall was printed. This resulted in a large and rough surface finish. Figure 5 shows the printed one-bead thick wall. The sides of the wall have large uneven lumps. This feature in a single bead would not be suitable when printing multi-bead thick parts. This will lead to uneven melting causing

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visible voids in the printed part. Uneven melting of the layers would occur due to the actual geometry of the bead. Since the bead itself has uneven geometry, when the beads overlap each other, the bead-to-bead spacing (Figure 6) would differentiate throughout the build. Less spacing would cause significant overbuilding throughout the layers, and more spacing would create pockets between the beads.

Figure 5. Single bead wall printed in MAR 250

Figure 6. Bead-to-bead spacing representation

Two-bead thick walls were printed to investigate on possible defects that could occur from these geometric instabilities observed in the one-bead thick wall experiment. The first set of walls (Figure 7) were printed with the welding waveform, Power Mode. It was determined that using a welding power of 1.7kW and increasing the travel speed improved the shape of the walls. Travel speed ranged from 16 in/min (6.77 mm/sec) to 30 in/min (12.7 mm/sec). Originally, 3.3 kW of power was used; however, this increased the surface roughness. The high power added excessive amounts of heat to the wall, thus causing molten metal to droop randomly during the print. In Figure 7c, the printed wall with a travel speed of 30 in/min (12.7 mm/sec) visibly has

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the least surface roughness. Although there were improvements, the printed walls still encountered uneven surface geometry.

Figure 7. Two-bead thick walls printed with Power Mode. a.) front view of the walls, b.) side view of the walls, c.) wall with

fastest travel speed used for this set.

A second set of two-bead thick walls (Figure 8) were printed with the welding waveform, surface tension transfer (STT). In STT, current automatically adjusts the heat without depending on the wire feed speed [9]. This minimizes the heat added to the weld, which is ideal for this material. In addition to minimizing heat, STT has more variables to control such as peak current, background current, and tail-out speed. This allows finer tuning of the welding parameters. The outcome of these walls was significantly better in surface roughness. It was evident by visual observation and was confirmed by software developed in MDF. This software (Figure 9) uses scan data to interpret surface roughness by cross-sectioning the point-cloud of a wall and analyzing each side of it. The surface roughness average data is shown in Table 1. Based on the results in Table 1, walls printed with STT have about a 30% lower surface roughness average compared to walls printed with Power Mode. The walls printed with STT had higher consistent bead geometry with less waviness at the top surface of each wall. There was no significant difference in wall surface roughness when increasing the weld speed from 24 in/min (10.16 mm/sec) to 30 in/min (12.7 mm/sec).

Figure 8. Two-bead thick walls printed with STT

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Figure 9. In-house software to find surface roughness average from point-cloud data

Table 1. Roughness averages of the two-bead thick walls printed with Power Mode and STT

In Figure 10, hardness values are shown for each heat treatment temperature used. As expected from maraging steel, the HRC values for no heat treatment were below 32. For heat treatment temperatures ranging from 420 C to 520 C, hardness was higher near the bottom of the wall. However, for 815 C and 1115 C, hardness was at its highest in the center of the wall. This was most likely caused by the weld dilution caused by welding on the base plate for the bottom portion. This area would be less pure in maraging steel as it has mixed some composition with the base plate. In the top layers of the wall, hardness was at its lowest. This was also seen in mild steel [4], which was caused by the less refined microstructures seen in this region.

Figure 10. Hardness values taken from three locations of a two-bead thick wall as well as different heat treatment temperatures

Cross Sections Right Ra (mm) Left Ra (mm) Right Ra (mm) Left Ra (mm)1 0.279 0.383 0.303 0.2132 0.401 0.319 0.252 0.2663 0.381 0.419 0.202 0.1984 0.312 0.344 0.189 0.2585 0.309 0.319 0.222 0.346

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Conclusion

Maraging steel shows promise in providing the desired hardness of an HRC above 50. By

using MAR 250 welding wire, weldability was tested and shown to be weldable. Different shielding gases were tested with Trimix gas producing the best results. Using the starting welding parameters from the weldability test, walls were printed to observe how the material bonds together. Results show that one-bead and two-bead thick walls were successfully printed; however, the geometric features of the walls were rough, with large waviness. Using another welding mode, STT, surface roughness of the beads improved with more homogenous layers.

Overall, process parameters for MAR 250 will need further adjustments to produce similar results shown in printing mild and stainless steel. On the other hand, its printability success makes it a feasible material for mBAAM. MAR 250 did result in a slightly lower hardness than the desired 50 HRC; however, it is significantly better compared to mild and stainless steel. Future tests will be conducted with MAR 350 welding wire to observe if the hardness has increased with the higher strength material. Ultimately, maraging steel will be used for multi-material prints (Figure 11) to develop high strength tools and dies with low costs. This can be achieved by printing an outer perimeter of maraging steel and an inner core of mild steel.

Figure 11. Multi-material stamping tool with an outer surface of stainless steel and an inner core of mild steel

Acknowledgements

This material is based upon work supported by the U.S. Department of Energy, Office of

Science, Office of Energy Efficiency & Renewable Energy, Advanced Manufacturing Office, under contract number DE-AC05-00OR22725. The authors would like to thank Lincoln Electric and Wolf Robotics for collaborating with us in development and providing the Wolf wire-arc system.

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References 1. Nycz, A., Adediran, A. I., Noakes, M. W., & Love, L. J. (2016). Large-Scale Metal Additive

Techniques Review. In Solid Freeform Fabrication 2016: Proceedings of the 27th AnnualInternational Solid Freeform Fabrication Symposium - An Additive ManufacturingConference. Retrieved from http://sffsymposium.engr.utexas.edu/sites/default/files/2016/161-Nycz.pdf

2. Nycz, A., Noakes, M. W., Richardson, B., Messing, A., Post, B., Paul, J., . . . Love, L. J. (2017).Challenges in Making Complex Metal Large-scale Parts for Additive Manufacturing: A CaseStudy Based on the Additive Manufacturing Excavator. In Solid Freeform Fabrication 2017:Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium – AnAdditive Manufacturing Conference. Retrieved fromhttp://sffsymposium.engr.utexas.edu/sites/default/files/2017/Manuscripts/ChallengesinMakingComplexMetalLargeScalePar.pdf

3. Tooling solutions for advanced high strength steels. Tooling solutions for advanced highstrength steels. Retrieved from https://www.uddeholm.com/files/Tooling_solutions.pdf

4. Shassere, B., Nycz, A., Noakes, M. W., Masuo, C., & Sridharan, N. (2019). Correlation ofMicrostructure and Mechanical Properties of Metal Big Area Additive Manufacturing. AppliedSciences, 9(4), 787.

5. (2012). 11 - Steels for aircraft structures. In Introduction to Aerospace Materials (pp. 232–250). Woodhead Publishing. doi: 10.1533/9780857095152.232

6. Garrison Jr, W. M., & Banerjee, M. K. (2016). Martensitic non-stainless steels: high strengthand high alloy.

7. Banerjee, M. K. (2017). 2.8 Heat Treatment of Commercial Steels for EngineeringApplications.

8. Lincoln Electric. (n.d.). Power Mode [Brochure]. Author. Retrieved fromhttps://www.lincolnelectric.com/assets/US/EN/literature/NX260.pdf

9. Lincoln Electric. (n.d.). Surface Tension Transfer (STT) [Brochure]. Author. Retrieved fromhttps://www.lincolnelectric.com/assets/US/EN/literature/NX220.pdf

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WelcomeTitle PagePrefaceOrganizing CommitteePapers to JournalsTable of ContentsBroader Impacts and EducationDesign for Additive Manufacturing: Simplification of Product Architecture by Part Consolidation for the LifecycleAn Open-Architecture Multi-Laser Research Platform for Acceleration of Large-Scale Additive Manufacturing (ALSAM)Large-Scale Identification of Parts Suitable for Additive Manufacturing: An Industry PerspectiveImplementation of 3D Printer in the Hands-On Material Processing Course: An Educational PaperConceptual Design for Additive Manufacturing: Lessons Learned from an Undergraduate CourseAn Empirical Study Linking Additive Manufacturing Design Process to Success in ManufacturabilityInvestigating the Gap between Research and Practice in Additive Manufacturing

Binder JettingInfluence of Drop Velocity and Droplet Spacing on the Equilibrium Saturation Level in Binder JettingProcess Integrated Production of WC-Co Tools with Local Cobalt Gradient Fabricated by Binder JettingThe Effect of Print Speed on Surface Roughness and Density Uniformity of Parts Produced Using Binder Jet 3D PrintingExperimental Investigation of Fluid-Particle Interaction in Binder Jet 3D PrintingBinder Saturation, Layer Thickness, Drying Time and Their Effects on Dimensional Tolerance and Density of Cobalt Chrome - Tricalcium Phosphate Biocomposite

Data AnalyticsPredicting and Controlling the Thermal Part History in Powder Bed Fusion Using Neural Networks‘Seeing’ the Temperature inside the Part during the Powder Bed Fusion ProcessConditional Generative Adversarial Networks for In-Situ Layerwise Additive Manufacturing DataIn-Situ Layer-Wise Quality Monitoring for Laser-Based Additive Manufacturing Using Image Series AApplications of Supervised Machine Learning Algorithms in Additive Manufacturing: A ReviewReal-Time 3D Surface Measurement in Additive Manufacturing Using Deep LearningRoughness Parameters for Classification of As-Built and Laser Post-Processed Additive Manufactured SurfacesApplication of the Fog Computing Paradigm to Additive Manufacturing Process Monitoring and ControlSpectral X-ray CT for Fast NDT Using Discrete Tomography

Hybrid AMPart Remanufacturing Using Hybird Manufacturing ProcessesIntegration Challenges with Additive/Subtractive In-Envelope Hybrid ManufacturingRobot-Based Hybrid Manufacturing Process ChainIntegrated Hardfacing of Stellite-6 Using Hybrid Manufacturing ProcessInkjet Printing of Geometrically Optimized Electrodes for Lithium-Ion Cells: A Concept for a Hybrid Process ChainUltrasonic Embedding of Continuous Carbon Fiber into 3D Printed Thermoplastic Parts

Materials: MetalsComparison of Fatigue Performance between Additively Manufactured and Wrought 304L Stainless Steel Using a Novel Fatigue Test SetupElevated Temperature Mechanical and Microstructural Characterization of SLM SS304LFatigue Behavior of Additive Manufactured 304L Stainless Steel Including Surface Roughness EffectsJoining of Copper and Stainless Steel 304L Using Direct Metal DepositionSS410 Process Development and CharacterizationEffect of Preheating Build Platform on Microstructure and Mechanical Properties of Additively Manufactured 316L Stainless SteelCharacterisation of Austenitic 316LSi Stainless Steel Produced by Wire Arc Additive Manufacturing with Interlayer CoolingEffects of Spatial Energy Distribution on Defects and Fracture of LPBF 316L Stainless SteelEnvironmental Effects on the Stress Corrosion Cracking Behavior of an Additively Manufactured Stainless SteelEffect of Powder Chemical Composition on Microstructures and Mechanical Properties of L-PBF Processed 17-4 PH Stainless Steel in the As-Built And Hardened-H900 ConditionsPowder Variation and Mechanical Properties for SLM 17-4 PH Stainless SteelFatigue Life Prediction of Additive Manufactured Materials Using a Defect Sensitive ModelEvaluating the Corrosion Performance of Wrought and Additively Manufactured (AM) Invar ® and 17-4PHComparison of Rotating-Bending and Axial Fatigue Behaviors of LB-PBF 316L Stainless SteelA Study of Pore Formation during Single Layer and Multiple Layer Build by Selective Laser MeltingDimensional Analysis of Metal Powder Infused Filament - Low Cost Metal 3D PrintingAdditive Manufacturing of Fatigue Resistant Materials: Avoiding the Early Life Crack Initiation Mechanisms during FabricationAdditive Manufacturing of High Gamma Prime Nickel Based Superalloys through Selective Laser Melting (SLM)Investigating the Build Consistency of a Laser Powder Bed Fused Nickel-Based Superalloy, Using the Small Punch TechniqueFatigue Behavior of Laser Beam Directed Energy Deposited Inconel 718 at Elevated TemperatureVery High Cycle Fatigue Behavior of Laser Beam-Powder Bed Fused Inconel 718Analysis of Fatigue Crack Evolution Using In-Situ TestingAn Aluminum-Lithium Alloy Produced by Laser Powder Bed FusionWire-Arc Additive Manufacturing: Invar Deposition CharacterizationStudy on the Formability, Microstructures and Mechanical Properties of Alcrcufeniᵪ High-Entropy Alloys Prepared by Selective Laser MeltingLaser-Assisted Surface Defects and Pore Reduction of Additive Manufactured Titanium PartsFatigue Behavior of LB-PBF Ti-6Al-4V Parts under Mean Stress and Variable Amplitude Loading ConditionsInfluence of Powder Particle Size Distribution on the Printability of Pure Copper for Selective Laser MeltingInvestigation of the Oxygen Content of Additively Manufactured Tool Steel 1.2344The Porosity and Mechanical Properties of H13 Tool Steel Processed by High-Speed Selective Laser MeltingFeasibility Analysis of Utilizing Maraging Steel in a Wire Arc Additive Process for High-Strength Tooling ApplicationsInvestigation and Control of Weld Bead at Both Ends in WAAM

Materials: PolymersProcess Parameter Optimization to Improve the Mechanical Properties of Arburg Plastic Freeformed ComponentsImpact Strength of 3D Printed Polyether-Ether-Ketone (PEEK)Mechanical Performance of Laser Sintered Poly(Ether Ketone Ketone) (PEKK)Influence of Part Microstructure on Mechanical Properties of PA6X Laser Sintered SpecimensOptimizing the Tensile Strength for 3D Printed PLA PartsCharacterizing the Influence of Print Parameters on Porosity and Resulting DensityCharacterization of Polymer Powders for Selective Laser SinteringEffect of Particle Rounding on the Processability of Polypropylene Powder and the Mechanical Properties of Selective Laser Sintering Produced PartsProcess Routes towards Novel Polybutylene Terephthalate – Polycarbonate Blend Powders for Selective Laser SinteringImpact of Flow Aid on the Flowability and Coalescence of Polymer Laser Sintering PowderCuring and Infiltration Behavior of UV-Curing Thermosets for the Use in a Combined Laser Sintering Process of PolymersRelationship between Powder Bed Temperature and Microstructure of Laser Sintered PA12 PartsUnderstanding the Influence of Energy-Density on the Layer Dependent Part Properties in Laser-Sintering of PA12Tailoring Physical Properties of Shape Memory Polymers for FDM-Type Additive ManufacturingInvestigation of The Processability of Different Peek Materials in the FDM Process with Regard to the Weld Seam StrengthStereolithography of Natural Rubber Latex, a Highly Elastic Material

Materials: Ceramics and CompositesMoisture Effects on Selective Laser Flash Sintering of Yttria-Stabilized ZirconiaThermal Analysis of Thermoplastic Materials Filled with Chopped Fiber for Large Area 3D PrintingThermal Analysis of 3D Printed Continuous Fiber Reinforced Thermoplastic Polymers for Automotive ApplicationsCharacterization of Laser Direct Deposited Magnesium Aluminate Spinel CeramicsTowards a Micromechanics Model for Continuous Carbon Fiber Composite 3D Printed PartsEffect of In-Situ Compaction and UV-Curing on the Performance of Glass Fiber-Reinforced Polymer Composite Cured Layer by Layer3D Printing of Compliant Passively Actuated 4D StructuresEffect of Process Parameters on Selective Laser Melting Al₂O₃-Al Cermet MaterialStrengthening of 304L Stainless Steel by Addition of Yttrium Oxide and Grain Refinement during Selective Laser MeltingApproach to Defining the Maximum Filler Packing Volume Fraction in Laser Sintering on the Example of Aluminum-Filled Polyamide 12Laser Sintering of Pine/Polylatic Acid CompositesCharacterization of PLA/Lignin Biocomposites for 3D PrintingElectrical and Mechancial Properties of Fused Filament Fabrication of Polyamide 6 / Nanographene Filaments at Different Annealing TemperaturesManufacturing and Application of PA11-Glass Fiber Composite Particles for Selective Laser SinteringManufacturing of Nanoparticle-Filled PA11 Composite Particles for Selective Laser SinteringTechnique for Processing of Continuous Carbon Fibre Reinforced Peek for Fused Filament FabricationProcessing and Characterization of 3D-Printed Polymer Matrix Composites Reinforced with Discontinuous FibersTailored Modification of Flow Behavior and Processability of Polypropylene Powders in SLS by Fluidized Bed Coating with In-Situ Plasma Produced Silica Nanoparticles

ModelingAnalysis of Layer Arrangements of Aesthetic Dentures as a Basis for Introducing Additive ManufacturingComputer-Aided Process Planning for Wire Arc Directed Energy DepositionMulti-Material Process Planning for Additive ManufacturingCreating Toolpaths without Starts and Stops for Extrusion-Based SystemsFramework for CAD to Part of Large Scale Additive Manufacturing of Metal (LSAMM) in Arbitrary DirectionsA Standardized Framework for Communicating and Modelling Parametrically Defined Mesostructure PatternsA Universal Material Template for Multiscale Design and Modeling of Additive Manufacturing Processes

Physical ModelingModeling Thermal Expansion of a Large Area Extrusion Deposition Additively Manufactured Parts Using a Non-Homogenized ApproachLocalized Effect of Overhangs on Heat Transfer during Laser Powder Bed Fusion Additive ManufacturingMelting Mode Thresholds in Laser Powder Bed Fusion and Their Application towards Process Parameter DevelopmentComputational Modelling and Experimental Validation of Single IN625 Line Tracks in Laser Powder Bed FusionValidated Computational Modelling Techniques for Simulating Melt Pool Ejecta in Laser Powder Bed Fusion ProcessingNumerical Simulation of the Temperature History for Plastic Parts in Fused Filament Fabrication (FFF) ProcessMeasurement and Analysis of Pressure Profile within Big Area Additive Manufacturing Single Screw ExtruderNumerical Investigation of Extrusion-Based Additive Manufacturing for Process Parameter Planning in a Polymer Dispensing SystemAlternative Approach on an In-Situ Analysis of the Thermal Progression during the LPBF-M Process Using Welded Thermocouples Embedded into the Substrate PlateDynamic Defect Detection in Additively Manufactured Parts Using FEA SimulationSimulation of Mutually Dependent Polymer Flow and Fiber Filled in Polymer Composite Deposition Additive ManufacturingSimulation of Hybrid WAAM and Rotation Compression Forming ProcessDimensional Comparison of a Cold Spray Additive Manufacturing Simulation ToolSimulated Effect of Laser Beam Quality on the Robustness of Laser-Based AM SystemA Strategy to Determine the Optimal Parameters for Producing High Density Part in Selective Laser Melting ProcessRheology and Applications of Particulate Composites in Additive ManufacturingComputational Modeling of the Inert Gas Flow Behavior on Spatter Distribution in Selective Laser MeltingPrediction of Mechanical Properties of Fused Deposition Modeling Made Parts Using Multiscale Modeling and Classical Laminate Theory

Process DevelopmentThe Use of Smart In-Process Optical Measuring Instrument for the Automation of Additive Manufacturing ProcessesDevelopment of a Standalone In-Situ Monitoring System for Defect Detection in the Direct Metal Laser Sintering ProcessFrequency Inspection of Additively Manufactured Parts for Layer Defect IdentificationMelt Pool Monitoring for Control and Data Analytics in Large-Scale Metal Additive ManufacturingFrequency Domain Measurements of Melt Pool Recoil Pressure Using Modal Analysis and Prospects for In-Situ Non-Destructive TestingInterrogation of Mid-Build Internal Temperature Distributions within Parts Being Manufactured via the Powder Bed Fusion ProcessReducing Computer Visualization Errors for In-Process Monitoring of Additive Manufacturing Systems Using Smart Lighting and Colorization SystemA Passive On-line Defect Detection Method for Wire and Arc Additive Manufacturing Based on Infrared ThermographyExamination of the LPBF Process by Means of Thermal Imaging for the Development of a Geometric-Specific Process ControlAnalysis of the Shielding Gas Dependent L-PBF Process Stability by Means of Schlieren and Shadowgraph TechniquesApplication of Schlieren Technique in Additive Manufacturing: A ReviewWire Co-Extrusion with Big Area Additive ManufacturingSkybaam Large-Scale Fieldable Deposition Platform System ArchitectureDynamic Build Bed for Additive ManufacturingEffect of Infrared Preheating on the Mechanical Properties of Large Format 3D Printed PartsLarge-Scale Additive Manufacturing of Concrete Using a 6-Axis Robotic Arm for Autonomous Habitat ConstructionOverview of In-Situ Temperature Measurement for Metallic Additive Manufacturing: How and Then WhatIn-Situ Local Part Qualification of SLM 304L Stainless Steel through Voxel Based Processing of SWIR Imaging DataNew Support Structures for Reduced Overheating on Downfacing Regions of Direct Metal Printed PartsThe Development Status of the National Project by Technology Research Assortiation for Future Additive Manufacturing (TRAFAM) in JapanInvestigating Applicability of Surface Roughness Parameters in Describing the Metallic AM ProcessA Direct Metal Laser Melting System Using a Continuously Rotating Powder BedEvaluation of a Feed-Forward Laser Control Approach for Improving Consistency in Selective Laser SinteringElectroforming Process to Additively Manufactured Microscale StructuresIn-Process UV-Curing of Pasty Ceramic CompositeDevelopment of a Circular 3S 3D Printing System to Efficiently Fabricate Alumina Ceramic ProductsRepair of High-Value Plastic Components Using Fused Deposition ModelingA Low-Cost Approach for Characterizing Melt Flow Properties of Filaments Used in Fused Filament Fabrication Additive ManufacturingIncreasing the Interlayer Bond of Fused Filament Fabrication Samples with Solid Cross-Sections Using Z-PinningImpact of Embedding Cavity Design on Thermal History between Layers in Polymer Material Extrusion Additive ManufacturingDevelopment of Functionally Graded Material Capabilities in Large-Scale Extrusion Deposition Additive ManufacturingUsing Non-Gravity Aligned Welding in Large Scale Additive Metals Manufacturing for Building Complex PartsThermal Process Monitoring for Wire-Arc Additive Manufacturing Using IR CamerasA Comparative Study between 3-Axis and 5-Axis Additively Manufactured Samples and Their Ability to Resist Compressive LoadingUsing Parallel Computing Techniques to Algorithmically Generate Voronoi Support and Infill Structures for 3D Printed ObjectsExploration of a Cable-Driven 3D Printer for Concrete Tower Structures

ApplicationsTopology Optimization for Anisotropic Thermomechanical Design in Additive ManufacturingCellular and Topology Optimization of Beams under Bending: An Experimental StudyAn Experimental Study of Design Strategies for Stiffening Thin Plates under CompressionMulti-Objective Topology Optimization of Additively Manufactured Heat ExchangersA Mold Insert Case Study on Topology Optimized Design for Additive ManufacturingDevelopment, Production and Post-Processing of a Topology Optimized Aircraft BracketManufacturing Process and Parameters Development for Water-Atomized Zinc Powder for Selective Laser Melting FabricationA Multi-Scale Computational Model to Predict the Performance of Cell Seeded Scaffolds with Triply Periodic Minimal Surface GeometriesMulti-Material Soft Matter Robotic Fabrication: A Proof of Concept in Patient-Specific Neurosurgical SurrogatesOptimization of the Additive Manufacturing Process for Geometrically Complex Vibro-Acoustic MetamaterialsEffects of Particle Size Distribution on Surface Finish of Selective Laser Melting PartsAn Automated Method for Geometrical Surface Characterization for Fatigue Analysis of Additive Manufactured PartsA Design Method to Exploit Synergies between Fiber-Reinforce Composites and Additive Manufactured ProcessesPreliminary Study on Hybrid Manufacturing of the Electronic-Mechanical Integrated Systems (EMIS) via the LCD Stereolithography TechnologyLarge-Scale Thermoset Pick and Place Testing and ImplementationThe Use of Smart In-Process Optical Measuring Instrument for the Automation of Additive Manufacturing ProcessesWet-Chemical Support Removal for Additive Manufactured Metal PartsAnalysis of Powder Removal Methods for EBM Manufactured Ti-6Al-4V PartsTensile Property Variation with Wall Thickness in Selective Laser Melted PartsMethodical Design of a 3D-Printable Orthosis for the Left Hand to Support Double Bass Perceptional TrainingPrinted Materials and Their Effects on Quasi-Optical Millimeter Wave Guide Lens SystemsPorosity Analysis and Pore Tracking of Metal AM Tensile Specimen by Micro-CtUsing Wax Filament Additive Manufacturing for Low-Volume Investment CastingFatigue Performance of Additively Manufactured Stainless Steel 316L for Nuclear ApplicationsFailure Detection of Fused Filament Fabrication via Deep LearningSurface Roughness Characterization in Laser Powder Bed Fusion Additive ManufacturingCompressive and Bending Performance of Selectively Laser Melted AlSi10Mg StructuresCompressive Response of Strut-Reinforced Kagome with Polyurethane ReinforcementA Computational and Experimental Investigation into Mechanical Characterizations of Strut-Based Lattice StructuresThe Effect of Cell Size and Surface Roughness on the Compressive Properties of ABS Lattice Structures Fabricated by Fused Deposition ModelingEffective Elastic Properties of Additively Manufactured Metallic Lattice Structures: Unit-Cell ModelingImpact Energy Absorption Ability of Thermoplastic Polyurethane (TPU) Cellular Structures Fabricated via Powder Bed FusionPermeability Analysis of Polymeric Porous Media Obtained by Material Extrusion Additive ManufacturingEffects of Unit Cell Size on the Mechanical Performance of Additive Manufactured Lattice StructuresMechanical Behavior of Additively-Manufactured Gyroid Lattice Structure under Different Heat TreatmentsFast and Simple Printing of Graded Auxetic StructuresCompressive Properties Optimization of a Bio-Inspired Lightweight Structure Fabricated via Selective Laser MeltingIn-Plane Pure Shear Deformation of Cellular Materials with Novel Grip DesignModelling for the Tensile Fracture Characteristic of Cellular Structures under Tensile Load with Size EffectDesign, Modeling and Characterization of Triply Periodic Minimal Surface Heat Exchangers with Additive ManufacturingInvestigating the Production of Gradient Index Optics by Modulating Two-Photon Polymerisation Fabrication ParametersAdditive Manufactured Lightweight Vehicle Door Hinge with Hybrid Lattice Structure

Attendee ListAuthor Index