Processing

Additive Manufacturing at World PM2016: Opportunities for the use of water atomised metal powders

At the World PM2016 Congress, held in Hamburg, Germany, 9-13 October, 2016, two papers discussed the potential for the replacement of gas-atomised powders with water-atomised powders as the raw material for Selective Laser Melting of different alloy types. Dr David Whittaker reports on the work undertaken to assess the viability of the water atomisation process for these materials which could, in turn, offer significant cost savings [First published in Metal AM Vol. 3 No. 1, Spring 2017] ... Read more »

Modelling the mechanical behaviour of additively manufactured cellular structures

One of the most promising aspects of Additive Manufacturing is the design freedom it enables. One manifestation of this design freedom lies in our ability to manufacture cellular structures such as lattices and honeycombs. Implementing cellular structures with AM, however, poses a range of design and manufacturing challenges. In this article Dr Dhruv Bhate, from Phoenix Analysis & Design Technologies, Inc. (PADT), focuses on a key area connecting design and manufacturing to final part implementation – the mechanical behaviour of these structures and the challenges and approaches to developing a reliable way to predict it [First published in Metal AM Vol. 2 No. 4, Winter 2016] ... Read more »

Cost and practicality of in-process monitoring for metal Additive Manufacturing

Additive Manufacturing gives industrial designers the freedom to create ever more complex and customised products. However, with the increasing adoption of the technology by sectors such as aerospace, where product failure can have catastrophic consequences, component verification is becoming a critical issue. In the following article Dr Chris Hole, from the UK’s TTP Group plc, reviews the challenges of verification in an industry that is associated with low volume runs of complex, often highly customised components with sophisticated hidden internal structures [First published in Metal AM Vol. 2 No. 4, Winter 2016] ... Read more »

FIT AG: Laying the foundations for high-volume metal Additive Manufacturing

There is no doubt that the Additive Manufacturing of series components is quickly becoming a reality. From high-profile applications in the aerospace industry to performance components for the automotive sector, there are now numerous examples of the successful implementation of metal AM. However, the route that a company chooses in order to adopt AM technology could have a significant impact on a component’s development time and cost. As Nick Williams reports, Germany’s FIT AG sees opportunities in leveraging its expertise to supporting companies with the outsourcing of component development and production. To achieve this, the company has created a model AM factory that it plans to replicate worldwide [First published in Metal AM Vol. 2 No. 3, Autumn 2016] ... Read more »

Selecting atomised aluminium alloy powders for the metal Additive Manufacturing process

As the metal Additive Manufacturing industry continues to grow at a rapid pace, aluminium and aluminium alloy powders are gaining ever more attention. Component and equipment manufacturers are deploying immense efforts in exploring advanced aluminium alloys in order to target more complex applications that demand higher mechanical performance. As they move forward, the selection and optimisation of powders is becoming increasingly important. In this article, Jessu Joys and colleagues from United States Metal Powders, Inc. (USMP), identify the most popular aluminium alloy grades for AM technology and discuss the unique properties of each powder [First published in Metal AM Vol. 2 No. 3, Autumn 2016] ... Read more »

AMPM2016: Developments in binder jetting technology highlighted at Boston conference

For the third consecutive year, the Metal Powder Industries Federation’s Additive Manufacturing with Powder Metallurgy (AMPM) conference was held in parallel with its long established POWDERMET conference. This year’s event took place in Boston, Massachusetts, USA, from June 5-8, 2016. In the first of our reports Dr David Whittaker reviews three presentations that focused on the binder jetting process [First published in Metal AM Vol. 2 No. 3, Autumn 2016] ... Read more »

Standards for metal Additive Manufacturing: A global perspective

As the metal Additive Manufacturing industry moves towards industrial production, the need for international standards covering all aspects of the technology becomes ever more pressing. In the following exclusive report for Metal Additive Manufacturing magazine, Fraunhofer IFAM’s Claus Aumund-Kopp and Frank Petzoldt review international progress to-date, summarise existing standards for metal AM and consider the challenges that lie ahead [First published in Metal AM Vol. 2 No. 2, Summer 2016] ... Read more »

GKN Sinter Metals: Global Tier 1 automotive supplier anticipates opportunities for Additive Manufacturing

GKN Sinter Metals, with more than 6,000 employees at 30 locations worldwide, is the world’s leading Powder Metallurgy group. The company produces 11 million PM parts per day, with around 80% going into the automotive industry. The company started its metal Additive Manufacturing activities at its Innovation Centre in Radevormwald, Germany, in 2013. Dr Georg Schlieper visited the centre on behalf of Metal AM magazine and reports on the company’s AM activities and ambitions [First published in Metal AM Vol. 2 No. 2, Summer 2016] ... Read more »

Material selection for the production of injection moulding tooling by Additive Manufacturing

As one of the first major markets for metal additively manufactured products, the importance of the tooling industry has long been recognised. There is still, however, limited information available on what mechanical properties can be expected for the various materials used. This report by Harish Irrinki, Brenton Barmore, Kunal H Kate and Sundar V Atre reviews the published data on various steel powders and processing conditions as well as the mechanical properties that have been obtained using the Selective Laser Melting process [First published in Metal AM Vol. 2 No. 2, Summer 2016] ... Read more »

Planning, preparing and producing: Walking the tightrope between additive and subtractive manufacturing

In the following article Delcam’s Kelvin Hamilton explores the current possibilities for design, topology optimisation, simulation, process planning and process preparation in metal Additive Manufacturing (AM). Exploring the three Ps, Plan, Prepare and Produce, all the processes involved in transforming three airbrake bracket designs into final products are revealed. As well as explaining how important it is to appreciate and plan for the significant amount of subtractive manufacturing in metal AM, a number of the lessons learnt in this project are discussed as the author reflects on the experience of planning, preparing and producing parts [First published in Metal AM Vol. 2 No. 1, Spring 2016] ... Read more »

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 168-page issue includes articles and reports on:

  • Metal Additive Manufacturing and the new Space Race: The inside track with Launcher and AMCM
  • Falcontech: The journey from materials engineering to large-scale metal Additive Manufacturing
  • Strategies for advancing the automation of metal Additive Manufacturing
  • Machine Learning and Additive Manufacturing: What does the future hold?
  • System 3R: Bridging critical gaps in the Additive Manufacturing workflow to enable serial production
  • Metal AM in South Africa: Research and commercial initiatives bring the benefit of AM to the African continent
  • CFD simulation for metal Additive Manufacturing: Applications in laser- and sinter-based processes
  • > More information

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