Short answer

Incorporate post-forming operations into the manufacturing workflow for additively manufactured metal parts to achieve more consistent and superior material properties.

Field: Final Production
Source: Procedia Manufacturing (2020)
Method: Experimental investigation
Evidence: Strong effect

Subsequent forming processes, including hot and cold forming, can significantly homogenize and optimize the mechanical properties of additively manufactured metal components. This final production research insight is drawn from a 2020 study published in Procedia Manufacturing. Using Experimental investigation, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Incorporate post-forming operations into the manufacturing workflow for additively manufactured metal parts to achieve more consistent and superior material properties.

Study

Final ProductionHigh ImpactStrong effect

Post-forming refines additively manufactured metal properties

Subsequent forming processes, including hot and cold forming, can significantly homogenize and optimize the mechanical properties of additively manufactured metal components.

Procedia Manufacturing · 2020

Key Findings

01Subsequent forming processes can lead to homogenization of mechanical properties in additively manufactured components.
02The direction of sampling (along vs. across welding direction) influences observed material properties due to anisotropy inherent in the AM process.
03Both hot and cold forming, along with heat treatment, can be used to optimize the material properties.

Application

Design takeaway

Incorporate post-forming operations into the manufacturing workflow for additively manufactured metal parts to achieve more consistent and superior material properties.

How to apply

When designing components using AM, evaluate the feasibility and benefits of including cold or hot forming steps to achieve desired material performance and uniformity.

Project actions

01When researching AM, look for studies that investigate post-processing steps like forming or heat treatment.
02Consider how anisotropy in AM parts might affect their performance and how post-processing could mitigate this.

Method & Evidence

AimTo investigate the impact of subsequent forming processes on the microstructural and mechanical properties of additively manufactured metal components.

MethodExperimental investigation

ProcedureCylindrical specimens were machined from additively manufactured (Wire Arc Additive Manufacturing - WAAM) thin-walled components. These specimens were subjected to compression tests, with sampling taken along and across the welding direction to account for anisotropy. Cast specimens with representative microstructures were also created for comparison. The study included cold forming, hot forming, and the effects of heat treatment, with microstructural analysis performed on each material state.

ContextAdditive manufacturing of metal components, specifically Wire Arc Additive Manufacturing (WAAM) with Cold Metal Transfer (CMT) for G4Si1 material.

Variables

IV["Type of forming process (cold, hot)","Heat treatment","Sampling direction (along/across welding)"]

DV["Mechanical properties (e.g., yield strength, tensile strength, ductility)","Microstructure","Degree of homogenization"]

CV["Base material (G4Si1)","Additive manufacturing process (WAAM-CMT)","Component geometry (thin-walled rectangular)"]

Strengths & Limitations

Strengths

+Direct experimental investigation of forming effects on AM parts.
+Consideration of anisotropy by sampling in multiple directions.
+Inclusion of various post-processing techniques (forming, heat treatment).

Limitations

The complexity of controlling forming parameters and the potential for introducing new defects during post-processing.

Reliability & validity

The study's validity is supported by direct experimental testing and microstructural analysis. Reliability could be enhanced by repeating tests across multiple samples and varying forming parameters.

Think critically

To what extent can forming processes fully compensate for the inherent material property variations in additively manufactured components, and are there trade-offs in terms of geometric complexity or introduced stresses?

Design Principles

"Material properties of additively manufactured components can be optimized through post-processing forming techniques."

Additive manufacturing (AM) often results in anisotropic and inhomogeneous material properties due to the layer-by-layer deposition. Integrating post-forming processes offers a pathway to overcome these limitations, enhancing component performance and reliability for a wider range of applications.

What This Means for Your Design

3D printing metal parts can sometimes result in uneven strength. By bending or shaping the part after printing, you can make its strength more consistent and even better.

How to use in your project

1.Reference this study when discussing the limitations of as-printed AM parts and how post-processing can address them.
2.Use the findings to justify the inclusion of forming processes in your own design project if you are using AM.

Add to My Project

Quick Cite

Paragraph starter

Research indicates that additively manufactured components often exhibit anisotropic and inhomogeneous material properties due to the layer-by-layer fabrication process. However, subsequent forming operations, such as cold or hot forming, have been shown to effectively homogenize these properties and optimize mechanical performance, as demonstrated by experimental investigations into Wire Arc Additive Manufacturing (WAAM) processes. This suggests that incorporating post-forming steps can significantly enhance the reliability and applicability of AM parts in demanding engineering contexts.

Source

Procedia Manufacturing

Experimental Investigation on the Forming of Additively Manufactured Components with Regard to Forming Behavior and Component Properties

journal · 2020

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Questions About This Research

What does the research say about post-forming refines additively manufactured metal properties?: Incorporate post-forming operations into the manufacturing workflow for additively manufactured metal parts to achieve more consistent and superior material properties. Evidence: Procedia Manufacturing (2020).
Why does "Post-forming refines additively manufactured metal properties" matter for design?: Additive manufacturing (AM) often results in anisotropic and inhomogeneous material properties due to the layer-by-layer deposition. Integrating post-forming processes offers a pathway to overcome these limitations, enhancing component performance and reliability for a wider range of applications.
How can designers apply this research?: Incorporate post-forming operations into the manufacturing workflow for additively manufactured metal parts to achieve more consistent and superior material properties.
What were the main findings?: Subsequent forming processes can lead to homogenization of mechanical properties in additively manufactured components.. The direction of sampling (along vs. across welding direction) influences observed material properties due to anisotropy inherent in the AM process.. Both hot and cold forming, along with heat treatment, can be used to optimize the material properties.
What research method was used?: Experimental investigation.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2020 journal from Procedia Manufacturing.
What should I do differently in my next project?: When designing components using AM, evaluate the feasibility and benefits of including cold or hot forming steps to achieve desired material performance and uniformity.
What are the limitations?: The study focused on a specific material (G4Si1) and AM process (WAAM-CMT); results may vary for other materials and technologies. The specific parameters of the forming processes were not exhaustively explored.