Meeting high precision requirements of additively manufactured components through hybrid manufacturing
Keywords: 
Área Ingeniería Mecánica, Naval y Aeronáutica
Metal additive manufacturing
Additive hybrid manufacturing
Milling; Finite element (FE)
Residual stress simulation
Ti6Al4V
Surfacae-roughness
Titanium-alloys
Heat-treatment
Laser
Issue Date: 
2023
ISSN: 
1755-5817
Editorial note: 
This is an open access article under the CC BY license
Citation: 
Loyda, A.; Arizmendi-Jaca, M. (Miguel); Ruiz de Galarreta-Moriones, S. (Sergio); et al. "Meeting high precision requirements of additively manufactured components through hybrid manufacturing". CIRP - JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY. 40, 2023, 199 - 212
Abstract
A hybrid approach combining the laser powder bed fusion (LPBF) process and post-processing operations through 5-axis milling was employed to manufacture a Ti6Al4V aerospace component. From the design step, the requirements and needs in all the stages of the Hybrid Additive Manufacturing process were taken into account. A numerical simulation of distortions promoted by residual stresses during the additive process was employed to consider material allowance. The status of the as-built and post-processed component was analysed through scanning and CMM inspection and roughness measurements. The 3D scanned model of the as-built LPBF-ed component was used to understand the distortion behaviour of the component and compared to the numerical simulation. Finally, 5-axis milling operations were conducted in some critical surfaces in order to improve surface quality and dimensional accuracy of the as-built com-ponent. The inspection of the as-built and post-processed component showed the improvement achieved through the proposed hybrid approach. The work aims to provide the baselines needed to enable the metal Hybrid Additive Manufacturing of components with complex geometries where mandatory precision is required by integrating high accuracy machining operations as post-processing technique.(c) 2022 The Author(s). This is an open access article under the CC BY license (http://creativecommons.org/ licenses/by/4.0/).

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