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Remanufacturing and Advanced Machining
3. Integration with sheet forming processes
4. Integration with joining by forming processes
The roots of combining metal HAM with processes to improve properties of deposited metals can be found in the processes of mechanical surface treatment, such as
application of pressure along weld beads produced by friction stir welding as a means
of controlling residual stresses and distortions. This process, known as surface rolling, subjects weld bead surfaces to plastic deformation in order to improve surface
finish and induce compressive stresses that will counteract residual stresses originating from heating-cooling cycles of welding. Another hybrid method in this group
is utilization of shot peening on successive layers of wire-arc additive manufacture
(WAAM)-based processes for relieving residual stresses and minimizing distortions and to improve fatigue life due to the effect of compressive stresses on delaying initiation of fatigue cracks. The combination of MAM with hot forging through
utilization of a customized WAAM torch may become an alternative solution for
decreasing residual porosity, refining microstructure, and improving mechanical
properties of a deposited material.
Integration with bulk forming processes in the case of an aluminum alloy AA5083
deposited by the WAAM method achieved an excellent ductility of deposited material. The combination of additive manufacturing with coining has also been recently
proposed as a novel process route to fabricate high value-added collector coins.
The integration of metal additive manufacturing with sheet forming processes
comprises combinations of MAM with bending, deep drawing, spinning, and incremental sheet forming.
Finally, integration with joining by forming processes found its application in
the area of assembly of structural components. It needs to replace conventional
welding, fastening, and adhesive bonding as it eliminates metallurgical problems
caused by heating–cooling cycles and by incidence of hard and brittle intermetallic
compounds with the aptitude to join dissimilar materials. Hybridization of additive
manufacturing with joining by forming processes provides flexibility, environmental
compliance, and adequacy for producing small, medium, and large batches of joints
(Pragana et al., 2021).
Zheng et al. (2020) stress that hybrid manufacturing combines advantages of AM
in building complex geometries and subtractive manufacturing’s benefits in obtaining dimensional precision and surface quality. The hybrid additive-subtractive technology shows a great potential for supporting repair and remanufacturing processes
and serves to repair end-of-life parts or remanufacture them to new features and
functionalities. Mixing AM and subtractive manufacturing provides a more flexible, productive, and capable manufacturing approach, and increases the ability to
remanufacture to a higher standard (Zheng et al., 2020).
2.1.2 maTerials Processed By am
A broad range of materials has been developed for AM techniques, including polymers, metals, ceramics, glasses, biomaterials, and multi-material systems. Further
Remanufacturing and Advanced Machining
3. Integration with sheet forming processes
4. Integration with joining by forming processes
The roots of combining metal HAM with processes to improve properties of deposited metals can be found in the processes of mechanical surface treatment, such as
application of pressure along weld beads produced by friction stir welding as a means
of controlling residual stresses and distortions. This process, known as surface rolling, subjects weld bead surfaces to plastic deformation in order to improve surface
finish and induce compressive stresses that will counteract residual stresses originating from heating-cooling cycles of welding. Another hybrid method in this group
is utilization of shot peening on successive layers of wire-arc additive manufacture
(WAAM)-based processes for relieving residual stresses and minimizing distortions and to improve fatigue life due to the effect of compressive stresses on delaying initiation of fatigue cracks. The combination of MAM with hot forging through
utilization of a customized WAAM torch may become an alternative solution for
decreasing residual porosity, refining microstructure, and improving mechanical
properties of a deposited material.
Integration with bulk forming processes in the case of an aluminum alloy AA5083
deposited by the WAAM method achieved an excellent ductility of deposited material. The combination of additive manufacturing with coining has also been recently
proposed as a novel process route to fabricate high value-added collector coins.
The integration of metal additive manufacturing with sheet forming processes
comprises combinations of MAM with bending, deep drawing, spinning, and incremental sheet forming.
Finally, integration with joining by forming processes found its application in
the area of assembly of structural components. It needs to replace conventional
welding, fastening, and adhesive bonding as it eliminates metallurgical problems
caused by heating–cooling cycles and by incidence of hard and brittle intermetallic
compounds with the aptitude to join dissimilar materials. Hybridization of additive
manufacturing with joining by forming processes provides flexibility, environmental
compliance, and adequacy for producing small, medium, and large batches of joints
(Pragana et al., 2021).
Zheng et al. (2020) stress that hybrid manufacturing combines advantages of AM
in building complex geometries and subtractive manufacturing’s benefits in obtaining dimensional precision and surface quality. The hybrid additive-subtractive technology shows a great potential for supporting repair and remanufacturing processes
and serves to repair end-of-life parts or remanufacture them to new features and
functionalities. Mixing AM and subtractive manufacturing provides a more flexible, productive, and capable manufacturing approach, and increases the ability to
remanufacture to a higher standard (Zheng et al., 2020).
2.1.2 maTerials Processed By am
A broad range of materials has been developed for AM techniques, including polymers, metals, ceramics, glasses, biomaterials, and multi-material systems. Further