AM Metals & Alloys

Direct Metal AM results in a fully-metal 3d-printed object, without any additional steps, and encompasses several different processes, each with its own unique characteristics and applications. Two of the most commonly used methods are Selective Laser Melting (SLM) and Electron Beam Melting (EBM):

• Selective Laser Melting (SLM) employs a high-powered laser to selectively melt and fuse layers of metal powder. It offers excellent resolution and is well-suited for producing intricate and detailed parts, making it popular in industries like aerospace and healthcare.

• Electron Beam Melting (EBM) utilizes an electron beam instead of a laser to melt the metal powder. EBM is known for its high build speeds and excellent material utilization, making it ideal for large, complex components found in industries like automotive and energy.

Indirect Metal Additive Manufacturing is an alternative approach to creating metal parts using 3D printing technology. In indirect metal AM, parts are initially 3D printed in a non-metallic form, often referred to as "green parts," which are subsequently converted into fully dense metal components through secondary processes like powder metallurgy and sintering. This approach offers certain advantages, such as cost-effectiveness and the ability to produce intricate geometries. Some commonly-used indirect metal AM processes include:

• Powder metallurgy is a key aspect of indirect metal AM. It involves blending metal powders to create a feedstock suitable for 3D printing. This feedstock is then used to print green parts, which are porous and not yet fully dense. Sintering is the process of heating these green parts to high temperatures, causing the metal particles to fuse and densify, resulting in a final, fully dense metal component.

• Binder jetting is a commonly used technique for creating green parts in indirect metal AM. In this process, a layer of metal powder is deposited, and a liquid binder is selectively jetted onto the powder to bind it together and form the desired shape. This approach offers versatility in terms of materials and can produce complex geometries.

AM Alloy Blending is a cutting-edge technique in additive manufacturing that allows engineers and manufacturers to create custom alloys tailored to specific applications. Traditional manufacturing processes often limit the availability of certain alloys, but with AM alloy blending, you can combine various metal powders to create unique material compositions. This capability opens up new possibilities for optimizing material properties and achieving superior performance in various industries.

When designing custom alloys for AM, it's essential to consider the specific requirements of the intended application. Factors like strength, hardness, thermal conductivity, and corrosion resistance should guide the alloy selection. The ability to fine-tune these properties provides a competitive advantage in industries such as aerospace, where lightweight yet strong materials are in high demand.

Several techniques can be employed to blend metal powders effectively. Mechanical mixing involves physically blending different metal powders to achieve a homogeneous mixture. Gas atomization is a method where molten metal is sprayed into fine droplets and rapidly solidified, resulting in powders with tailored particle sizes and distributions. In-situ alloying involves creating alloys directly in the 3D printing process by selectively depositing different metal powders layer by layer.