Review Article

Hybrid Processes in Additive Manufacturing

[+] Author and Article Information
Michael P. Sealy

Department of Mechanical and
Materials Engineering,
University of Nebraska-Lincoln,
W342 Nebraska Hall,
Lincoln, NE 68588-0526
e-mail: sealy@unl.edu

Gurucharan Madireddy

Department of Mechanical and
Materials Engineering,
University of Nebraska-Lincoln,
W342 Nebraska Hall,
Lincoln, NE 68588-0526
e-mail: gmadireddy2@huskers.unl.edu

Robert E. Williams

Department of Mechanical and
Materials Engineering,
University of Nebraska-Lincoln,
W342 Nebraska Hall,
Lincoln, NE 68588-0526
e-mail: rwilliams2@unl.edu

Prahalada Rao

Department of Mechanical and
Materials Engineering,
University of Nebraska-Lincoln,
W342 Nebraska Hall,
Lincoln, NE 68588-0526
e-mail: rao@unl.edu

Maziar Toursangsaraki

School of Mechanical Engineering,
Iran University of Science and Technology,
Tehran 16846-13114, Iran
e-mail: maziar.tour@gmail.com

1Corresponding author.

Manuscript received July 12, 2017; final manuscript received November 26, 2017; published online March 23, 2018. Assoc. Editor: Zhijian J. Pei.

J. Manuf. Sci. Eng 140(6), 060801 (Mar 23, 2018) (13 pages) Paper No: MANU-17-1429; doi: 10.1115/1.4038644 History: Received July 12, 2017; Revised November 26, 2017

Hybrid additive manufacturing (hybrid-AM) has described hybrid processes and machines as well as multimaterial, multistructural, and multifunctional printing. The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing (AM) paradigm. This work primarily focuses on defining hybrid-AM in relation to hybrid manufacturing (HM) and classifying hybrid-AM processes. Hybrid-AM machines, materials, structures, and function are also discussed. Hybrid-AM processes are defined as the use of AM with one or more secondary processes or energy sources that are fully coupled and synergistically affect part quality, functionality, and/or process performance. Historically, defining HM processes centered on process improvement rather than improvements to part quality or performance; however, the primary goal for the majority of hybrid-AM processes is to improve part quality and part performance rather than improve processing. Hybrid-AM processes are typically a cyclic process chain and are distinguished from postprocessing operations that do not meet the fully coupled criterion. Secondary processes and energy sources include subtractive and transformative manufacturing technologies, such as machining, remelting, peening, rolling, and friction stir processing (FSP). As interest in hybrid-AM grows, new economic and sustainability tools are needed as well as sensing technologies that better facilitate hybrid processing. Hybrid-AM has ushered in the next evolutionary step in AM and has the potential to profoundly change the way goods are manufactured.

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Fig. 1

HM methodologies. Modified from Refs. [5] and [8].

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Fig. 2

HM processes: (a) assisted HM processes and (b) mixed or combined HM processes. Adapted from Refs. [1316].

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Fig. 3

Schematic of a hybrid-AM machining process on (a) side surface and (b) top surface

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Fig. 4

Selective laser erosion of SLM printed part

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Fig. 5

Selective laser remelting of SLM printed part

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Fig. 6

Cross-sectional optical microscopy image of (a) only-SLM part and (b) SLM with laser remelting [43] (Reprinted with permission from Production Engineering Institute (PEI), @ 2011)

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Fig. 7

Laser-assisted plasma deposition

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Fig. 9

Experimentally measured residual stress (hole drilling technique) on austenitic SS 316 L after hybrid-AM by LSP using a concept M2 PBF printer: (a) 40% and (b) 80% overlap ratios. Circles indicate depth of laser peened layers. Modified from Ref. [59].

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Fig. 10

Hybrid-AM using UP

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Fig. 11

Hybrid-AM using SP

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Fig. 12

Hybrid-AM using PLD that combines printing and peening using a single laser source

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Fig. 13

Microstructural grain refinement during hybrid-AM by rolling

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Fig. 14

Intralayer friction stir AM

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Fig. 15

Hybrid-AM material, structure, and function: (a) material complexity—gradient material properties (i.e., magnetism) from DED (sample provided by Optomec), (b) structural complexity—hybrid microstructure by changing process conditions in SLM (Reprinted with permission from Niendorf et al. [129]. Copyright 2014 by Wiley.), (c) functional complexity—hybrid function smart cap using fused deposition technology (Reprinted with permission from Wu et al. [130]. Copyright 2015 by Springer Nature.)

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Fig. 16

New hybrid-AM systems since 2015: (a) LENS 3D metal hybrid controlled atmosphere system by Optomec (Albuquerque, NM), (b) Lumex Avance-60 by Matsuura (Fukui, Japan), (c) 3Dn system with an nMill™ attachment by nScrypt (Orlando, FL), and (d) Hydra series by Hyrel 3D (Atlanta, GA)




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