A novel additive manufacturing process for the production of metal parts

Butt, Javaid (2016) A novel additive manufacturing process for the production of metal parts. Doctoral thesis, Anglia Ruskin University.

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Abstract

The majority of additive manufacturing methods use different materials for the production of parts. The current methods employing powder metals have their limitations and are very expensive. This research presents a novel additive manufacturing process for the generation of modest and high quality metal parts. The procedure, referred to as Composite Metal Foil Manufacturing, is a blend of Laminated Object Manufacturing and soldering/brazing strategies. A calculated model of a machine in view of the new process has been outlined and its parts accepted for usefulness either by experimentation or recreations. The viability of the new process is accepted with lap-shear testing, peel testing, microstructural examination and tensile testing. Distinctive metals, such as copper and aluminium, with shifting thicknesses were used to demonstrate the adaptability of the procedure. Composites of aluminium and copper were additionally delivered and tried for their mechanical properties to show the flexibility of the process. The outcomes of the research attained have been promising and show that the new process is not just fit for delivering astounding metal parts efficiently but can create more grounded parts contrasted with customary subtractive techniques. The comparative tensile testing demonstrated that the parts created by the new process had force values that were 11%, 8% and 11% higher than the parent copper, aluminium and composite examples individually. This shows that the procedure has the capability to be a solid competitor in the field of metal prototyping. It has been demonstrated that the proposed procedure can have a gigantic effect as it has lessened the confinements, for example, cost, pace, material determinations and beyond. The additive manufacturing identified with the generation of metal parts using the new process can work with an extensive variety of metals under typical conditions regardless of their joining capacities. The feedback that parts delivered by added substance fabrication techniques are not sufficiently strong for genuine applications can without much of a stretch is hushed with the obtained trial results. Applications can extend from little bespoke parts to large scale functional products that can be utilized with minimal post handling.

Item Type: Thesis (Doctoral)
Keywords: rapid prototyping, mechanical testing, microstructural analysis, metal foils, product development
Faculty: Theses from Anglia Ruskin University
Depositing User: Unnamed user with email melissa.campey@anglia.ac.uk
Date Deposited: 24 Oct 2016 14:47
Last Modified: 30 Nov 2016 08:51
URI: http://arro.anglia.ac.uk/id/eprint/701001

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