Metal Additive Manufacturing (MAM) Applications in Production of Vehicle Parts and Components—A Review
Abstract
:1. Introduction
2. Materials and Methods
- methodology of the product formation,
- type of base material used,
- processing method.
- Material Jetting,
- Binder Jetting,
- Vat Photopolymerization,
- Powder Bed Fusion,
- Material Extrusion,
- Energy Deposition,
- Sheet Lamination.
- Solid-based (Laminated Object Manufacturing “LOM”, Fused Deposition Modelling “FDM”, Wire and Arc Additive Manufacturing “WAAM”, Electron Beam Free Form Fabrication “EBFFF”),
- Powder-based (Selective Laser Sintering “SLS” and Direct Metal Laser Sintering “DMLS”, Electron Beam Melting “EBM”, Selective Laser Melting “SLM”, Laser Metal Deposition “LMD”),
- Liquid-based (Stereolithography “SLS”, Direct Light Processing “DLP”, PolyJet printing).
- Laser beam,
- Ultraviolet rays,
- Thermal means.
3. Metal Additive Manufacturing
3.1. MAM Technologies
3.2. Examples of Vehicles Parts Produced via Metal Additive Manufacturing
3.2.1. Combustion Engines Components
3.2.2. Electric Motor Components
3.2.3. Drivetrain Components
3.2.4. Other Components
4. Discussion
5. Conclusions
- Additive techniques enable the production of components with intricate geometries that are often impossible to manufacture using other conventional techniques. This includes components with internal cellular structures designed in the CAD software like Solidworks, CATIA (Dassault Systemes, Vélizy, France).
- Additive techniques enable the creation of the manufacturing topology optimization model, for example with software like Fusion 360 (Autodesk, San Francisco, CA, USA). This results in significant material savings while maintaining appropriate mechanical properties.
- Additive manufacturing is associated with Industry 4.0 due to its ability to produce a component using a single machine, for example the EOS company (Krailling, Germany) or SLM Solutions Group AG (Lubeka, Germany). The direct operation of large and complex machines is avoided to ensure human safety.
- In the additive manufacturing process using powdered material, a small amount of waste is generated, in contrast to other manufacturing techniques like milling. Any unused powder can be reused in subsequent processes, provided it has been properly sieved and dried. This reduces the cost per element.
- Additive techniques enable the production of parts using a variety of metals and alloys, ranging from steel and its variants to aluminum, copper, and their alloys, as well as high-strength titanium alloys or Inconel.
- Typically, items produced through additive manufacturing exhibit a high strength-to-weight ratio. Thus, additive techniques are widely used in the mechanical industry to produce components such as pistons, crankshafts, valves, spur gears, camshafts, brake calipers, seat belts mount, movable roof mounts, etc.
- Additive techniques have been found to offer advantages over conventional methods for producing single-piece components with complex geometries.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Metal Additive Manufacturing Technique | Advantages | Disadvantages | Mainly Used Materials | Application |
---|---|---|---|---|
Powder Bed Fusion (PBF) | fabricating complex structures, lattice structures, high strength combined with lower weight large components, no support structures required, saving and re-use material, reduction of material waste and fuel consumption | part size limitation, production time, cost of machines and materials, number of available materials, need for post-processing (porosity, surface roughness, cracks and residual stresses) | aluminum alloys, magnesium alloys, titanium alloys, steels, Ni-based superalloys, nitinol based alloys, Zn-based, pure copper or copper alloys | manufacturing complex parts for aerospace, automobile, aeronautic, biomedical implants, industrial parts, |
Sheet Lamination | process high speed, low cost, ease of material handling, multi-material process | strength and integrity largely rely on the adhesives used, material preparation before process | aluminum sheets, steel sheets | large surface components (aircraft wings) |
Directed Energy Deposition (DED) | freedom in the materials domain, enabling fabrication of multi-material structures, build environment’s freeform with 5-axis to free axis deposition heads, more possibilities to repair damaged parts | production time, need for post-processing (surface roughness, cracks, delaminations and residual stresses) | titanium alloys, steels, Ni-based superalloys, aluminum alloys | repair or manufacturing parts for aerospace, automobile, aeronautic, biomedical implants, industrial parts |
+ | − |
---|---|
better working conditions | lower dimensional accuracy |
mass customization and personalization | lower surface quality |
reduced time to market | more expensive part manufacturing |
flexibility for design changes | limited part dimensions |
possibility to produce more complex parts | high requirements for input metals |
shorter process and assembly chains | higher failure tests |
fewer spare parts | higher specific energy demand |
no need for complex tooling | need for support structures |
on-demand manufacturing | |
higher material efficiency | |
improved remanufacturability | |
less waste production | |
weight reduction |
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Sarzyński, B.; Śnieżek, L.; Grzelak, K. Metal Additive Manufacturing (MAM) Applications in Production of Vehicle Parts and Components—A Review. Metals 2024, 14, 195. https://doi.org/10.3390/met14020195
Sarzyński B, Śnieżek L, Grzelak K. Metal Additive Manufacturing (MAM) Applications in Production of Vehicle Parts and Components—A Review. Metals. 2024; 14(2):195. https://doi.org/10.3390/met14020195
Chicago/Turabian StyleSarzyński, Bartłomiej, Lucjan Śnieżek, and Krzysztof Grzelak. 2024. "Metal Additive Manufacturing (MAM) Applications in Production of Vehicle Parts and Components—A Review" Metals 14, no. 2: 195. https://doi.org/10.3390/met14020195