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The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G)

Grant number: 16/11309-0
Support type:Research Projects - Thematic Grants
Duration: September 01, 2017 - August 31, 2022
Field of knowledge:Engineering - Mechanical Engineering - Manufacturing Processes
Principal researcher:Reginaldo Teixeira Coelho
Grantee:Reginaldo Teixeira Coelho
Home Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
Pesquisadores principais:
( Atuais )
Claudemiro Bolfarini ; Jorge Vicente Lopes da Silva ; Mário Boccalini Júnior ; Milton Sergio Fernandes de Lima
Pesquisadores principais:
( Anteriores )
João Fernando Gomes de Oliveira ; Nelson Guedes de Alcântara
Assoc. researchers:Alex Camilli Bottene ; Andre Luiz Nunis da Silva ; Claudemiro Bolfarini ; Daniel Leal Bayerlein ; Éder Sócrates Najar Lopes ; Eraldo Jannone da Silva ; Joao Batista Ferreira Neto ; João Ricardo Filipini da Silveira ; Jose Donato Ambrósio ; Kandice Suane Barros Ribeiro ; Marcelo Bertolete Carneiro ; Moysés Leite de Lima ; Pablo Aronne Funchal de Barros ; Paulo Inforçatti Neto ; Pedro Yoshito Noritomi ; Piter Gargarella ; Raphael Galdino dos Santos ; Sheila Medeiros de Carvalho
Associated grant(s):19/08926-6 - Advanced post processing for quality enhancement of 3D-printed engineering components, AP.R SPRINT
17/24122-9 - Multi-user equipment approved in grant 16/11309-0: equipment to DED - direct energy deposition, AP.EMU
Associated scholarship(s):21/07195-8 - Additive manufacturing by L-DED of functionally graded Ti-beta alloys, BP.PD
21/10448-5 - Surface treatment of additive manufactured AISI H13 tool steel produced by selective laser melting, BP.IC
21/10167-6 - Forecast of deposited volume by directed energy deposition from process parameters, BP.IC
+ associated scholarships 20/07692-9 - Fabrication and characterization of Fe-based bulk metallic glass composites produced by additive manufacturing, BP.DR
20/05049-1 - Design and evaluation of the mechanical properties of high modulus low-density steel - with formation of TiB2 in situ - processed by additive manufacturing and powder metallurgy, BP.DR
20/08432-0 - Experimental development of gas turbine repair using laser direct energy deposition, BP.DD
20/03110-5 - Characterization of WC-Co deposited through additive manufacturing (AM) using the Direct Energy Deposition (DED) method, BP.IC
20/03119-2 - The study and development of monitoring strategies for hybrid process, BP.IC
19/26362-2 - Study of tungsten carbide (WC) coatings produced by DED Direct Energy Deposition in AISI H13 and 4140 steels, BP.PD
19/25229-7 - The fabrication of small satellites with use of lasers, BP.PD
20/00035-2 - Evaluation of post processing operations of parts manufactured using hybrid manufacturing (Mfh) for roughness, BP.IC
19/13715-4 - Studies of the process variables in the inert gas atomization in the production of metal powders for DED - Direct Energy Deposition and PBD - Powder Bed Deposition, BP.PD
19/10758-4 - Study and development of post-processing in metal parts produced by additive manufacturing: application of high speed machining/grinding and magnetic abrasive finishing process, BP.DR
19/01829-5 - Additive manufacturing through selective laser melting and directed energy deposition of 316L stainless steel: effect of process parameters on mechanical properties, BP.DR
19/02772-7 - Study, development and application of hybrid process: Additive Manufacturing (AM)+High Speed Machining/Grinding (HSM/G), BP.PD
19/00343-1 - Control of directed energy deposition process for manufacturing complex geometry components by Additive Manufacturing (AM), BP.DR
18/23884-5 - Evaluation of the additive manufacturing process in the microstructural and mechanical performance of repairs for injection molds, BP.DR
18/16898-0 - Selective laser melting of a 316L stainless steel, BP.IC
18/17981-8 - Additive manufacturing of H13 tool steel, BP.IC
18/15659-1 - Selective laser melting of H13 tool steel, BP.DD
18/09999-4 - Laboratory technical support in the metallographic preparation and mechanical testing, BP.TT
18/06691-9 - 316L steel commercial powder characterization, BP.IC
18/05845-2 - H13 steel commercial powder characterization, BP.IC - associated scholarships

Abstract

Economic and sustainable production is among the most recent and enduring challenges being faced by the manufacturing area nowadays. The Additive Manufacturing (AM), capable of producing with flexibility, fully automation and sustainability, arises with a strong appeal to replace traditional processes such as casting, forging and conventional machining. AM technology was addressed in a workshop at IPT in 2015, with the presence of directors, researchers and representatives from industry and FAPESP. Due to the importance of the subject, it was suggested a gathering of main institutions working with AM in the State of São Paulo, in order to align the efforts for further development of such recent and innovative manufacturing technology. After a series of meetings the team put together the present proposal and highlights that future developments using AM technology are, however, marked by a number of technological challenges, some of them addressed in the project proposed herein. The surface finishing of workpieces produced by AM is one of them, since it may not meet some high performance applications. Thus, subtractive processes such as High Speed Machining/Grinding (HSM/G) may be employed, creating a new class of processes known as Hybrid Processes (HPr). Other issues within this almost unknown field are the metallurgical quality and the right amount of stock to machine the workpieces. In order to manage them, the whole powder production route, AM and HSM/G parameters have to be known and controlled, also a subject proposed to be studied by the present project. Regarding AM, two processes are being addressed: the Powder Bed Deposition-PBD and the Direct Energy Deposition-DED. The former uses laser to selectively bonds a tiny layer of metal powder, building the workpiece by adding sequential layers. The latter uses laser to create a fused pool over the substrate, injecting at it powder using a flow of inert gas. Following that, pool material is added creating the 3D shape. Finally, the present proposal aims to organize the researches and knowledge acquired to apply them into two particularly suitable products as a benchmark for a broad field of applications: a mold for injection molding of thermoplastics, and a turbine blade commonly used in energy generation plants. Both products will be obtained by using the HPr developed during the project. The outcome of the present research project will certainly promote scientific and technological advancements in AM, as well as it will contribute to create new resources in this most recent and innovative engineering area. In addition to that, the project intends to go beyond the average research goals by applying the newly acquired knowledge to manufacture real parts, which grants to it a strong innovative feature too. Annual workshops involving the project team and industrial partners are among the planned targets, as well as patent requests for possibly new processes, procedures and products. (AU)

Articles published in Pesquisa FAPESP Magazine about the research grant:
El avance de la impresión 3D 
The advancement of 3D printing 
Articles published in Agência FAPESP Newsletter about the research grant:
Articles published in other media outlets (0 total):
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VEICULO: TITULO (DATA)
VEICULO: TITULO (DATA)

Scientific publications (18)
(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)
DAVILA, JOSE LUIS; INFORCATTI NETO, PAULO; NORITOMI, PEDRO YOSHITO; COELHO, REGINALDO TEIXEIRA; LOPES DA SILVA, JORGE VICENTE. Algorithms-aided design applied to the tool-paths generation for hybrid manufacturing. MANUFACTURING LETTERS, v. 27, p. 53-57, . (16/11309-0, 19/02772-7)
MANSUR, VINICIUS MACHADO; DE FIGUEIREDO MANSUR, RAQUEL ALVIM; DE CARVALHO, SHEILA MEDEIROS; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; FERNANDES DE LIMA, MILTON SERGIO. Effect of laser welding on microstructure and mechanical behaviour of dual phase 600 steel sheets. HELIYON, v. 7, n. 12, . (19/25229-7, 16/11309-0)
BRAGA, V; SIQUEIRA, R. H. M.; ATILIO, I; MANSUR, R.; VIEIRA, D.; CHEN, D. L.; LIMA, M. S. F.. Microstructural and mechanical aspects of laser metal deposited H13 powder for die repair. MATERIALS TODAY COMMUNICATIONS, v. 29, . (19/25229-7, 16/11309-0, 18/23884-5)
GOMES, MILLA CAROLINE; DOS SANTOS, ALINE GONCALVES; DE OLIVEIRA, DEBORAH; FIGUEIREDO, GABRIEL VIANA; BARROS RIBEIRO, KANDICE SUANE; BARRAGAN DE LOS RIOS, GERMAN ALBERTO; DA SILVA, MARCIO BACCI; COELHO, REGINALDO TEIXEIRA; HUNG, WAYNE N. P.. Micro-machining of additively manufactured metals: a review. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 118, n. 7-8, . (20/03110-5, 19/00343-1, 19/08926-6, 16/11309-0)
MARIANI, FABIO EDSON; RIBEIRO, KANDICE SUANE BARROS; LOMBARDI, AMADEU NETO; CASTELETTI, LUIZ CARLOS; COELHO, REGINALDO TEIXEIRA. Effect of Laser Polishing Post-Processing Technique on the Roughness and Wear Resistance of Inconel 625 Deposited by Laser Cladding on AISI 304L Stainless Steel. Journal of Materials Engineering and Performance, v. 30, n. 9, SI, p. 6713-6721, . (19/00343-1, 19/26362-2, 16/11309-0)
GIULIANA SARDI VENTER; MAÍRA MARTINS DA SILVA. Vibration Control Using Multilayer Piezoelectric Actuators: Towards Chatter Supression in Turning Operations. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 23, n. 4, p. -, . (16/11309-0, 14/23108-4)
GONCALVES, THAIS SOARES; DE FARIA, GERALDO LUCIO; DE SIQUEIRA, RAFAEL HUMBERTO MOTA; DE LIMA, MILTON SERGIO FERNANDES. Weldability and mechanical behavior of laser-welded TRIP 750 steel sheets. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 107, n. 5-6, . (16/11309-0, 19/25229-7)
OLIVEIRA, ADRIEL P.; LIMA, LUIZ H. Q. R.; FELIPE, BIANCA C. A.; BOLFARINI, CLAUDEMIRO; COELHO, REGINALDO T.; GARGARELLA, PITER. Effect of microstructure and defect formation on the bending properties of additive manufactured H13 tool steel. JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T, v. 15, p. 3598-3609, . (18/15659-1, 16/11309-0, 17/27031-4)
BARRAGAN, G. A.; ROJAS, D.; GRASS, J. S.; COELHO, R. T.. Observations on Laser Additive Manufacturing (LAM) in Terms of Directed Energy Deposition (DED) with Metal Powder Feedstock. LASERS IN ENGINEERING, v. 50, n. 1-3, p. 117-141, . (16/11309-0)
RICCARDO AUGUSTO MOREIRA MONTUORI; GUSTAVO FIGUEIRA; THIAGO PACAGNAN CATALDI; NELSON GUEDES DE ALCÂNTARA; CLAUDEMIRO BOLFARINI; REGINALDO TEIXEIRA COELHO; PITER GARGARELLA. Manufatura Aditiva de Aço Inoxidável 316L por Fusão Seletiva a Laser. Soldagem & Inspeção, v. 25, . (19/01829-5, 17/27031-4, 18/16898-0, 18/06691-9, 16/11309-0)
LIMA, M. S. F.; CARVALHO, S. M.; SIQUEIRA, R. H. M.; CUNHA, M. C.; GONCALVES, C. M.; GODEFROID, L. B.. Laser-induced heating for enhanced fatigue life of aerospace aluminum alloys. Journal of the Brazilian Society of Mechanical Sciences and Engineering, v. 40, n. 11, . (16/11309-0, 16/16683-8)
DE ANDRADE FERREIRA, CAROLINE CRISTINE; BRAGA, VAGNER; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; DE CARVALHO, SHEILA MEDEIROS; FERNANDES DE LIMA, MILTON SERGIO. Laser beam welding of DP980 dual phase steel at high temperatures. OPTICS AND LASER TECHNOLOGY, v. 124, . (16/11309-0, 16/16683-8)
SOUZA, ADRIEL MAGALHAES; FERREIRA, RODRIGO; BARRAGAN, GERMAN; NUNEZ, JOHAN GRASS; MARIANI, FABIO EDSON; DA SILVA, ERALDO JANNONE; COELHO, REGINALDO TEIXEIRA. Effects of Laser Polishing on Surface Characteristics and Wettability of Directed Energy-Deposited 316L Stainless Steel. Journal of Materials Engineering and Performance, v. 30, n. 9, SI, p. 6752-6765, . (19/10758-4, 19/26362-2, 16/11309-0)
RAQUEL ALVIM DE FIGUEIREDO MANSUR; CAROLINE CRISTINE DE ANDRADE FERREIRA; ISABELA ATÍLIO; SHEILA MEDEIROS DE CARVALHO; VAGNER BRAGA; RAFAEL HUMBERTO DE MOTA SIQUEIRA; MILTON SERGIO FERNANDES DE LIMA. A Comparative Study of Abbreviated Heat Treatments for SAE 4130 Steel After Laser Welding. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 23, n. 4, p. -, . (18/23884-5, 16/11309-0, 19/25229-7)
SAKAMITI, GUILHERME PENNACHIN; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; DE CARVALHO, SHEILA MEDEIROS; MEIRELES, JOAO BATISTA; FERNANDES DE LIMA, MILTON SERGIO. Weldability of a zirconium alloy comparing resistance and pulsed laser methods. NUCLEAR MATERIALS AND ENERGY, v. 20, . (16/11309-0, 16/16683-8)
DEISI VIEIRA; JOSE EDUARDO MAY; GRAZIELA DA SILVA SAVONOV; RAFAEL HUMBERTO MOTA DE SIQUEIRA; MILTON SÉRGIO FERNANDES DE LIMA. Determination of Tensile Shear Strength and Corrosion Behavior of Circular Bead Produced by a Laser Beam for Overlapped AISI 304 Steel Sheets. Soldagem & Inspeção, v. 26, p. -, . (16/11309-0, 19/25229-7)
BARRAGAN, GERMAN; ROJAS PERILLA, DANIEL ANDRES; GRASS NUNEZ, JOHAN; MARIANI, FABIO; COELHO, REGINALDO. Characterization and Optimization of Process Parameters for Directed Energy Deposition Powder-Fed Laser System. Journal of Materials Engineering and Performance, v. 30, n. 7, SI, p. 5297-5306, . (19/26362-2, 16/11309-0)
MARTINS BARCELOS GONCALVES, KARINA APARECIDA; DE FARIA, GERALDO LUCIO; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; DE OLIVEIRA, TARCISIO REIS; FERNANDES DE LIMA, MILTON SERGIO. Heat treatment effects on the hardness and wear behavior of laser-welded AISI40 martensitic steel plates. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 114, n. 3-4, p. 1155-1163, . (16/11309-0, 19/25229-7)

Please report errors in scientific publications list by writing to: cdi@fapesp.br.