Economic validation of metal powder bed based AM processes

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dc.contributor Aalto-yliopisto fi
dc.contributor Aalto University en
dc.contributor.advisor Flores, Inigo Kretzschmar, Niklas 2015-06-23T10:51:45Z 2015-06-23T10:51:45Z 2015-06-08
dc.description.abstract This master thesis focused on current metal-based Additive Manufacturing (AM) systems in terms of cost and feasibility by developing a metal-based AM decision support tool. In addition, the main differences between laser-beam (DMLM) and electron-beam (EBM) based systems have been investigated. Initially, main principles in AM and powder bed fusion (PBF) are presented. Moreover, DMLM and EBM based systems are compared in terms of performance characteristics, such as build size, beam power as well as beam spot size. Subsequently, existing AM classification schemes are shown and resulting research gaps are outlined. Secondly, a cost and time decision support system based on ”MathWorks Matlab” has been developed to provide a comparison of two metal-based AM machines simultaneously. In total, 9 different machines (i.e. EOS, SLM and Arcam), 3 different material types (i.e. aluminum, tool steel and titanium alloys) and 3 different accuracy levels (i.e. high, low, and skin-core) can be chosen as input parameters. Therefore, build volume rates of machines in the range of 50 to 3000 W were calculated and implemented into the model. As an output of the model, the decision maker receives information, such as cost per part, total cost comparison and a build time evaluation for the selected machines, materials and accuracy level. This information allows to select which machine the best choice is for the user’s specific interests. To conclude, several experiments including a sensitivity analysis for mass and building height, followed by a skin-core analysis (novel AM production method), an exemplary comparison of DMLM and EBM machines and a random test on all implemented machines and five exemplary parts showing differences in volume and size were performed. Moreover, the Design of Experiments is finished with a Taguchi L-18 orthogonal array test, leading to main effects and influences on several parameters on costs and build time. en
dc.format.extent 89+9
dc.format.mimetype application/pdf en
dc.language.iso en en
dc.title Economic validation of metal powder bed based AM processes en
dc.type G2 Pro gradu, diplomityö en Insinööritieteiden korkeakoulu fi
dc.subject.keyword additive manufacturing en
dc.subject.keyword powder bed fusion en
dc.subject.keyword direct metal laser melting en
dc.subject.keyword decision making tool en
dc.identifier.urn URN:NBN:fi:aalto-201506303423
dc.programme.major Production Engineering fi
dc.programme.mcode K3002 fi
dc.type.ontasot Master's thesis en
dc.type.ontasot Diplomityö fi
dc.contributor.supervisor Partanen, Jouni
dc.programme Master’s Programme in Mechanical Engineering fi
dc.ethesisid Aalto 9769
dc.location P1

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