A physical simulation technique for cleaner and more sustainable research in additive manufacturing

• Published in: Journal of cleaner production Vol. 285; p. 124910
• Main Authors: Hosseini, Vahid A, Cederberg, Emil, Hurtig, Kjell, Karlsson, Leif
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 20.02.2021
• Subjects: 3D printers; Additive manufacturing; Duplex stainless steels; Physical simulation; Production Technology; Produktionsteknik; Sustainable materials research; Thermal cycles; Wire-arc AM; Wire-arc AM; Duplex stainless steels; Thermal cycles; Sustainable materials research; Additive manufacturing; Physical simulation; Additives; Heat treatment; Total processing time; Experimental alloys; Pollution control; Microstructure and properties; Super duplex stainless steel; Wire; Microstructural evolution; Specific component; Industrial research; Investments; Austenite; Cleaner production; Duplex stainless steel; Thermal cycling; Water-cooled chambers
• ISSN: 0959-6526; 1879-1786; 1879-1786
• DOI: 10.1016/j.jclepro.2020.124910

Additive manufacturing (AM) introduces a new domain for zero waste and cleaner production. Research for verification of materials in AM and effects of the process on the material behavior, however, demands a significant amount of materials, energy, and man-hours. The design of suitable physical simulation techniques that can duplicate complex AM thermal cycles without performing AM is therefore crucial for cleaner and more sustainable AM research. This paper aims at introducing a novel technique to reproduce AM thermal cycles in a controlled way on a small sample, thereby supporting sustainable alloy verification and cleaner research. In this technique, a stationary arc is applied to a disc-shaped sample mounted on a water-cooled chamber, where the arc and water provide rapid heating and cooling, respectively. In the present study, a super duplex stainless steel (SDSS) was used as the experimental alloy to simulate the evolution of microstructure and properties during wire-arc additive manufacturing. The experiment was performed using the stationary arc with the holding time of 5 s, applied 1, 5, or 15 times. The total processing time was only 450 s (7.5 min) for the 15 a.m. thermal cycles experiment. The SDSS showed a progressive increase in the austenite fraction at 600–1200 °C and the formation of detrimental sigma phase at 700–1000 °C, but a reduction of austenite fraction above 1300 °C. The results were in good agreement with the literature, verifying the applicability of the physical simulation technique for AM research. Calculations showed that using arc heat treatment as the initial step is 6–20 times more efficient in different respects (materials, energy, and man-hours) compared to wire arc additive manufacturing. Therefore, this methodology can be implemented to gain an understanding of materials in AM applications thereby eliminating the need for investments in additive manufacturing of a specific component. •A novel physical simulation was introduced for additive manufacturing (AM) research.•It uses arc as the power source and water as the cooling media.•It physically simulates material behavior subjected to AM without doing AM.•It significantly reduces materials, energy, and person-hours needed for AM research.•It contribute sustainable AM research with a fast, clean, and controllable approach.