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Technologies 2017, 5(2), 15; doi:10.3390/technologies5020015

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

1
Department of Industrial and Systems Engineering and Engineering Management, University of Alabama in Huntsville, Technology Hall N143, 301 Sparkman Drive, Huntsville, AL 35899, USA
2
Department of Industrial and Enterprise Systems Engineering, University of Illinois at Urbana-Champaign, Transportation Building 117, 104 South Mathews Avenue, Urbana, IL 61801, USA
*
Author to whom correspondence should be addressed.
Academic Editors: Salvatore Brischetto, Paolo Maggiore and Carlo Giovanni Ferro
Received: 24 March 2017 / Revised: 7 April 2017 / Accepted: 10 April 2017 / Published: 12 April 2017
(This article belongs to the Special Issue Additive Manufacturing Technologies and Applications)
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Abstract

A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review. View Full-Text
Keywords: additive manufacturing; 3D printing; metal additive manufacturing; selective laser melting (SLM); direct metal laser sintering (DMLS); metal powder processing additive manufacturing; 3D printing; metal additive manufacturing; selective laser melting (SLM); direct metal laser sintering (DMLS); metal powder processing
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Patterson, A.E.; Messimer, S.L.; Farrington, P.A. Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need. Technologies 2017, 5, 15.

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