Top

Progress in Additive Manufacturing

Published in:

31-01-2022 | Review Article

Metal hybrid additive manufacturing: state-of-the-art

Authors: Eyob Messele Sefene, Yeabsra Mekdim Hailu, Assefa Asmare Tsegaw

Published in: Progress in Additive Manufacturing | Issue 4/2022

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

At present, the manufacturing industries are coming up with a Hybrid Additive Manufacturing (HAM) process for minimizing the cost of manufacturing, enhancing the mechanical property and surface quality of the product. HAM is a combination of additive manufacturing with a conventional manufacturing process, and this hybrid manufacturing process can impart 1 + 1 = 3 benefits compared to a single manufacturing process. The process is categorized into two major groups: material extrusion with the conventional process and hybrid metal additive manufacturing. Therefore, this review article provides a short and precise study on the state-of-the-art of Metal Hybrid Additive Manufacturing (MHAM) processes current technologies and benefits.

Graphical abstract

previous article Pin-bearing mechanical behaviour of continuous reinforced Kevlar fibre composite fabricated via fused filament fabrication

next article A dimensional assessment of small features and lattice structures manufactured by laser powder bed fusion

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Mahmoud MA, Grace J (2019) Towards the adoption of smart manufacturing systems: a development framework. Int J Adv Comput Sci Appl 10(7):29–35. https://doi.org/10.14569/IJACSA.2019.0100705CrossRef

Dilberoglu UM, Gharehpapagh B, Yaman U, Dolen M (2017) The role of additive manufacturing in the era of industry 4.0. Procedia Manuf 11:545–554. https://doi.org/10.1016/j.promfg.2017.07.148CrossRef

Tomaz I et al (2021) The development of a smart additively manufactured part with an embedded surface acoustic wave sensor. Addit Manuf Lett. https://doi.org/10.1016/j.addlet.2021.100004CrossRef

Kusiak A (2018) Smart manufacturing. Int J Prod Res 56(1–2):508–517. https://doi.org/10.1080/00207543.2017.1351644CrossRef

Ko H, Witherell P, Lu Y, Kim S, Rosen DW (2021) Machine learning and knowledge graph based design rule construction for additive manufacturing. Addit Manuf. https://doi.org/10.1016/j.addma.2020.101620CrossRef

Shen J et al (2012) In-situ synchrotron X-ray diffraction analysis of the elastic behaviour of martensite and H-phase in a NiTiHf shape memory alloy fabricated by laser powder bed fusion. Addit Manuf Lett. https://doi.org/10.1016/j.addlet.2021.100003CrossRef

Abdulhameed O, Al-Ahmari A, Ameen W, Mian SH (2019) Additive manufacturing: challenges, trends, and applications. Adv Mech Eng. https://doi.org/10.1177/1687814018822880CrossRef

Nawafleh N, Celik E (2020) Additive manufacturing of short fiber reinforced thermoset composites with unprecedented mechanical performance. Addit Manuf 33:101109. https://doi.org/10.1016/j.addma.2020.101109CrossRef

Attaran M (2017) The rise of 3-D printing: the advantages of additive manufacturing over traditional manufacturing. Bus Horiz 60(5):677–688. https://doi.org/10.1016/j.bushor.2017.05.011CrossRef

10.

Mohd Yusuf S, Cutler S, Gao N (2019) The impact of metal additive manufacturing on the aerospace industry. Metals 9(12):1286. https://doi.org/10.3390/met9121286CrossRef

11.

Strong D, Kay M, Conner B, Wakefield T, Manogharan G (2018) Hybrid manufacturing—integrating traditional manufacturers with additive manufacturing (AM) supply chain. Addit Manuf 21:159–173. https://doi.org/10.1016/j.addma.2018.03.010CrossRef

12.

Pragana JPM, Sampaio RFV, Bragança IMF, Silva CMA, Martins PAF (2021) Hybrid metal additive manufacturing: a state–of–the-art review. Adv Indus Manuf Eng 2:100032. https://doi.org/10.1016/j.aime.2021.100032CrossRef

13.

Kardys G (2017) Factors to consider when 3D printing or additive manufacturing metal parts. Engineering 360, p 3–7. https://insights.globalspec.com/article/7447/factors-to-consider-when-3d-printing-or-additive-manufacturing-metalparts. Accessed 19 Jan 2022

14.

Berger R (2013) Additive manufacturing: a game changer for the manufacturing industry. Roland Berger Strat Consult GmbH, Munich 1(5):1

15.

Bacciaglia A, Ceruti A, Liverani A (2020) Additive manufacturing challenges and future developments in the next ten years. Springer, Berlin, pp 891–902

16.

Thompson MK et al (2016) Design for additive manufacturing: trends, opportunities, considerations, and constraints. CIRP Ann 65(2):737–760. https://doi.org/10.1016/j.cirp.2016.05.004CrossRef

17.

Zhu Z, Dhokia VG, Nassehi A, Newman ST (2013) A review of hybrid manufacturing processes–state of the art and future perspectives. Int J Comput Integr Manuf 26(7):596–615. https://doi.org/10.1080/0951192X.2012.749530CrossRef

18.

Van Sice C, Faludi J (2021) Comparing environmental impacts of metal additive manufacturing to conventional manufacturing. Proc Des Soc 1:671–680. https://doi.org/10.1017/pds.2021.67CrossRef

19.

Kundra T (2019) Comparison of additive manufacturing with conventional manufacturing processes. Additive manufacturing. CRC Press, New York, pp 13–24

20.

Yamazaki T (2016) Development of a hybrid multi-tasking machine tool: integration of additive manufacturing technology with CNC machining. Procedia CIRP 42:81–86. https://doi.org/10.1016/j.procir.2016.02.193CrossRef

21.

Grzesik W (2018) Hybrid additive and subtractive manufacturing processes and systems: a review. J Mach Eng. https://doi.org/10.5604/01.3001.0012.7629CrossRef

22.

Ambrogio G, Gagliardi F, Muzzupappa M, Filice L (2019) Additive-incremental forming hybrid manufacturing technique to improve customised part performance. J Manuf Process 37:386–391. https://doi.org/10.1016/j.jmapro.2018.12.008CrossRef

23.

Sealy MP, Madireddy G, Williams RE, Rao P, Toursangsaraki M (2018) Hybrid processes in additive manufacturing. J Manuf Sci Eng. https://doi.org/10.1115/1.4038644CrossRef

24.

Flynn JM, Shokrani A, Newman ST, Dhokia V (2016) Hybrid additive and subtractive machine tools—research and industrial developments. Int J Mach Tools Manuf 101:79–101. https://doi.org/10.1016/j.ijmachtools.2015.11.007CrossRef

25.

Silva M, Felismina R, Mateus A, Parreira P, Malça C (2017) Application of a hybrid additive manufacturing methodology to produce a metal/polymer customized dental implant. Procedia Manuf 12:150–155. https://doi.org/10.1016/j.promfg.2017.08.019CrossRef

26.

Ding D, Pan Z, Cuiuri D, Li H (2015) A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM). Robot Comput-Integr Manuf 31:101–110. https://doi.org/10.1016/j.rcim.2014.08.008CrossRef

27.

Stawovy MT (2018) Comparison of LCAC and PM Mo deposited using Sciaky EBAM™. Int J Refract Metal Hard Mater 73:162–167. https://doi.org/10.1016/j.ijrmhm.2018.02.009CrossRef

28.

Popov VV, Fleisher A (2020) Hybrid additive manufacturing of steels and alloys. Manuf Rev 7:6. https://doi.org/10.1051/mfreview/2020005CrossRef

29.

Jiménez A, Bidare P, Hassanin H, Tarlochan F, Dimov S, Essa K (2021) Powder-based laser hybrid additive manufacturing of metals: a review. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-021-06855-4CrossRef

30.

Chen X et al (2017) Cellular carbon microstructures developed by using stereolithography. Carbon 123:34–44. https://doi.org/10.1016/j.carbon.2017.07.043CrossRef

31.

Karamooz Ravari MR, Kadkhodaei M, Badrossamay M, Rezaei R (2014) Numerical investigation on mechanical properties of cellular lattice structures fabricated by fused deposition modeling. Int J Mech Sci 88:154–161. https://doi.org/10.1016/j.ijmecsci.2014.08.009CrossRef

32.

Tang Y, Zhou Y, Hoff T, Garon M, Zhao Y (2016) Elastic modulus of 316 stainless steel lattice structure fabricated via binder jetting process. Mater Sci Technol 32(7):648–656. https://doi.org/10.1179/1743284715Y.0000000084CrossRef

33.

Leary M et al (2016) Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Des 98:344–357. https://doi.org/10.1016/j.matdes.2016.02.127CrossRef

34.

Challis VJ, Xu X, Zhang LC, Roberts AP, Grotowski JF, Sercombe TB (2014) High specific strength and stiffness structures produced using selective laser melting. Mater Des 63:783–788. https://doi.org/10.1016/j.matdes.2014.05.064CrossRef

35.

Plotkowski A et al (2017) Evaluation of an Al-Ce alloy for laser additive manufacturing. Acta Mater 126:507–519. https://doi.org/10.1016/j.actamat.2016.12.065CrossRef

36.

Gibson I, Rosen DW, Stucker B, Khorasani M (2021) Additive manufacturing technologies. Springer, BerlinCrossRef

37.

Kalentics N et al (2017) 3D laser shock peening—a new method for the 3D control of residual stresses in selective laser melting. Mater Des 130:350–356. https://doi.org/10.1016/j.matdes.2017.05.083CrossRef

38.

Sun R et al (2018) Microstructure, residual stress and tensile properties control of wire-arc additive manufactured 2319 aluminum alloy with laser shock peening. J Alloy Compd 747:255–265. https://doi.org/10.1016/j.jallcom.2018.02.353CrossRef

39.

Guo W et al (2018) Laser shock peening of laser additive manufactured Ti6Al4V titanium alloy. Surf Coat Technol 349:503–510. https://doi.org/10.1016/j.surfcoat.2018.06.020CrossRef

40.

Madireddy G, Li C, Liu J, Sealy MP (2019) Modeling thermal and mechanical cancellation of residual stress from hybrid additive manufacturing by laser peening. Nanotechnol Precis Eng 2(2):49–60. https://doi.org/10.1016/j.npe.2019.07.001CrossRef

41.

Schuh G, Kreysa J, Orilski S (2009) Roadmap “hybride produktion.” Zeitschrift für wirtschaftlichen Fabrikbetrieb 104(5):385–391CrossRef

42.

Lorenz K, Jones J, Wimpenny D, Jackson M (2015) A review of hybrid manufacturing. Solid Freeform Fabric Conf Proc 53:96–108

43.

Lauwers B, Klocke F, Klink A, Tekkaya AE, Neugebauer R, McIntosh D (2014) Hybrid processes in manufacturing. CIRP Ann 63(2):561–583. https://doi.org/10.1016/j.cirp.2014.05.003CrossRef

44.

HM Technologies. Hybrid manufacturing resources. https://hybridmanutech.com/resources/. Accessed 7 Aug 2021

45.

Jones JB (2016) The synergies of hybridizing CNC and additive manufacturing. Hybrid Manufacturing Technologies, McKinney

46.

Dilberoglu UM, Gharehpapagh B, Yaman U, Dolen M (2021) Current trends and research opportunities in hybrid additive manufacturing. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-021-06688-1CrossRef

47.

Bambach M, Sizova I, Sydow B, Hemes S, Meiners F (2020) Hybrid manufacturing of components from Ti-6Al-4V by metal forming and wire-arc additive manufacturing. J Mater Process Technol 282:116689. https://doi.org/10.1016/j.jmatprotec.2020.116689CrossRef

48.

Gong M, Zhang S, Lu Y, Wang D, Gao M (2021) Effects of laser power on texture evolution and mechanical properties of laser-arc hybrid additive manufacturing. Addit Manuf 46:102201. https://doi.org/10.1016/j.addma.2021.102201CrossRef

49.

Liravi F, Toyserkani E (2018) A hybrid additive manufacturing method for the fabrication of silicone bio-structures: 3D printing optimization and surface characterization. Mater Des 138:46–61. https://doi.org/10.1016/j.matdes.2017.10.051CrossRef

50.

Cortina M, Arrizubieta JI, Ruiz JE, Ukar E, Lamikiz A (2018) Latest developments in industrial hybrid machine tools that combine additive and subtractive operations. Materials 11(12):2583. https://doi.org/10.3390/ma11122583CrossRef

51.

Klocke F, Wirtz H, Meiners W (1996) Direct manufacturing of metal prototypes and prototype tools. In: International Solid Freeform Fabrication Symposium

52.

Nagel JK, Liou, FW (2012) Hybrid manufacturing system modeling and development. In: international design engineering technical conferences and computers and information in engineering conference, vol. 45028: American Society of Mechanical Engineers, p 189–198

53.

Jeng J-Y, Lin M-C (2001) Mold fabrication and modification using hybrid processes of selective laser cladding and milling. J Mater Process Technol 110(1):98–103CrossRef

54.

Kerschbaumer M, Ernst G (2004) Hybrid manufacturing process for rapid high performance tooling combining high speed milling and laser cladding. In: international congress on applications of lasers & electro-optics vol. 2004, no. 1: Laser Institute of America, p 1710

55.

Jones JB, McNutt P, Tosi R, Perry C, Wimpenny DI (2012) Remanufacture of turbine blades by laser cladding, machining and in-process scanning in a single machine. De Montfort University, Leicester

56.

Avance L (2021) Hybrid metal 3D printer. https://www.lumex-matsuura.com/english/. Accessed 7 Aug 2021

57.

Helou M, Kara S (2018) Design, analysis and manufacturing of lattice structures: an overview. Int J Comput Integr Manuf 31(3):243–261. https://doi.org/10.1080/0951192X.2017.1407456CrossRef

58.

Riva L, Ginestra PS, Ceretti E (2021) Mechanical characterization and properties of laser-based powder bed–fused lattice structures: a review. Int J Adv Manuf Technol 113(3):649–671. https://doi.org/10.1007/s00170-021-06631-4CrossRef

59.

M S Manufacturing. Hybrid Metal 3D Printer LUMEX Series. https://www.lumex-matsuura.com/english/samplework. Accessed 7 Aug 2021

60.

M. M. USA. Matsuura Lumex Avance-25 Hybrid Metal 3D Printer Review. https://www.matsuurausa.com/matsuura-lumex-avance-25-hybrid-metal-3d-printer-review/. Accessed 7 Aug 2021

61.

Grzesik W (2018) Hybrid manufacturing of metallic parts integrated additive and subtractive processes. Mechanik 91(7):468–475CrossRef

62.

Jones JB (2016) Repurposing mainstream CNC machine tools for laser-based additive manufacturing. Laser 3D manufacturing III. International Society for Optics and Photonics, Bellingham

63.

H. M. Technologies. Different deposition heads of the Ambit hybrid manufacturing system. https://hybridmanutech.com/services/. Accessed 7 Aug 2021

64.

Zhang Z, Sun C, Xu X, Liu L (2018) Surface quality and forming characteristics of thin-wall aluminium alloy parts manufactured by laser assisted MIG arc additive manufacturing. Int J Lightw Mater Manuf 1(2):89–95. https://doi.org/10.1016/j.ijlmm.2018.03.005CrossRef

65.

Wu D et al (2020) Al–Cu alloy fabricated by novel laser-tungsten inert gas hybrid additive manufacturing. Addit Manuf 32:100954. https://doi.org/10.1016/j.addma.2019.100954CrossRef

66.

Li R et al (2020) Optimization of the geometry for the end lateral extension path strategy to fabricate intersections using laser and cold metal transfer hybrid additive manufacturing. Addit Manuf 36:101546. https://doi.org/10.1016/j.addma.2020.101546CrossRef

67.

Avegnon KLM et al (2021) Use of energy consumption during milling to fill a measurement gap in hybrid additive manufacturing. Addit Manuf 46:102167. https://doi.org/10.1016/j.addma.2021.102167CrossRef

68.

Altıparmak SC, Yardley VA, Shi Z, Lin J (2021) Challenges in additive manufacturing of high-strength aluminium alloys and current developments in hybrid additive manufacturing. Int J Lightw Mater Manuf 4(2):246–261. https://doi.org/10.1016/j.ijlmm.2020.12.004CrossRef

Title: Metal hybrid additive manufacturing: state-of-the-art
Authors: Eyob Messele Sefene
Yeabsra Mekdim Hailu
Assefa Asmare Tsegaw
Publication date: 31-01-2022
Publisher: Springer International Publishing
Published in: Progress in Additive Manufacturing / Issue 4/2022
Print ISSN: 2363-9512
Electronic ISSN: 2363-9520
DOI: https://doi.org/10.1007/s40964-022-00262-1

Springer Professional

Abstract

Graphical abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 4/2022

The influence of the energy density on dimensional, geometric, mechanical and morphological properties of SLS parts produced with single and multiple exposure types

Review of binder jetting 3D printing in the construction industry

Bio-composites for fused filament fabrication: effects of maleic anhydride grafting on poly(lactic acid) and microcellulose

Effect of printing parameters on the tensile strength of FDM 3D samples: a meta-analysis focusing on layer thickness and sample orientation

A comprehensive investigation of the 3D printing parameters’ effects on the mechanical response of polycarbonate in fused filament fabrication

Pin-bearing mechanical behaviour of continuous reinforced Kevlar fibre composite fabricated via fused filament fabrication

Premium Partners