One of the key technical challenges of our time is the need to reduce time costs multiple times in all cycles of creating and manufacturing products. Making large metal structures by traditional methods takes a lot of time. Meanwhile, hybrid additive technology—high-performance metal 3D printing combined with subsequent processing—can meet the industry’s demand for the speed of obtaining finished products, but is often inferior to traditional technology in terms of strength and plasticity. The resulting product. Perm Polytechnic scientists have found a solution to this problem.
control samples, forged with pneumatic hammer
The study was conducted in collaboration with the Institute of Continuous Media Mechanics, Ural Branch of the Russian Academy of Sciences, one of the areas of Perm's academic strategic leadership priority program in 2030. The results help ensure Russia's technological sovereignty. An article on the study results of was published in in the journal Computational Continuous Physics.
Metal 3D printing is increasingly used in industries such as aircraft and mechanical engineering, energy, medicine and even jewelry. With its help, you can create lightweight and durable metal structures in complex shapes and save materials. During the "printing" process, the added material layer is combined with the already formed layer. In this case, metal atoms usually form crystals similar to trees—dendrites, and the preferred form is grains—polyhedral or circular crystal shapes.
Forging Process Solution
"Metal 3D printing produces metal alloys to a large extent limited by crystal dendritic structures. The formation of this structure can be inhibited using hybrid additive manufacturing techniques.
In our study, we used the impact of an air hammer to alternate the surface of the aluminum-magnesium alloy with layer by layer plastic deformation (forging) and found that in this way an isoaxial granular structure can be obtained," said Dmitry Trushnikov.
Calculation scheme of the process of depositing metal layers at the edge of the beam and dividing the calculation area into finite elements
The most important result of this study is the establishment of a mathematical model of the process. She showed that a mixing technique combining surfacing and forging of materials can destroy pores formed during processing of aluminum-magnesium alloys. Furthermore, mathematical models can significantly optimize forging parameters, significantly improving the strength and ductility of the material.
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