SAE Update - April 2023 - 11

Materials and additive manufacturing
teaming for the win
TECH FOCUS:
MATEriAlS
Works (Figure 2). This is a novel, low-cost,
highly flexible, and environmentally friendly
approach to powder production that has
yielded some impactful results.
Cu-alloys for additive manufacturing
have gained significant interest, from
electrical and thermal management in the
automotive sector, to waveguide
production for power amplifier/
transmitters. Cu-alloys are particularly
challenging to deploy in laser-based AM
processes due to their high reflectivity and
high thermal conductivity. Cu-alloys are
known for drastically changing their
absorptivity (jumping from very low to high
absorptivity value) as a function of
temperature during the laser-material
interaction, resulting in high-power
requirements to start melting powders and
immediate process instability due to
material vaporization. The MSAM group
have combined modeling, process
monitoring, and machine learning
algorithms to understand and influence
part quality and achieve densities wellabove
99.9% (Figure 3).
By understanding the nature of the AMmaterials
relationship, the door opens to
more alloys and more options for
manufacturing them. Teams like MPW/
MSAM/TBGA have the necessary skills to
unlock the benefits by understanding the
sphericity, morphology, and the processing
benefits. For example, the MSAM lab is
investigating evidence that the <0.9
sphericity powder may have better laserUPDATE
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from SAE International by SAE International [Sales Team], Monday, February 27, 2023
Determining Design
Properties for Metal
Additive Manufacturing
in the Mobility Industry
Kevin T. Slattery, DSc
EMERGING ISSUES IN NEW MOBILITY
New SAE research report on
additive manufacturing released
As metal additive manufacturing (MAM),
also known as " metal 3D printing, " moves
from prototype to low- and high-rate
production for increasingly critical
applications for more industries, many
product teams are tasked with determining
design properties for the first time in many
years. So says Kevin Slattery, author of a
new SAE report. " Not only is it necessary to
determine the basic material properties, but
it is also necessary to accommodate new
geometries and design concepts as well.
While some of the methods and approaches
are common to other product forms, others
are unique to MAM. "
As the ninth in a series of SAE EDGE
Research Reports on additive
manufacturing, this report (Determining
Design Properties for Metal Additive
Manufacturing in the Mobility Industry)
covers the challenges in determining design
properties and provides a comparison with
existing technologies, along with an example
and recommendations for future work. n
April 2023
11

https://saemobilus.sae.org/content/EPR2023004/ https://www.sae.org/publications/edge-research-reports https://www.sae.org/publications/edge-research-reports https://saemobilus.sae.org/content/EPR2023004/ https://saemobilus.sae.org/content/EPR2023004/ https://saemobilus.sae.org/content/EPR2023004/

SAE Update - April 2023

Table of Contents for the Digital Edition of SAE Update - April 2023