AUGUST 20229MANUFACTURING TECHNOLOGY INSIGHTSbed fusion as well as sintering-based technologies such as binder jet and fused deposition modeling.For manufacturers looking to incorporate metal AM for large-format applications, i.e., components that measure several feet or more with weights in the hundreds, if not thousands, of pounds, there are alternative AM technologies that are quickly establishing themselves as reliable and cost-effective. Wire-based AM technologies such as arc welding, laser, and electron beam can be used by manufacturers now to produce not just prototypes, but tooling, replacement parts, and in-service components using well-established welding alloys and processes that have been used for decades in critical applications. Manufacturers can take advantage of lower lead times, less material waste, improved part performance, and enhanced designs afforded by AM.The database of mechanical properties is growing as well as industry codes and standards, which should increase confidence in the technologies. For example, ASME's Boiler and Pressure Vessel Code has been a trusted global standard for over 100 years. ASME's Section IX committee, which oversees welding, recently approved a code case for manufacturers to qualify procedures for gas metal arc AM. Others such as the American Welding Society and DNV have also developed metal AM standards with others also in the works. With ASME and other standards bodies developing codes and specifications in coming years, manufactures can confidently adopt large-format metal AM.Further driving adoption is the rapid development of the technology: software capabilities, facility efficiencies, and process improvements, all of which improve quality and reduce costs. Software advancements will lead to improved prediction residual stresses and mechanical properties. As more factories install systems, manufacturing efficiencies and quality will increase dramatically. Process development will continue to improve not only reliability but also costs. For example, Oak Ridge National Laboratory in conjunction with Lincoln Electric recently demonstrated a 3x improvement in deposition rates by utilizing 3 robot arms simultaneously.AM is not a panacea and it will not take over manufacturing wholesale. What it does provide is a powerful tool in the manufacturer's tool belt that opens up new worlds of possibilities in speed to market, part performance, or designs, and manufacturers can start using AM now for their large-format applications. Software advancements will lead to improved prediction of residual stresses and mechanical properties
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