Abstract
Deposition process: beam solid deposition (laser, electron beam based); arc welding based deposition using gas Tungsten arc, gas metal arc, and plasma arc; cold spray based deposition; friction based deposition such as additive friction stir deposition and friction surfacing based AM; extrusion based deposition using filaments, pellets; air and ion depositions; water deposition, slurry deposition; and layerless deposition are described. Powder depositions such as coaxial continuous, coaxial discrete, and off-axial are given while laser–powder interactions are briefly explained. The difference between feedstocks: wire and powder is given.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Zheng S, Zlatin M, Selvaganapathy PR, Brook MA (2018) Multiple modulus silicone elastomers using 3D extrusion printing of low viscosity inks. Addit Manuf 24:86–92
Gannarapu A, Arda Gozen B (2019) Micro-extrusion-based additive manufacturing with liquid metals and alloys: flow and deposition driven by oxide skin mechanics. Extreme Mech Lett 33:100554
Izadi M, Farzaneh A, Mohammed M et al (2020) A review of laser engineered net shaping (LENS) build and process parameters of metallic parts. Rapid Prototyp J 26(6):1059–1078
Chaturvedi M, Scutelnicu E, Rusu CC et al (2021) Wire arc additive manufacturing: review on recent findings and challenges in industrial applications and materials characterization. Metals 11(6):939
Rajan K, Samykano M, Kadirgama K et al (2022) Fused deposition modeling: process, materials, parameters, properties, and applications. Int J Adv Manuf Technol 1–40
Yu HZ (2022) Emerging processes—friction stir based. In: Caballero FG (ed) Encyclopedia of materials: metals and alloys. Elsevier, pp 153–161
Castrejon-Pita JR, Baxter WRS, Morgan J et al (2013) Future, opportunities and challenges of inkjet technologies. At Sprays 23(6)
Pathak S, Saha GC (2017) Development of sustainable cold spray coatings and 3D additive manufacturing components for repair/manufacturing applications: a critical review. Coatings 7(8):122
Brant A, Sundaram M (2022) Electrochemical additive manufacturing of graded NiCoFeCu structures for electromagnetic applications. Manuf Lett 31:52–55
Kumar S (2020) Other solid deposition process. In: Additive manufacturing processes. Springer, Cham, pp 111–130
Grong O, Sandnes L, Berto F (2019) A status report on the hybrid metal extrusion & bonding (HYB) process and its applications. Mater Des Process Commun 1(2)
Blackburn S, Szymiczek M (2021) Extrusion. In: Pomeroy M (ed) Encyclopedia of materials: technical ceramics and glasses. Elsevier, pp 162–178
Blindheim J, Grong O, Welo T, Steinert M (2020) On the mechanical integrity of AA6082 3D structures deposited by hybrid metal extrusion & bonding additive manufacturing. J Mater Process Technol 282:116684
Vilar R (2014) Laser powder deposition. In: Comprehensive materials processing, vol 10. Elsevier Ltd, pp 163–216
Huang W, Xiao J, Chen S, Jiang X (2020) Control of wire melting behavior during laser hot wire deposition of aluminum alloy. Opt Laser Technol 150:107978
Yan Z, Liu W, Tang Z et al (2018) Review on thermal analysis in laser-based additive manufacturing. Opt Laser Technol 106:427–441
Tarasov SY, Filippov AV, Shamarin NN et al (2019) Microstructural evolution and chemical corrosion of electron beam wire-feed additively manufactured AISI 304 stainless steel. J Alloys Compd 803:364–370
Feng Y, Zhan B, He J, Wang K (2018) The double-wire feed and plasma arc additive manufacturing process for deposition in Cr-Ni stainless steel. J Mater Process Technol 259:206–215
Nieto DM, López VC, Molina SI (2018) Large-format polymeric pellet-based additive manufacturing for the naval industry. Addit Manuf 23:79–85
Steen WM, Majumder J (2010) Laser material processing. Springer-Verlag London Limited
Wang L, Zhu G, Shi T et al (2018) Laser direct metal deposition process of thin-walled parts using variable spot by inside-beam powder feeding. Rapid Prototyp J 24(1):18–27
Chen H, Lu Y, Luo D et al (2020) Epitaxial laser deposition of single crystal Ni-based superalloys: repair of complex geometry. J Mater Process Technol 285:116782
Zhao T, Wang Y, Xu T et al (2021) Some factors affecting porosity in directed energy deposition of AlMgScZr-alloys. Opt Laser Technol 143:107337
Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; part II: mechanical behavior, process parameter optimization and control. Addit Manuf 8:12–35
Oliveira UD, OcelÃk V, De Hosson JTM (2005) Analysis of coaxial laser cladding processing conditions. Surf Coat Technol 197(2–3):127–136
Eisenbarth D, Esteves PMB, Wirth F, Wegener K (2019) Spatial powder flow measurement and efficiency prediction for laser direct metal deposition. Surf Coat Technol 362:397–408
Gao X, Yao XX, Niu FY, Zhang Z (2022) The influence of nozzle geometry on powder flow behaviors in directed energy deposition additive manufacturing. Adv Powder Technol 33(3):103487
Vilar R (1999) Laser cladding. J Laser Appl 11(2):64–79
Turichin G, Zemlyakov E, Klimova O, Babkin K (2016) Hydrodynamic instability in high-speed direct laser deposition for additive manufacturing. Phys Procedia 83:674–683
Yuan L, Pan Z, Ding D et al (2021) Fabrication of metallic parts with overhanging structures using the robotic wire arc additive manufacturing. J Manuf Process 63:24–34
Wu J, Zhao P, Wei H et al (2018) Development of powder distribution model of discontinuous coaxial powder stream in laser direct metal deposition. Powder Technol 340:449–458
Kumar S (2020) Beam based solid deposition process. In: Additive manufacturing processes. Springer, Cham, pp 93–109
Li L, Huang Y (2018) Interaction of l-beam, powder stream and molten pool in laser deposition processing with coaxial nozzle. J Phys Conf Ser 1063:012078
Meacock C, Vilar R (2008) Laser powder microdeposition of CP2 titanium. Mater Des 29:353–361
Geldart D (1973) Types of gas fluidization. Powder Technol 7:285–292
Sergachev DV, Kovalev OB, Grachev GN et al (2020) Diagnostics of powder particle parameters under laser radiation in direct material deposition. Opt Laser Technol 121:105842
McLaskey GC, Glaser SD (2010) Hertzian impact: experimental study of the force pulse and resulting stress waves. J Accoust Soc Am 128(3):1087–1096
Kumar S (2020) Future additive manufacturing processes. In: Additive manufacturing processes. Springer, Cham, pp 187–202
Haley JC, Schoenung JM, Lavernia EJ (2019) Modelling particle impact on the melt pool and wettability effects in laser directed energy deposition additive manufacturing. Mater Sci Eng A 761:138052
Pirch N, Linnenbrink S, Gasser A, Schleifenbaum H (2019) Laser-aided directed energy deposition of metal powder along edges. Int J Heat Mass Transf 143:118464
Hassen AA, Noakes M, Nandwana P et al (2020) Scaling up metal additive manufacturing process to fabricate molds for composite manufacturing. Addit Manuf 32:101093
Schmidt M, Merklein M, Bourell D et al (2017) Laser based additive manufacturing in industry and academia. CIRP Ann 66(2):561–583
Kumar P, Jain NK (2020) Effect of material form on deposition characteristics in micro-plasma transferred arc additive manufacturing process. CIRP J Manuf Sci Technol 30:195–205
Blinn B, Lion P, Jordan O et al (2021) Process-influenced fatigue behavior of AISI 316L manufactured by powder-and wire-based laser direct energy deposition. Mater Sci Eng A 818:141383
Watson JK, Taminger KMB, Hafley RA, Petersen DD (2002) Development of a prototype low voltage electron beam freeform fabrication system. In: SFF proceedings, pp 458–465
Taminger KMB, Hafley RA (2013) Electron beam freeform fabrication: a rapid metal deposition process. In: Proceedings of the 3rd annual automotive composites conference, Troy, MI
Kumar S (2022) Comparison. In: Additive manufacturing solutions. Springer, Cham, pp 57–92
Dilip JJS, Babu S, Rajan SV et al (2013) Use of friction surfacing for additive manufacturing. Mater Manuf Process 28:1–6
Schultz JP, Creehan KD (2014) Friction stir fabrication. US patent US 8893954 B2
Rao KP, Sankar A, Rafi HK (2012) Friction surfacing on nonferrous substrate: a feasibility study. Int J Adv Manuf Technol 65(5–8):755–762
Gandra J, Krohn H, Miranda RM et al (2014) Friction surfacing—a review. J Mater Process Technol 214(5):1062–1093
Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R 50(1–2):1–78
Ali Y, Henckell P, Hildebrand J et al (2019) Wire arc additive manufacturing of hot work tool steel with CMT process. J Mater Process Technol 269:109–116
Chi B, Jiao Z, Yang W (2017) Design and experimental study on the freeform fabrication with polymer melt deposition. Rapid Prototyp J 23(3):633–641
Brenken B, Barocio E, Favaloro A et al (2018) Fused filament fabrication of fiber-reinforced polymers: a review. Addit Manuf 21:1–16
Wang Z, Liu R, Sparks T, Liou F (2016) Large scale deposition system by an industrial robot (I): design of fused pellet modeling system and extrusion process analysis. 3D Print Addit Manuf 3(1):39–47
Kumar N, Jain PK, Tandon P, Pandey PM (2018) Investigation on the effects of process parameters in CNC assisted pellet based fused layer modeling process. J Manuf Process 35:428–436
Roschli A, Gaul KT, Boulger AM et al (2019) Designing for big area additive manufacturing. Addit Manuf 25:275–285
Boyle BM, Xiong PT, Mensch TE et al (2019) 3D printing using powder melt extrusion. Addit Manuf 29:100811
Lieberwirth C, Harder A, Seitz H (2017) Extrusion based additive manufacturing. J Mech Eng Autom 7:79–83
Bellini A (2002) Fused deposition of ceramics: a comprehensive experimental, analytical and computational study of material behavior, fabrication process and equipment design. Drexel University
Feilden E, Blanca EGT, Giuliani F et al (2016) Robocasting of structural ceramic parts with hydrogel inks. J Eur Ceram Soc 36(10):2525–2533
Mondal D, Willett TL (2020) Mechanical properties of nanocomposite biomaterials improved by extrusion during direct ink writing. J Mech Behav Biomed Mater 104:103653
Singh G, Missiaen JM, Bouvard D, Chaix JM (2021) Additive manufacturing of 17–4 PH steel using metal injection molding feedstock: analysis of 3D extrusion printing, debinding and sintering. Addit Manuf 47:102287
O’Dowd P, Hoskins S, Geisow A, Walters P (2015) Modulated extrusion for textured 3D printing. In: NIP & digital fabrication conference, vol 1, pp 173–178
Kanada Y (2015) Support-less horizontal filament stacking by layer-less FDM. In: SFF proceedings, pp 56–70
Gu X, Hou Z, Xu J et al (2017) A novel additive manufacturing method for spiral parts. In: 2017 IEEE 7th annual international conference on CYBER technology in automation, control, and intelligent systems, pp 791–796
Guo S, Gosselin F, Guerin N et al (2015) Solvent-cast three-dimensional printing of multifunctional microsystems. Small 9(24):4118–4122
Hauser C, Sutcliffe C, Egan M, Fox P (2005) Spiral growth manufacturing (SGM)—a continuous additive manufacturing technology for processing metal powder by selective laser melting. In: SFF symposium proceedings, Texas, USA
Dudley K (2015) 3D printing using spiral buildup. US patent US20140265034A1
Kumar S (2022) Fabrication strategy. In: Additive manufacturing solutions. Springer, Cham, pp 111–144
Jordon JB, Allison PG, Phillips BJ et al (2020) Direct recycling of machine chips through a novel solid-state additive manufacturing process. Mater Des 193:108850
Goh GL, Agarwala S, Tan YJ, Yeong WY (2018) A low cost and flexible carbon nanotube pH sensor fabricated using aerosol jet technology for live cell applications. Sens Actuators B Chem 260:227–235
Wilkinson NJ, Smith MAA, Kay RW et al (2019) A review of aerosol jet printing—a non-traditional hybrid process for micro-manufacturing. Int J Adv Manuf Technol 1–21
Castellano PMH, Vega ANB, Padilla ND et al (2017) Design and manufacture of structured surfaces by electroforming. Procedia Manuf 13:402–409
Matsuzaki R, Kanatani T, Todoroki A (2019) Multi-material additive manufacturing of polymers and metals using fused filament fabrication and electroforming. Addit Manuf 29:100812
Kamraj A, Lewis S, Sundaram M (2016) Numerical study of localized electrochemical deposition for micro electrochemical additive manufacturing. Procedia CIRP 42:788–792
Mora J, Dudoff JK, Moran BD et al (2018) Projection based light-directed electrophoretic deposition for additive manufacturing. Addit Manuf 22:330–333
Habib MA, Gan SW, Rahman M (2009) Fabrication of complex shape electrodes by localized electrochemical deposition. J Mater Process Technol 209(9):4453–4458
Lin JC, Chang TK, Yang JH et al (2010) Localized electrochemical deposition of micrometer copper columns by pulse plating. Electrochim Acta 55(6):888–1894
Paul R, Anand S (2015) Optimization of layered manufacturing process for reducing form errors with minimal support structures. J Manuf Syst 36:231–243
Brant A, Sundaram M (2016) A novel electrochemical micro additive manufacturing method of overhanging metal parts without reliance on support structures. Procedia Manuf 5:928–943
Manukyan N, Kamaraj A, Sundaram M (2019) Localized electrochemical deposition using ultra-high frequency pulsed power. Procedia Manuf 34:197–204
Singh P, Dutta D (2001) Multi-direction slicing for layered manufacturing. J Comput Inf Sci Eng 1(2):129–142
Coupek D, Friedrich J, Battran D, Riedel O (2018) Reduction of support structures and building time by optimized path planning algorithms in multi-axis additive manufacturing. Procedia CIRP 67:221–226
Pikalova EY, Kalinina EG (2019) Electrophoretic deposition in the solid oxide fuel cell technology: fundamentals and recent advances. Renew Sustain Energy Rev 116:109440
Derby B (2015) Additive manufacturing of ceramic components by ink jet printing. Engineering 1(1):113–123
Lee JH, Kweon JW, Cho WS et al (2018) Formulation and characterization of black ceramic ink for a digital ink-jet printing. Ceram Int 44:14151–14157
Cappi B, Özkol E, Ebert J, Telle R (2008) Direct inkjet printing of Si3N4: characterization of ink, green bodies and microstructure. J Eur Ceram Soc 28(13):2625–2628
Ball AK, Das R, Das D et al (2018) Design, development and experimental investigation of E-jet based additive manufacturing process. Mater Today Proc 5:7355–7362
Jayabal DKK, Zope K, Cormier D (2018) Fabrication of support-less engineered lattice structures via jetting of molten aluminum droplets. In: SFF symposium proceedings, pp 757–764
Simonelli M, Aboulkhair N, Rasa M et al (2019) Towards digital metal additive manufacturing via high-temperature drop-on-demand jetting. Addit Manuf 30:100930
Wijshoff H (2018) Drop dynamics in the inkjet printing process. Curr Opin Colloid Interface Sci 36:20–27
Meisel N, Dillard D, Williams C (2018) Impact of material concentration and distribution on composite parts manufactured via multi-material jetting. Rapid Prototyp J 24(5):872–879
Leu M, Isanaka SP, Richards VL (2009) Increase of heat transfer to reduce build time in rapid freeze prototyping. In: SFF symposium proceedings, pp 219–230
Barnett E, Angeles J, Pasini D, Sijpkes P (2009) Robot-assisted rapid prototyping for ice structures. In: 2009 IEEE international conference on robotics and automation, Kobe
Kumar S (2022) Application. In: Additive manufacturing solutions. Springer, Cham, pp 93–110
Zhang W, Leu MC (2000) Investment casting with ice patterns made by rapid freeze prototyping. In: SFF symposium proceedings, pp 66–72
Pham CB, Leong KF, Lim TC, Chian KS (2008) Rapid freeze prototyping technique in bio-plotters for tissue scaffold fabrication. Rapid Prototyp J 14(4):246–253
Sames WJ, List FA, Pannala S et al (2016) The metallurgy and processing science of additive manufacturing. Int Mater Rev 1–46
Vega EJ, Cabeza MG, Muñoz-Sánchez BN et al (2014) A novel technique to produce metallic microdrops for additive manufacturing. Int J Adv Manuf Technol 70:1395–1402
Zuo H, Li H, Qi L, Zhong S (2016) Influence of interfacial bonding between metal droplets on tensile properties of 7075 aluminum billets by additive manufacturing technique. J Mater Sci Technol 32(5):485–488
Fang X, Wei Z, Du J et al (2017) Forming metal components through a fused-coating based additive manufacturing. Rapid Prototyp J 23(5):893–903
Özkol E, Ebert J, Uibel K et al (2009) Development of high solid content aqueous 3Y-TZP suspensions for direct inkjet printing using a thermal inkjet printer. J Eur Ceram Soc 29(3):403–409
Hagen D, Kovar D, Beaman JJ, Gammage M (2019) Laser flash sintering of additive manufacturing of ceramics. ARL-TR-8657, Defence Tech Info Centre, US
Ren X, Shao H, Lin T, Zheng H (2016) 3D gel-printing—an additive manufacturing method for producing complex shaped parts. Mater Des 101:80–87
Tang S, Yang L, Li G et al (2019) 3D printing of highly-loaded slurries via layered extrusion forming: parameters optimization and control. Addit Manuf 28:546–553
Wu W, Liu W, Jiang J et al (2019) Preparation and performance evaluation of silica gel/tricalcium silicate composite slurry for 3D printing. J Non-Cryst Solids 503–504:334–339
Author information
Authors and Affiliations
Rights and permissions
Copyright information
© 2022 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this chapter
Cite this chapter
Kumar, S. (2022). Deposition Process. In: Additive Manufacturing Classification . Synthesis Lectures on Engineering, Science, and Technology. Springer, Cham. https://doi.org/10.1007/978-3-031-14220-8_3
Download citation
DOI: https://doi.org/10.1007/978-3-031-14220-8_3
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-14219-2
Online ISBN: 978-3-031-14220-8
eBook Packages: Synthesis Collection of Technology (R0)eBColl Synthesis Collection 11