The application of additive manufacturing (AM) is becoming widely used today. However many challenges remain especially for metal parts printed directly from AM process: lack of forging quality, rough surface finish that requires an additional machining step, as well as low printing speed, etc. This paper presents a new breakthrough, an integrated printing technology that has casting, forging and milling all in one process for parts small to large (size up to 4m x 2m x 2m), using an efficient and inexpensive energy source of arc welding. The synchronous arc welding and continuous semi-solid in-situ forging is attained with micro-rolling, resulting in equiaxed fine-grain microstructure whose property exceeds conventional hot forgings. Milling is also incorporated into this process to achieve a high quality surface finish without going through a separate machining process. Titanium alloy aviation parts have been manufactured by this technology, and the aero-engine transition section part has passed the European standard x-ray inspection and test. A stainless steel marine propeller is ready for underwater testing. An austenite-bainite steel Frog used for high speed rail is ready to go to market. This technology offers an innovative way of simplified, efficient and green manufacturing with one piece of integrated equipment producing high performance forging components as its output.
- Change the concept that AM technology cannot manufacture forgings
- Discuss the new simplified, efficient and green processes called casting-forging-milling composite (CFMC) Additive Manufacturing technology
- Learn CFMC application in the presentation report