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Additive Manufacturing (AM) has grown considerably in recent years. The gradual transition from prototyping activities to direct manufacturing of functional parts undermines traditional methods of design and manufacturing based on conventional methods. This article focuses on the different AM technologies and fields of use throughout product life cycles. Various industrial applications are described through examples from the advanced technology sector.
Metal binder jetting (MBJ) is an additive manufacturing (AM) process. The shaping of metal parts by MBJ is comparable to inkjet printing technologies on paper. It aims to achieve higher production rates than other AM processes, combined with complex and very fine levels of detail. The printed part is sintered to achieve its final dimensions and mechanical properties. The purpose of this article is to present the specific features of all the steps involved in shaping and consolidation, in terms of design, parameterization, production flow, and post-processing.
Thermite welding is the final stage in the production of continuous long electrically welded rails. The process is easy to implement and requires little more than a qualified workforce. It allows for the temporary restoration of the service, which only slows down the traffic for a little while after its execution; which is an advantage when welding repair bars. The method consists in producing molten steel, formed by the chemical reaction between aluminum and iron oxide grains, cast between portions of rail set 25 millimeters apart and tight side molds made of refractory material. Once solidified, the ingot consolidates the two ends of the rails and unites them.
After manufacturing, rails from 25 to 110 meters are shipped by rail or boat to Flash Butt Welding Plants belonging generally to railroad companies. Electric welding allows for the manufacture of long welded rails (so-called "LWR") which, transported by special vehicles (generally trains) are laid down on the tracks, either in new portions or in long repair portions. These LWR are quite long elementary units (400 meters) which are then welded together by thermite welding. This article describes the principle of the electric process, its practical realization and a few imperfections inherent to the welding process.
When designing structures or components, it is often necessary to join elements together. One of the techniques used among others is welding. These welded joints can be subjected to cyclic loads in service, such as the rolling, the wind, the swell, the lifting of loads, etc. This article presents the necessary concepts to know about the phenomenon of fatigue and its consequences in order to better design welded joints. It will cover the following topics: notions of welding, basic notions of fatigue, the fatigue resistance of welded joints, the testing, and calculation methodology.
Microsystems are intelligent miniaturized multifunctional devices that combine mechanical, optical, electromagnetic, thermal or fluidic elements with on-board electronics. They can play the role of sensors, identifying the physical parameters of their environment (pressure, acceleration, temperature, etc.), or the role of actuators acting on that environment.This article describes microsystems, from the essential definitions to the main applications, while detailing the main categories of devices including their real implementation.
Depending on the machining operation considered, the material removal process will primarily require either high lubricating performance (in the case of neat oils) or strong cooling properties (in the case of soluble oils). Soluble oils are a mixture of water and oil concentrate. As such, they constitute a highly technical product that demands a rigorous selection process, methodical use, and increased vigilance. This article focuses on the case of soluble oils and aims to shed light on the specific characteristics of this type of cutting fluid as well as its fields of application, in order to better understand its usage.
Cutting fluids play a decisive role in the efficiency of machining operations on mechanical components. They are an important lever for increasing productivity and the quality of machined parts, as well as for optimizing the service life of cutting tools. Cutting fluids are therefore a substantial factor in competitiveness in machining. This article explains the role of cutting fluids in order to gain a better understanding of the issues involved in their use, as well as the choices to be made in a highly technical, competitive and strategic environment.
Due to their lubricating properties, full oils play a role in optimising friction at the tool/material interface during machining. In practical terms, this reduces the mechanical load on the cutting tool and keeps the temperature rise in the cutting zone within a more favourable range. Furthermore, due to their relatively high viscosity, neat oils effectively help to transport chips away from the cutting zone to prevent them from being recycled, for example. All of these characteristics, combined with control over spray and flow rate, help to increase tool life, productivity and machining quality. Full oils also provide effective protection against oxidation caused by air, humidity or temperature variations.
Additive manufacturing is increasingly used in industry and the medical sector. However, the technology can be fully adopted only if there is proof that the characteristics of the additive manufactured parts are equivalent to those produced traditionally. Inspections are required at all stages of the manufacturing process chain: feedstock, material, finished part and machinery. After a reminder of some basics, this article specifies the inspections needed in additive manufacturing. These are then presented in detail, and characterization methods are proposed.
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