Mechanical Characterization of Meta-Materials Manufactured by a Novel Hybrid SLM Technique Utilizing Powder Metallurgy

Abstract

In this study, a novel hybrid manufacturing approach was introduced, seamlessly integrating selective laser melting (SLM) with powder metallurgy (PM), aimed at maximizing SLM machine utilization. The method involved using SLM for creating detailed outer shells and intricate lattice structures, while employing PM for sintering metal powders within enclosed volumes. This hybrid approach reduced production time on SLM machines by up to 70%. The parts produced using this technique featured an outer shell, intricate lattice structure, and porous interior, resulting in significant weight reductions of 67 to 83%. Mechanical analysis revealed a 50% reduction in yield strength, which is advantageous for applications requiring greater flexibility and impact absorption. Additionally, the parts demonstrated an 80% increase in toughness, indicating improved durability. These findings highlight the potential of this hybrid technique to revolutionize manufacturing processes in critical sectors such as aerospace and automotive. By overcoming the limitations of traditional SLM methods and leveraging their strengths, this approach offers a significant step forward in manufacturing technology, providing enhanced performance and efficiency.