Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: A review

Journal article

Bidare, P., Jiménez, A., Hassanin, H. and Essa, K. 2021. Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: A review. Advances in Manufacturing. https://doi.org/10.1007/s40436-021-00365-y

Publication dates
Authors	Bidare, P., Jiménez, A., Hassanin, H. and Essa, K.
Abstract	Additive manufacturing (AM) technologies are currently employed for the manufacturing of completely functional parts and have gained the attention of high-technology industries such as the aerospace, automotive, and biomedical fields. This is mainly due to their advantages in terms of low material waste and high productivity, particularly owing to the flexibility in the geometries that can be generated. In the tooling industry, specifically the manufacturing of dies and molds, AM technologies enable the generation of complex shapes, internal cooling channels, the repair of damaged dies and molds, and an improved performance of dies and molds employing multiple AM materials. In the present paper, a review of AM processes and materials applied in the tooling industry for the generation of dies and molds is addressed. AM technologies used for tooling applications and the characteristics of the materials employed in this industry are first presented. In addition, the most relevant state-of-the-art approaches are analyzed with respect to the process parameters and microstructural and mechanical properties in the processing of high-performance tooling materials used in AM processes. Concretely, studies on the additive manufacturing of ferrous (maraging steels and H13 steel alloy) and non-ferrous (Stellite alloys and WC alloys) tooling alloys are also analyzed.
Keywords	Additive manufacturing; Tooling alloys; Super alloys; Hybrid manufacturing; Post processing
Year	2021
Journal	Advances in Manufacturing
Publisher	Springer Nature
ISSN	2195-3597
	2095-3127
Digital Object Identifier (DOI)	https://doi.org/10.1007/s40436-021-00365-y
Official URL	https://link.springer.com/article/10.1007/s40436-021-00365-y
Print	16 Sep 2021
Publication process dates
Deposited	07 Jul 2021
Accepted	05 Jul 2021
Accepted author manuscript	AM_of_Tooling_Alloys_Manuscript.pdf License CC BY 4.0
Output status	Published
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Abena, A., Ataya, S., Hassanin, H., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ahmed, M. and Essa, K. 2023. Hybrid finite element–smoothed particle hydrodynamics modelling for optimizing cutting parameters in CFRP composites. Polymers. 15 (13), p. 2789. https://doi.org/10.3390/polym15132789

Embracing sustainable farming: Unleashing the circular economy potential of second-life EV batteries in agricultural applications

Al-Alawi, M., Cugley, J. and Hassanin, H. 2023. Embracing sustainable farming: Unleashing the circular economy potential of second-life EV batteries in agricultural applications.

Entrained defects and mechanical properties of aluminium castings

El-Sayed, M., Essa, K. and Hassanin, H. 2023. Entrained defects and mechanical properties of aluminium castings.

Preparation of polylactic acid/calcium peroxide compo-site filaments for fused deposition modelling

Mohammed, A., Kovacev , N., Elshaer, A., Melaibari, A., Iqbal, J., Hassanin, H., Essa, K. and Memić, A. 2023. Preparation of polylactic acid/calcium peroxide compo-site filaments for fused deposition modelling. Polymers. 15 (9), p. 2229. https://doi.org/10.3390/polym15092229

Non-destructive disassembly of interference fit under wear conditions for sustainable remanufacturing

Yeung, H., Ataya, S., Hassanin, H., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ahmed, M. and Essa, K. 2023. Non-destructive disassembly of interference fit under wear conditions for sustainable remanufacturing. Machines. 11 (5), p. 538. https://doi.org/10.3390/machines11050538

Fabrication and characterization of oxygen-generating polylactic acid/calcium peroxide composite filaments for bone scaffolds

Mohammed, A., Saeed, A., Elshaer, A., Melaibari, A., Memić, A., Hassanin, H. and Essa, K. 2023. Fabrication and characterization of oxygen-generating polylactic acid/calcium peroxide composite filaments for bone scaffolds. Pharmaceuticals. 16 (4), p. 627. https://doi.org/10.3390/ph16040627

Using second-life batteries and solar power to help farms become energy efficient.

Al-Alawi, M., Cugley, J. and Hassanin, H. 2023. Using second-life batteries and solar power to help farms become energy efficient. Canterbury Christ Church University.

Chip formation and orthogonal cutting optimisation of unidirectional carbon fibre composites

Hassanin, H., Abena, A., Soo, L., Ataya, S., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ahmed, M. and Essa, K. 2023. Chip formation and orthogonal cutting optimisation of unidirectional carbon fibre composites. Polymers. 15 (8), p. 1897. https://doi.org/10.3390/polym15081897

Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing

Bittredge, Oliver, Hassanin, H., El-Sayed, M., Eldessouky, Hossam Mohamed, A. Alsaleh, N., Alrasheedi, Nashmi H., Essa, K. and Ahmadein, M. 2022. Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing. Materials (Basel, Switzerland). 15 (9), p. e3095. https://doi.org/10.3390/ma15093095

Elastomer-based visuotactile sensor for normality of robotic manufacturing systems

Hassanin, H., Zaid, I., Halwani, M., Ayyad, A., Imam, A., Almaskari, F. and Zweiri, Y. 2022. Elastomer-based visuotactile sensor for normality of robotic manufacturing systems. Polymers. 14 (23), p. 5097. https://doi.org/10.3390/polym14235097

Techno-economic feasibility of retired electric-vehicle batteries repurpose/reuse in second-life applications: A systematic review

Hassanin, H., Al-Alawi, M. and Cugley, J. 2022. Techno-economic feasibility of retired electric-vehicle batteries repurpose/reuse in second-life applications: A systematic review. Energy and Climate Change. 3 (100086). https://doi.org/10.1016/j.egycc.2022.100086

Planning, operation, and design of market-based virtual power plant considering uncertainty

Hassanin, H., Ullah, Z., Arshad, Cugley, J. and Al-Alawi, M. 2022. Planning, operation, and design of market-based virtual power plant considering uncertainty. Energies. 19 (15), p. 7290. https://doi.org/10.3390/en15197290

The epistemic insight digest: Issue : Autumn 2022

Gordon, A., Shalet, D., Simpson, S., Hassanin, H., Lawson, F., Lawson, M., Litchfield, A., Thomas, C., Canetta, E., Manley, K. and Choong, C. Shalet, D. (ed.) 2022. The epistemic insight digest: Issue : Autumn 2022. Canterbury Canterbury Christ Church University.

Modeling, optimization, and analysis of a virtual power plant demand response mechanism for the internal electricity market considering the uncertainty of renewable energy sources

Ullah, Z., Arshad and Hassanin, H. 2022. Modeling, optimization, and analysis of a virtual power plant demand response mechanism for the internal electricity market considering the uncertainty of renewable energy sources. Energies. 15 (14), p. 5296. https://doi.org/doi.org/10.3390/en15145296

Interdisciplinary engineering education - essential for the 21st century

Gordon, A., Simpson, S. and Hassanin, H. 2022. Interdisciplinary engineering education - essential for the 21st century.

Multipoint forming using hole-type rubber punch

Hassanin, H., Tolipov, A., El-Sayed, M., Eldessouky, H., A. Alsaleh, N., Alfozan, A., Essa, K. and Ahmadein, M. 2022. Multipoint forming using hole-type rubber punch. Metals. 12 (3), p. 491. https://doi.org/10.3390/met12030491

Influence of bifilm defects generated during mould filling on the tensile properties of Al−Si−Mg cast alloys

El-Sayed, M., Essa, K. and Hassanin, H. 2022. Influence of bifilm defects generated during mould filling on the tensile properties of Al−Si−Mg cast alloys. Metals. 12 (1), p. e160. https://doi.org/10.3390/met12010160

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Yan, Zhou, Hassanin, H., El-Sayed, M., Eldessouky, Hossam Mohamed, Djuansjah, Joy Rizki Pangestu, A. Alsaleh, N., Essa, K. and Ahmadein, M. 2021. Multistage Tool Path Optimisation of Single-Point Incremental Forming Process. Materials (Basel, Switzerland). 14 (22), p. e6794. https://doi.org/10.3390/ma14226794

Effect of runner thickness and hydrogen content on the mechanical properties of A356 alloy castings

El-Sayed, M., Essa, K. and Hassanin, H. 2021. Effect of runner thickness and hydrogen content on the mechanical properties of A356 alloy castings . International Journal of Metalcasting. https://doi.org/10.1007/s40962-021-00753-x

Parts design and process optimization

Hassanin, Hany, Bidare, Prveen, Zweiri, Yahya and Essa, Khamis 2021. Parts design and process optimization. in: Salunkhe, S., Hussein, H. and Davim, J. (ed.) Applications of Artificial Intelligence in Additive Manufacturing USA IGI Global. pp. 25-49

Micro-additive manufacturing technologies of three-dimensional MEMS

Hassanin, H., Sheikholeslami, G., Pooya, S. and Ishaq, R. 2021. Micro-additive manufacturing technologies of three-dimensional MEMS . Advanced Engineering Materials. https://doi.org/10.1002/adem.202100422

Machine learning applied to the design and inspection of reinforced concrete bridges: Resilient methods and emerging applications

Fan , W., Chen, Y., Li, J., Sun, Y., Feng, F., Hassanin, H. and Sareh, P. 2021. Machine learning applied to the design and inspection of reinforced concrete bridges: Resilient methods and emerging applications. Structures. 33, pp. 3954-3963. https://doi.org/10.1016/j.istruc.2021.06.110

Laser powder bed fusion of Ti-6Al-2Sn-4Zr-6Mo alloy and properties prediction using deep learning approaches

Hassanin, H., Zweiri, Y., Finet, L., Essa, K., Qiu, C. and Attallah, M. 2021. Laser powder bed fusion of Ti-6Al-2Sn-4Zr-6Mo alloy and properties prediction using deep learning approaches. Materials. 14 (8), p. 2056. https://doi.org/10.3390/ma14082056

3DP printing of oral solid formulations: a systematic review

Brambilla, C., Okafor-Muo, O., Hassanin, H. and ElShaer, A. 2021. 3DP printing of oral solid formulations: a systematic review. Pharmaceutics. 13 (3), p. 358. https://doi.org/10.3390/pharmaceutics13030358

Powder-based laser hybrid additive manufacturing of metals: A review

Hassanin, H. 2021. Powder-based laser hybrid additive manufacturing of metals: A review. The International Journal of Advanced Manufacturing Technology.

Micro-fabrication of ceramics: additive manufacturing and conventional technologies

Hassanin, H., Essa, K., Elshaer, A., Imbaby, M. and El-Sayed, T. E. 2021. Micro-fabrication of ceramics: additive manufacturing and conventional technologies. Journal of Advanced Ceramics. 10, pp. 1-27. https://doi.org/10.1007/s40145-020-0422-5

4D Printing of origami structures for minimally invasive surgeries using functional scaffold

Langford, T, Mohammed, A., Essa, K., Elshaer, A. and Hassanin, H. 2020. 4D Printing of origami structures for minimally invasive surgeries using functional scaffold. Applied Sciences. 11 (1), p. 332. https://doi.org/10.3390/app11010332

Reconfigurable multipoint forming using waffle-type elastic cushion and variable loading profile

Hassanin, H., Mohammed, M., Abdel-Wahab, A. and Essa, K 2020. Reconfigurable multipoint forming using waffle-type elastic cushion and variable loading profile. Materials.

3D printing of solid oral dosage forms: numerous challenges with unique opportunities

Hassanin, H. 2020. 3D printing of solid oral dosage forms: numerous challenges with unique opportunities. Journal of Pharmaceutical Sciences. https://doi.org/10.1016/j.xphs.2020.08.029

Design optimisation of additively manufactured titanium lattice structures for biomedical implants

El-Sayed, M.A., Essa, K., Ghazy, M. and Hassanin, H. 2020. Design optimisation of additively manufactured titanium lattice structures for biomedical implants. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-020-05982-8

4D Printing of NiTi auxetic structure with improved ballistic performance

Hassanin, H., Abena, A., Elsayed, M.A. and Essa, K. 2020. 4D Printing of NiTi auxetic structure with improved ballistic performance. Micromachines. 11 (8), p. 745. https://doi.org/doi.org/10.3390/mi11080745