Investigation of the selective laser melting (SLM) process, using finite element method, to understand the influences of laser power and scanning speed on the heat flow and melt-pool dimensions is a challenging task. Most of the existing studies are focused on the study of thin layer thickness and comparative study of same materials under different manufacturing conditions. The present work is focused on comparative analysis of thermal cycles and complex melt-pool behavior of a high layer thickness multi-layer laser additive manufacturing (LAM) of pure Titanium (Ti) and Inconel 718. A transient 3D finite-element model is developed to perform a quantitative comparative study on two materials to examine the temperature distribution and disparities in melt-pool behaviours under similar processing conditions. It is observed that the layers are properly melted and sintered for the considered process parameters. The temperature and melt-pool increases as laser power move in the same layer and when new layers are added. The same is observed when the laser power increases, and opposite is observed for increasing scanning speed while keeping other parameters constant. It is also found that Inconel 718 alloy has a higher maximum temperature than Ti material for the same process parameter and hence higher melt-pool dimensions.

Friction stir welding is a solid-state joining process used to weld various materials. Tool life is an important consideration when welding strong metals with the Friction stir welding technique (FSW). The current research aims to calculate tool life by mathematical derivation and simulation using ANSYS transient structural analysis. There are two tool materials and five-pin profiles to consider. The calculated tool life using mathematical formulation is within 15% of the simulation outcome. Further changes are made to the simulation to make the tool life estimate more realistic under FSW’s operation. PcBN tool has superior mechanical properties over the tungsten carbide tool, so the procedure started with the tungsten carbide tool. The conical pin profile is giving 31466 cycles of tool life, which is 70 min run time while working at 450 rpm rotational speed. As a result, for high-strength materials joining, the tool must be chosen based on tool life parameters. The addition of a 1.5 mm fillet at the pin-to-shoulder junction has improved the tool life by 1147 cycles. The PcBN tool is simulated with a conical tool with new pin profiles of conical with grooves and cylindrical fillet with grooves. The maximum tool life of 94018 cycles is obtained for the conical PcBN tool.

The contemporary work manifests that friction stir welding (FSW) is a viable avenue for joining AA1100 aluminium (Al) to C12200 copper (Cu) plates. In this present study, the response of distinctive welding parameters (viz. tool geometries, tool rotational speed, tool travel speed, and tool...

3D printing, popularly known as additive manufacturing (AM), has been a revolutionary production method for various applications. Although it is very popular, the mechanical performance of parts or objects generated with this method lacks proper analysis. This study used the fused deposition modeling (FDM) method to manufacture experimental study samples. Polylactic acid (PLA), a well-known biodegradable thermoplastic polymer, is widely used due to its environmentally friendly properties and printing capabilities. ASTM D638 Type I Standard is employed to evaluate the tensile properties of PLA specimens in the MTS Acumen Universal Testing Machine (UTM). The study is focused on the influence of infill patterns and density. Nine samples were prepared using SolidWorks computer-aided design (CAD) software, featuring honeycomb and grid infill structures, which were incorporated to examine variations in strength with infill density at levels of 20%, 40%, 60%, and 80%, as well as a fully solid sample with a 100% infill, then printed using an Olivetti 3D desktop printer. Four samples of a honeycomb structure, and four samples of a grid structure were used. For simulation, the corresponding samples were analyzed using ANSYS software to determine stress distribution and deformation behavior. The results showed strong similarity between experimental and simulated data. It was found that an 80% honeycomb infill possesses the most favorable balance between mechanical strength and weight, i.e. a better strength-to-weight ratio. This study indicates that the structural optimization of 3D-printed parts relies heavily on infill pattern and density, particularly in 3D-printed PLA parts using FDM.