This engaging volume presents the exciting new technology of additive manufacturing (AM) of metal objects for a broad audience of academic and industry researchers, manufacturing professionals, undergraduate and graduate students, hobbyists, and artists. Innovative applications ranging from rocket nozzles to custom jewelry to medical implants illustrate a new world of freedom in design and fabrication, creating objects otherwise not possible by conventional means.
The author describes the various methods and advanced metals used to create high value components, enabling readers to choose which process is best for them. Of particular interest is how harnessing the power of lasers, electron beams, and electric arcs, as directed by advanced computer models, robots, and 3D printing systems, can create otherwise unattainable objects.
A timeline depicting the evolution of metalworking, accelerated by the computer and information age, ties AM metal technology to the rapid evolution of global technology trends. Charts, diagrams, and illustrations complement the text to describe the diverse set of technologies brought together in the AM processing of metal. Extensive listing of terms, definitions, and acronyms provides the reader with a quick reference guide to the language of AM metal processing. The book directs the reader to a wealth of internet sites providing further reading and resources, such as vendors and service providers, to jump start those interested in taking the first steps to establishing AM metal capability on whatever scale. The appendix provides hands-on example exercises for those ready to engage in experiential self-directed learning.
John O. Milewski received his B.S. in Computer Engineering from the University of New Mexico and his M.S. in Electrical Engineering from Vanderbilt University. He began his technical career with five years' metal fabrication experience ranging from heavy industry production as an ASME code welder to light manufacturing and applied research. He spent 32 years at Los Alamos National Laboratory, in positions including Welding Technologist, Engineer, Team Leader, Experimental Component Fabrication Program Manager, and Group Leader for Manufacturing Capability. He is currently retired from the Lab, writing and consulting as APEX3D LLC regarding the new and exciting applications of AM technology.
His technical expertise includes arc systems electron beam, laser welding, robotics, sensing and controls, and the joining of less common metals. His work experience also includes CAD/CAM/CNC model based engineering, process modeling, and simulation with validation methods to include residual stress measurement. In addition, he served 2 years in the late 1980s as Vice President of Synthemet Corporation, an entrepreneurial high tech start-up, with the goal of development and commercialization of 3D additive manufacturing of metals.
He is author and co-author of numerous publications related to high energy beam processing and process modeling. His awards include an R&D 100 Award for Directed Light Fabrication, Fellow of the American Welding Society (AWS) and the AWS Robert L. Peaslee Award. He is inventor or co-inventor for a number of patents related to laser welding and additive manufacturing.
He has had extensive formal collaborations with universities and sponsored students resulting in refereed publication and patenting. His professional society involvement included Chairman, Co-Chairman, and advisor of AWS committees related to High Energy Beam, Electron Beam, and Laser Beam Welding. In addition, he currently serves as an advisor to the AWS D20 Additive Manufacturing committee and provides peer review to technical publications of AWS and ASM International.
His international technical contributions include US Delegate to the High Energy Beam Welding Commission of the IIW (International Institute of Welding), Invited Keynote Lecturer at the 58th Annual Assembly and International Conference of IIW, and the AWS R.D. Thomas Award winner for his international contributions and committee work on the harmonization of international standards.
Preface.- Chapter 1: Envision. 1.1 Evolution of Metalworking.- 1.2 Advent of Computers.- Chapter 2: Additive Manufacturing Metal, The Art of the Possible. 2.1 AM Destinations: Novel Applications and Designs. 2.2 Artistic.- Chapter 3: On the Road to AM. 3.1 You are Here.- 3.2 AM Vehicles, the machines to take you there.- Chapter 4: Understanding Metal for Additive Manufacturing. 4.1 Structure. 4.2 Physical Properties.- Chapter 5: Lasers, Electron Beams, Plasma Arcs.- 5.1 The Molten Pool.- 5.2 Lasers.- Chapter 6: Computers, Solid Models and Robots.- 6.1 Computer Aided Design.- 6.2 Computer Aided Engineering.- Chapter 7: Origins of 3D Metal Printing.- 7.1 Plastic Prototyping and 3D Printing.- 7.2 Weld Cladding and 3D Weld Metal Buildup.- Chapter 8: Current System Configurations.- 8.1 Laser Powder Bed Fusion Systems.- 8.2 Laser Directed Energy Deposition Systems.- Chapter 9: Inspiration to 3D Design.- 9.1 Inspired Design.- 9.2 Elements of Design.- Chapter 10: Process Development.- 10.1 Parameter Selection.- 10.2 Parameter Optimization.- Chapter 11: Building, Post Processing and Inspecting.- 11.1 Building the Part.- 11.2 Post Processing and Finishing.- Chapter 12: Trends in Government, Industry, Research, Business.- 12.1 Government and Community.- 12.2 University and Corporate Research.- Acknowledgements.- Professional Society and Organization Links.- Terms and AM Jargon.- Acronyms.- References.- AM Machine and Service Resource Links.- About the Author.- Appendices.