Metal Additive Manufacturing

Name: Metal Additive Manufacturing
Brand: Wiley
Price: 103.99 EUR
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Ehsan Toyserkani Dyuti Sarker Osezua Obehi Ibhadode Farzad Liravi Paola Russo Katayoon Taherkhani(Autor*in)

Wiley (Verlag)

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Erschienen am 19. Oktober 2021

624 Seiten

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Beschreibung

METAL ADDITIVE MANUFACTURING

A comprehensive review of additive manufacturing processes for metallic structures

Additive Manufacturing (AM)--also commonly referred to as 3D printing--builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise.

Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource:

* Provides a thorough analysis of AM processes and their theoretical foundations

* Explains the classification, advantages, and applications of AM processes

* Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software

* Discusses the opportunities, challenges, and current and emerging trends within the field

* Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes

* Includes illustrative cases studies and numerous figures and tables

Featuring material drawn from the lead author's research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.

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Inhalt

Cover
Title Page
Copyright Page
Contents
Preface
Abbreviations
Chapter 1 Additive Manufacturing Process Classification, Applications, Trends, Opportunities, and Challenges
1.1 Additive Manufacturing: A Long-Term Game Changer
1.2 AM Standard Definition and Classification
1.3 Why Metal Additive Manufacturing?
1.4 Market Size: Current and Future Estimation
1.5 Applications of Metal AM
1.5.1 Medical and Dental
1.5.2 Aerospace and Defense
1.5.3 Communication
1.5.4 Energy and Resources
1.5.5 Automotive
1.5.6 Industrial Tooling and Other Applications
1.6 Economic/Environmental Benefits and Societal Impact
1.7 AM Trends, Challenges, and Opportunities
1.8 Looking Ahead
References
Chapter 2 Basics of Metal Additive Manufacturing
2.1 Introduction
2.2 Main Metal Additive Manufacturing Processes
2.2.1 Powder Bed Fusion (PBF)
2.2.2 Directed Energy Deposition (DED)
2.2.3 Binder Jetting (BJ)
2.2.4 Emerging Metal AM Processes
2.3 Main Process Parameters for Metal DED, PBF, and BJ
2.3.1 Main Output Parameters
2.3.2 Combined Thermal Energy Source Parameters for PBF and DED
2.3.3 Beam Scanning Strategies and Parameters for PBF and DED
2.3.4 Powder Properties for PBF, DED, and BJ
2.3.5 Wire Properties for DED
2.3.6 Layer Thickness for PBF, DED, and BJ
2.3.7 Ambient Parameters for PBF, DED, and BJ
2.3.8 Geometry-Specific Parameters (PBF)
2.3.9 Support Structures for PBF
2.3.10 Binder Properties for BJ
2.3.11 Binder Saturation for BJ
2.4 Materials
2.4.1 Ferrous Alloys
2.4.2 Titanium Alloys
2.4.3 Nickel Alloys
2.4.4 Aluminum Alloys
References
Chapter 3 Main Sub-Systems for Metal AM Machines
3.1 Introduction
3.2 System Setup of AM Machines
3.2.1 Laser Powder Bed Fusion (LPBF)
3.2.2 Laser Directed Energy Deposition (LDED) with Blown Powder Known as Laser Powder-Fed (LPF)
3.2.3 Binder Jetting (BJ)
3.3 Laser Basics: Important Parameters Needed to be Known for AM
3.3.1 Laser Theory
3.3.2 Laser Components
3.3.3 Continuous Vs. Pulsed Laser
3.3.4 Laser Types
3.3.5 Laser Beam Properties
3.4 Electron Beam Basics
3.4.1 Comparisons and Contrasts between Laser and Electron Beams
3.4.2 Electron Beam Powder Bed Fusion Setup
3.4.3 Electron Beam Mechanism
3.4.4 Vacuum Chambers
3.5 Powder Feeders and Delivery Nozzles Technology
3.5.1 Classification of Powder Feeders
3.5.2 Powder Delivery Nozzles for DED
3.5.3 Powder Bed Delivery and Spreading Mechanisms
3.5.4 Wire Feed System
3.5.5 Positioning Devices and Scanners in Laser-Based AM
3.5.6 Print-Head in Binder Jetting
3.6 CAD File Formats
3.6.1 CAD/CAM Software
3.7 Summary
References
Chapter 4 Directed Energy Deposition (DED): Directed Energy Deposition (DED)
4.1 Introduction
4.2 Laser Material Interaction and the Associated Significant Parameters to Laser AM
4.2.1 Continuous Versus Pulsed/Modulated Lasers
4.2.2 Absorption, Reflection, and Transmission Factors
4.2.3 Dependencies of Absorption Factor to Wavelength and Temperature
4.2.4 Angle of Incidence
4.2.5 Surface Roughness Effects
4.2.6 Scattering Effects
4.3 E-beam Material Interaction
4.4 Power Density and Interaction Time for Various Heat Source-based Material Processing
4.5 Physical Phenomena and Governing Equations During DED
4.5.1 Absorption
4.5.2 Heat Conduction
4.5.3 Surface Convection and Radiation
4.5.4 Fluid Dynamics
4.5.5 Phase Transformation
4.5.6 Rapid Solidification
4.5.7 Thermal Stresses
4.5.8 Flow Field in DED with Injected Powder
4.6 Modeling of DED
4.6.1 Analytical Modeling: Basics, Simplified Equations, and Assumptions
4.6.2 Numerical Models for DED
4.6.3 Experimental-based Models: Basics and Approaches
4.7 Case Studies on Common Modeling Platforms for DED
4.7.1 Lumped Analytical Model for Powder-Fed LDED
4.7.2 Comprehensive Analytical Model for Powder-Fed LDED (PF-LDED)
4.7.3 Numerical Modeling of LDED: Heat Transfer Model
4.7.4 Modeling of Wire-Fed E-beam DED (WF-EDED)
4.7.5 A Stochastic Model for Powder-Fed LDED
4.8 Summary
References
Chapter 5 Powder Bed Fusion Processes: Physics and Modeling
5.1 Introduction and Notes to Readers
5.2 Physics of Laser Powder bed Fusion (LPBF)
5.2.1 Heat Transfer in LPBF: Governing Equations and Assumptions
5.2.2 Fluid Flow in the Melt Pool of LPBF: Governing Equations and Assumptions
5.2.3 Vaporization and Material Expulsion: Governing Equations and Assumptions
5.2.4 Thermal Residual Stresses: Governing Equations and Assumptions
5.2.5 Numerical Modeling of LPBF
5.2.6 Case Studies on Common LPBF Modeling Platforms
5.3 Physics and Modeling of Electron Beam Additive Manufacturing
5.3.1 Electron Beam Additive Manufacturing Parameters
5.3.2 Emissions in Electron Beam Sources
5.3.3 Mathematical Description of Free Electron Current
5.3.4 Modeling of Electron Beam Powder Bed Fusion (EB-PBF)
5.3.5 Case Studies
5.3.6 Summary
References
Chapter 6 Binder Jetting and Material Jetting: Binder Jetting and Material Jetting: Physics and Modeling
6.1 Introduction
6.2 Physics and Governing Equations
6.2.1 Droplet Formation
6.2.2 Droplet-Substrate Interaction
6.2.3 Binder Imbibition
6.3 Numerical Modeling
6.3.1 Level-Set ModelThis section is mainly adopted from the authors' previous work with permission from Elsevier.
6.3.2 Lattice Boltzmann Method
6.4 Summary
References
Chapter 7 Material Extrusion: Material Extrusion: Physics and Modeling
7.1 Introduction
7.2 Analytical Modeling of ME
7.2.1 Heat Transfer and Outlet Temperature
7.2.2 Flow Dynamics and Drop Pressure
7.2.3 Die Swell
7.2.4 Deposition and Healing
7.3 Numerical Modeling of ME
7.4 Summary
References
Chapter 8 Material Design and Considerations for Metal Additive Manufacturing
8.1 Historical Background on Materials
8.2 Materials Science: Structure-Property Relationship
8.3 Manufacturing of Metallic Materials
8.4 Solidification of Metals: Equilibrium
8.5 Solidification in Additive Manufacturing: Non-Equilibrium
8.6 Equilibrium Solidification: Theory and Mechanism
8.6.1 Cooling Curve and Phase Diagram
8.7 Non-Equilibrium Solidification: Theory and Mechanism
8.8 Solute Redistribution and Microsegregation
8.9 Constitutional Supercooling
8.10 Nucleation and Growth Kinetics
8.10.1 Nucleation
8.10.2 Growth Behavior
8.11 Solidification Microstructure in Pure Metals and Alloys
8.12 Directional Solidification in AM
8.13 Factors Affecting Solidification in AM
8.13.1 Cooling Rate
8.13.2 Temperature Gradient and Solidification Rate
8.13.3 Process Parameters
8.13.4 Solidification Temperature Span
8.13.5 Gas Interactions
8.14 Solidification Defects
8.14.1 Porosity
8.14.2 Balling
8.14.3 Cracking
8.14.4 Lamellar Tearing
8.15 Post Solidification Phase Transformation
8.15.1 Ferrous Alloys/Steels
8.15.2 Al Alloys
8.15.3 Nickel Alloys/Superalloys
8.15.4 Titanium Alloys
8.16 Phases after Post-Process Heat Treatment
8.16.1 Ferrous Alloys
8.16.2 Al Alloys
8.16.3 Ni Alloys
8.16.4 Ti Alloys
8.17 Mechanical Properties
8.17.1 Hardness
8.17.2 Tensile Strength and Static Strength
8.17.3 Fatigue Behavior of AM-Manufactured Alloys
8.18 Summary
References
Chapter 9 Additive Manufacturing of Metal Matrix Composites
9.1 Introduction
9.2 Conventional Manufacturing Techniques for Metal Matrix Composites (MMCs)
9.3 Additive Manufacturing of Metal Matrix Composites (MMCs)
9.4 AM Challenges and Opportunities
9.5 Preparation of Composite Materials: Mechanical Mixing
9.6 Different Categories of MMCs
9.7 Additive Manufacturing of Ferrous Matrix Composites
9.7.1 316 SS-TiC Composite
9.7.2 316 SS-TiB2 Composite
9.7.3 H13-TiB2 Composite
9.7.4 H13-TiC Composite
9.7.5 Ferrous-WC Composite
9.7.6 Ferrous-VC Composites
9.8 Additive Manufacturing of Titanium-Matrix Composites (TMCs)
9.8.1 Ti-TiC Composite
9.8.2 Ti-TiB Composites
9.8.3 Ti-Hydroxyapatite (Ti-HA) Composites
9.8.4 Ti-6Al-4V-Metallic Glass (MG) Composites
9.8.5 Ti-6Al-4V+B4C Pre-alloyed Composites
9.8.6 Ti-6Al-4V+Mo Composite
9.8.7 Structure and Properties of Different TMCs
9.9 Additive Manufacturing of Aluminum Matrix Composites
9.9.1 Al-Fe2O3 Composite
9.9.2 AlSi10Mg-SiC Composite
9.9.3 AlSi10Mg-TiC Composite
9.9.4 2024Al-TiB2 Composite
9.9.5 AlSi10Mg-TiB2 Composite
9.9.6 AA7075-TiB2 Composite
9.10 Additive Manufacturing of Nickel Matrix Composites
9.10.1 Inconel 625-TiC Composites
9.10.2 Inconel 625-TiB2 Composite
9.11 Factors Affecting Composite Property
9.11.1 Mixing of Matrix and Reinforcing Elements
9.11.2 Size of Reinforcing Elements
9.11.3 Decomposition Temperature
9.11.4 Viscosity and Pore Formation
9.11.5 Volume of Reinforcing Elements and Pore Formation
9.11.6 Buoyancy Effects and Surface Tension Forces
9.12 Summary
References
Chapter 10 Design for Metal Additive Manufacturing
10.1 Design Frameworks for Additive Manufacturing
10.1.1 Integrated Topological and Functional Optimization DfAM
10.1.2 Additive Manufacturing-Enabled Design Framework
10.1.3 Product Design Framework for AM with Integration of Topology Optimization
10.1.4 Multifunctional Optimization Methodology for DfAM
10.1.5 AM Process Model for Product Family Design
10.2 Design Rules and Guidelines
10.2.1 Laser Powder Bed Fusion (LPBF)
10.2.2 Electron Beam Powder Bed Fusion (EB-PBF)
10.2.3 Binder Jetting
10.2.4 Technologies Compared
10.3 Topology Optimization for Additive Manufacturing
10.3.1 Structural Optimization
10.3.2 Topology Optimization
10.3.3 Design-Dependent Topology Optimization
10.3.4 Efforts in AM-Constrained Topology Optimization
10.4 Lattice Structure Design
10.4.1 Unit Cell
10.4.2 Lattice Framework
10.4.3 Uniform Lattice
10.4.4 Conformal Lattices
10.4.5 Irregular/Randomized Lattices
10.4.6 Design Workflows for Lattice Structures
10.5 Design for Support Structures
10.5.1 Principles that Should Guide Support Structure Design
10.5.2 Build Orientation Optimization
10.5.3 Support Structure Optimization
10.6 Design Case Studies
10.6.1 Redesign of an Aerospace Bracket to be Made by LPBF
10.6.2 Design and Development of a Structural Member in a Suspension Assembly Using EB Powder Bed Fusion
10.6.3 Binder Jetting of the Framework of a Partial Metal Denture
10.6.4 Redesign of a Crank and Connecting Rod
10.6.5 Redesign of a Mechanical Assembly
10.6.6 Solid-Lattice Hip Prosthesis Design
10.7 Summary
References
Chapter 11 Monitoring and Quality Assurance for Metal Additive Manufacturing
11.1 Why are Closed-Loop and Quality Assurance Platforms Essential?
11.2 In-Situ Sensing Devices and Setups
11.2.1 Types of Sensors Used in Metal AM
11.2.2 Mounting Strategies for In-line Monitoring Sensors in Metal AM Setups
11.3 Commercially Available Sensors
11.3.1 LPBF Commercial Sensors
11.3.2 LDED Commercial Sensors
11.4 Signal/Data Conditioning, Methodologies, and Classic Controllers for Monitoring, Control, and Quality Assurance in Metal AM Processes
11.4.1 Signal/Data Conditioning and Controllers for Melt Pool Geometrical Analysis
11.4.2 Signal/Data Conditioning and Methodologies for Temperature Monitoring and Analysis
11.4.3 Signal/Data Conditioning and Methodologies for the Detection of Porosity
11.4.4 Signal/Data Conditioning and Methodologies for Detection of Crack and Delamination
11.4.5 Signal/Data Conditioning and Methodologies for Detection of Plasma Plume and Spatters
11.5 Machine Learning for Data Analytics and Quality Assurance in Metal AM
11.5.1 Supervised Learning
11.5.2 Unsupervised Learning
11.6 Case Study
11.6.1 Design of Experiments
11.6.2 In-Situ Sensors and Quality Assurance Algorithm
11.6.3 Correlation Between CT Scan and Analyzed Data
11.7 Summary
References
Chapter 12 Safety
12.1 Introduction
12.2 Overview of Hazards
12.3 AM Process Hazards
12.4 Laser Safety in Additive Manufacturing
12.4.1 Laser Categorization
12.4.2 Laser Hazards
12.4.3 Eye Protection
12.4.4 Laser Protective Eyewear Requirements
12.5 Electron Beam Safety
12.6 Powder Hazards
12.6.1 Combustibility
12.7 Human Health Hazards
12.8 Comprehensive Steps to AM Safety Management
12.8.1 Engineering Controls
12.8.2 Personal Protective Equipment
12.8.3 AM Guidelines and Standards
12.9 Summary
References
Index
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