Download or read book Energy Analysis for Process Parameter Prediction of Direct Energy Deposition Metal Additive Manufacturing written by Daniel Pulscher and published by . This book was released on 2019 with total page 48 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal Additive Manufacturing with the Direct Energy Deposition (DED) process allows for rapid prototyping and low-volume custom manufacturing of complex geometries at a lower cost than traditional manufacturing methods. Direct energy deposition is a complex process having many inter-related process parameters that affect the overall quality and mechanical properties of the build. When new powder feedstocks are used, calibrating these process parameters is typically done empirically in trials that can contain more than a hundred different combinations of parameters. This time-consuming process can be reduced by performing an analytical analysis on how the energy from the laser transfers into the metal using the physical properties of the powder paired with empirical relations to predict where optimal process parameters will occur.Typical builds use a fixed process parameter set and do not feature any in-situ process control. Previous research has shown that combining the variables of powder flow and travel speed into a ratio allows for consistent results. For this thesis the relation was improved upon to compare the bead volume per pass to the powder flow improving the relation and allowing powder flow to be predicted. The energy analysis was used to improve build quality of different parameter sets resulting in reduction of porosity and nearly fully dense parts. A methodology for process parameter prediction is introduced and validated using the analytical and empirical relations proved in this thesis. The ability to increase bead size allows for the process to be more efficient in time, energy, and powder usage, lessening time per part and cost for industry. The ability to have beads of different dimensions also allows for large deposition to occur followed by smaller deposits for fine features with uniform properties.

Download or read book Direct Energy Deposition Additive Manufacturing Process Key Parameter Investigation and Process Planning Development written by Jordan Cave and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "Direct Energy Deposition (DED) is an emerging technology in the field of additive manufacturing. However, economics currently limit its application to high value components or applications. One area of interest is the repair of aerospace components such as turbine or compressor blades, blisks, or even landing gear. There are currently some limited applications of DED repair in industry presently, but a universal solution is not available. This work aims to create a generic solution for the repair of aerospace components using the alloy Ti-6Al-4V. In doing so, a computer aided process planning system is developed to improve the reliability of builds and predict resultant build qualities. This system involves identifying key process variables, physical experimentation, and computer-aided toolpath generation. The result of this computer-aided process planning (CAPP) system development is the automation of much of the manufacturing procedure and the formulation of common process variables for use on any DED production platform. The CAPP model is successful in generating semi-autonomous repair procedures for the repair of generic components. Further work is required to fully automate the process and push the technology into mainstream application." --

Download or read book Additive Manufacturing for the Aerospace Industry written by Francis H. Froes and published by Elsevier. This book was released on 2019-02-15 with total page 483 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing for the Aerospace Industry explores the design, processing, metallurgy and applications of additive manufacturing (AM) within the aerospace industry. The book's editors have assembled an international team of experts who discuss recent developments and the future prospects of additive manufacturing. The work includes a review of the advantages of AM over conventionally subtractive fabrication, including cost considerations. Microstructures and mechanical properties are also presented, along with examples of components fabricated by AM. Readers will find information on a broad range of materials and processes used in additive manufacturing. It is ideal reading for those in academia, government labs, component fabricators, and research institutes, but will also appeal to all sectors of the aerospace industry. - Provides information on a broad range of materials and processes used in additive manufacturing - Presents recent developments in the design and applications of additive manufacturing specific to the aerospace industry - Covers a wide array of materials for use in the additive manufacturing of aerospace parts - Discusses current standards in the area of aerospace AM parts

Download or read book Additive Manufacturing Technologies written by Ian Gibson and published by Springer. This book was released on 2014-11-26 with total page 509 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers in detail the various aspects of joining materials to form parts. A conceptual overview of rapid prototyping and layered manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Unusual and emerging applications such as micro-scale manufacturing, medical applications, aerospace, and rapid manufacturing are also discussed. This book provides a comprehensive overview of rapid prototyping technologies as well as support technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. This book also: Reflects recent developments and trends and adheres to the ASTM, SI, and other standards Includes chapters on automotive technology, aerospace technology and low-cost AM technologies Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered

Download or read book Additive Manufacturing Technologies written by Ian Gibson and published by Springer Nature. This book was released on 2020-11-10 with total page 685 pages. Available in PDF, EPUB and Kindle. Book excerpt: This textbook covers in detail digitally-driven methods for adding materials together to form parts. A conceptual overview of additive manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Well-established and emerging applications such as rapid prototyping, micro-scale manufacturing, medical applications, aerospace manufacturing, rapid tooling and direct digital manufacturing are also discussed. This book provides a comprehensive overview of additive manufacturing technologies as well as relevant supporting technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. Reflects recent developments and trends and adheres to the ASTM, SI and other standards; Includes chapters on topics that span the entire AM value chain, including process selection, software, post-processing, industrial drivers for AM, and more; Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered.

Download or read book Additive Manufacturing of Metals written by John O. Milewski and published by Springer. This book was released on 2017-06-28 with total page 351 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Optimization Methods written by Marco Cavazzuti and published by Springer Science & Business Media. This book was released on 2012-09-11 with total page 272 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is about optimization techniques and is subdivided into two parts. In the first part a wide overview on optimization theory is presented. Optimization is presented as being composed of five topics, namely: design of experiment, response surface modeling, deterministic optimization, stochastic optimization, and robust engineering design. Each chapter, after presenting the main techniques for each part, draws application oriented conclusions including didactic examples. In the second part some applications are presented to guide the reader through the process of setting up a few optimization exercises, analyzing critically the choices which are made step by step, and showing how the different topics that constitute the optimization theory can be used jointly in an optimization process. The applications which are presented are mainly in the field of thermodynamics and fluid dynamics due to the author's background.

Download or read book Thermal stress Characteristics of Direct Energy Deposition Additive Manufacturing written by Jose Angel Diosdado De la Pena and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This work discusses the relevance of Metal Additive Manufacturing (MAM) and focuses on one method: Direct Energy Deposition (DED). Different types of DED processes are discussed, including their main parameters and issues. A general procedure to simulate DED processes is presented and founded on the finite element analysis (FEA) workflow. Based on this, two initial case studies are analyzed, which were selected from the literature and reproduced via a commercially available FEA software. Their results provided evidence of the feasibility of the software in simulating a DED process. Two experiments were carried out, called single bead and rectangular prism, for the purpose of this research. These were built with a hot wire and laser DED system, where experimental thermal data was obtained. Geometric information was obtained later via a 3D scan. Limitations of the equipment used as well as observed defects in the material deposition are discussed based on the experimental data. FEA models were developed to duplicate the experiments, which included a detailed geometry of the single bead. Two modifications to the bead geometry are presented and evaluated, where it was concluded that a semicircular bead approximation provides better results than if a rectangular one is assumed. This led to the definition of a thermal and structural equivalent model of the single bead, which was the basis for the numerical work of the rectangular prism. The results obtained for the latter show good agreement with the thermal results, although differences in the structural results are perceptible.

Download or read book Solar Absorptances and Spectral Reflectances of 12 Metals for Temperatures Ranging from 300 to 500 K written by and published by . This book was released on 1969 with total page 28 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Quality Analysis of Additively Manufactured Metals written by Javad Kadkhodapour and published by Elsevier. This book was released on 2022-11-15 with total page 856 pages. Available in PDF, EPUB and Kindle. Book excerpt: Quality Analysis of Additively Manufactured Metals: Simulation Approaches, Processes, and Microstructure Properties provides readers with a firm understanding of the failure and fatigue processes of additively manufactured metals. With a focus on computational methods, the book analyzes the process-microstructure-property relationship of these metals and how it affects their quality while also providing numerical, analytical, and experimental data for material design and investigation optimization. It outlines basic additive manufacturing processes for metals, strategies for modeling the microstructural features of metals and how these features differ based on the manufacturing process, and more. Improvement of additively manufactured metals through predictive simulation methods and microdamage and micro-failure in quasi-static and cyclic loading scenarios are covered, as are topology optimization methods and residual stress analysis techniques. The book concludes with a section featuring case studies looking at additively manufactured metals in automotive, biomedical and aerospace settings. Provides insights and outlines techniques for analyzing why additively manufactured metals fail and strategies for avoiding those failures Defines key terms and concepts related to the failure analysis, quality assurance and optimization processes of additively manufactured metals Includes simulation results, experimental data and case studies

Download or read book Laser Cladding written by Ehsan Toyserkani and published by CRC Press. This book was released on 2004-08-12 with total page 288 pages. Available in PDF, EPUB and Kindle. Book excerpt: Capitalizing on the rapid growth and reduced costs of laser systems, laser cladding is gaining momentum, and in some instances replacing conventional techniques of depositing thin films because it can accommodate a great variety of materials, achieve uniform thickness and precise widths of layers, and provide improved resistance to wear and corrosion in the final product. Laser cladding technology also offers a revolutionary layered manufacturing and prototyping technique that can fabricate complex components without intermediate steps. Laser Cladding reviews the parameters, techniques and equipment, process modeling and control, and the physical metallurgy of alloying and solidification during laser cladding. The authors clarify the interconnections laser cladding has with CAD/CAM design; automation and robotics; sensors, feedback, and control; physics, material science, heat transfer, fluid dynamics, and powder metallurgy to promote further development and improved process quality of this growing technology. As the first book entirely dedicated to the topic, it also offers a history of its development and a guide to applications and market opportunities. While a considerable part of Laser Cladding is dedicated to industrial applications, this volume brings together valuable information illustrated with real case studies based on the authors' vast experience, and research and analysis in the field to provide a timely source for both academia and industry.

Download or read book Thermo Mechanical Modeling of Additive Manufacturing written by Michael Gouge and published by Butterworth-Heinemann. This book was released on 2017-08-03 with total page 296 pages. Available in PDF, EPUB and Kindle. Book excerpt: Thermo-mechanical Modeling of Additive Manufacturing provides the background, methodology and description of modeling techniques to enable the reader to perform their own accurate and reliable simulations of any additive process. Part I provides an in depth introduction to the fundamentals of additive manufacturing modeling, a description of adaptive mesh strategies, a thorough description of thermal losses and a discussion of residual stress and distortion. Part II applies the engineering fundamentals to direct energy deposition processes including laser cladding, LENS builds, large electron beam parts and an exploration of residual stress and deformation mitigation strategies. Part III concerns the thermo-mechanical modeling of powder bed processes with a description of the heat input model, classical thermo-mechanical modeling, and part scale modeling. The book serves as an essential reference for engineers and technicians in both industry and academia, performing both research and full-scale production. Additive manufacturing processes are revolutionizing production throughout industry. These technologies enable the cost-effective manufacture of small lot parts, rapid repair of damaged components and construction of previously impossible-to-produce geometries. However, the large thermal gradients inherent in these processes incur large residual stresses and mechanical distortion, which can push the finished component out of engineering tolerance. Costly trial-and-error methods are commonly used for failure mitigation. Finite element modeling provides a compelling alternative, allowing for the prediction of residual stresses and distortion, and thus a tool to investigate methods of failure mitigation prior to building. - Provides understanding of important components in the finite element modeling of additive manufacturing processes necessary to obtain accurate results - Offers a deeper understanding of how the thermal gradients inherent in additive manufacturing induce distortion and residual stresses, and how to mitigate these undesirable phenomena - Includes a set of strategies for the modeler to improve computational efficiency when simulating various additive manufacturing processes - Serves as an essential reference for engineers and technicians in both industry and academia

Download or read book Metal Additive Manufacturing written by Ehsan Toyserkani and published by John Wiley & Sons. This book was released on 2021-10-25 with total page 628 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Advances in Energy Science and Equipment Engineering II Volume 2 written by Shiquan Zhou and published by CRC Press. This book was released on 2017-09-19 with total page 1162 pages. Available in PDF, EPUB and Kindle. Book excerpt: The 2016 2nd International Conference on Energy Equipment Science and Engineering (ICEESE 2016) was held on November 12-14, 2016 in Guangzhou, China. ICEESE 2016 brought together innovative academics and industrial experts in the field of energy equipment science and engineering to a common forum. The primary goal of the conference is to promote research and developmental activities in energy equipment science and engineering and another goal is to promote scientific information interchange between researchers, developers, engineers, students, and practitioners working all around the world. The conference will be held every year to make it an ideal platform for people to share views and experiences in energy equipment science and engineering and related areas. This second volume of the two-volume set of proceedings covers the field of Structural and Materials Sciences, and Computer Simulation & Computer and Electrical Engineering.

Download or read book Additive Manufacturing of Titanium Alloys written by Bhaskar Dutta and published by Butterworth-Heinemann. This book was released on 2016-06-17 with total page 96 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing of Titanium Alloys: State of the Art, Challenges and Opportunities provides alternative methods to the conventional approach for the fabrication of the majority of titanium components produced via the cast and wrought technique, a process which involves a considerable amount of expensive machining. In contrast, the Additive Manufacturing (AM) approach allows very close to final part configuration to be directly fabricated minimizing machining cost, while achieving mechanical properties at least at cast and wrought levels. In addition, the book offers the benefit of significant savings through better material utilization for parts with high buy-to-fly ratios (ratio of initial stock mass to final part mass before and after manufacturing). As titanium additive manufacturing has attracted considerable attention from both academicians and technologists, and has already led to many applications in aerospace and terrestrial systems, as well as in the medical industry, this book explores the unique shape making capabilities and attractive mechanical properties which make titanium an ideal material for the additive manufacturing industry. - Includes coverage of the fundamentals of microstructural evolution in titanium alloys - Introduces readers to the various Additive Manufacturing Technologies, such as Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) - Looks at the future of Titanium Additive Manufacturing - Provides a complete review of the science, technology, and applications of Titanium Additive Manufacturing (AM)

Download or read book Analysis of Process Parameters for Metal Additive Manufacturing written by Benyamin Salehi Najafabadi and published by . This book was released on 2017 with total page 60 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal additive manufacturing (MAM) is finding its way into mainstream manufacturing. Currently the approach when using MAM in industry is to empirically determine appropriate processing parameters. Once obtained no further changes are made and printers are dedicated to the particular part and material to build them with traditional sacrificial test builds to determine quality of the metal 3D printed part. The problem is that by taking this approach you now constrain this powerful technology. If it is possible to develop a basic understanding of the relationships between the amount of energy needed to build a part and the associated conditions required then it will enable metal additive manufacturing to e build any part with any material on any system without having to worry about quality. Before this can be achieved it is necessary to understand what the key metrics are that influence the metal additive manufacturing parts properties. Previous studies on process parameters and their impact on the microstructure are often limited to single wall samples and does not provide robust data. The aim of this Thesis is to create a universal design of experiment for determining optimal processing parameters in metal additive manufacturing. By creating this DOE we can then understand the relationships with respect to the amount of energy required to achieve a given microstructure. In order to show this DOE is applicable and repeatable, the experiment will be applied on different laser power levels and results will be studied.

Download or read book Proceedings of 5th International Conference on the Industry 4 0 Model for Advanced Manufacturing written by Lihui Wang and published by Springer Nature. This book was released on 2020-05-15 with total page 370 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book gathers the proceedings of the 5th International Conference on the Industry 4.0 Model for Advanced Manufacturing (AMP 2020), held in Belgrade, Serbia, on 1–4 June 2020. The event marks the latest in a series of high-level conferences that bring together experts from academia and industry to exchange knowledge, ideas, experiences, research findings, and information in the field of manufacturing. The book addresses a wide range of topics, including: design of smart and intelligent products, developments in CAD/CAM technologies, rapid prototyping and reverse engineering, multistage manufacturing processes, manufacturing automation in the Industry 4.0 model, cloud-based products, and cyber-physical and reconfigurable manufacturing systems. By providing updates on key issues and highlighting recent advances in manufacturing engineering and technologies, the book supports the transfer of vital knowledge to the next generation of academics and practitioners. Further, it will appeal to anyone working or conducting research in this rapidly evolving field.