Download or read book Multiscale Modeling of Additively Manufactured Metals written by Yi Zhang and published by Elsevier. This book was released on 2020-06-29 with total page 252 pages. Available in PDF, EPUB and Kindle. Book excerpt: Multiscale Modeling of Additively Manufactured Metals: Application to Laser Powder Bed Fusion Process provides comprehensive coverage on the latest methodology in additive manufacturing (AM) modeling and simulation. Although there are extensive advances within the AM field, challenges to predictive theoretical and computational approaches still hinder the widespread adoption of AM. The book reviews metal additive materials and processes and discusses multiscale/multiphysics modeling strategies. In addition, coverage of modeling and simulation of AM process in order to understand the process-structure-property relationship is reviewed, along with the modeling of morphology evolution, phase transformation, and defect formation in AM parts. Residual stress, distortion, plasticity/damage in AM parts are also considered, with scales associated with the spatial, temporal and/or material domains reviewed. This book is useful for graduate students, engineers and professionals working on AM materials, equipment, process, development and modeling. Includes the fundamental principles of additive manufacturing modeling techniques Presents various modeling tools/software for AM modeling Discusses various design methods and how to optimize the AM process using these models

Download or read book Quality Analysis of Additively Manufactured Metals written by Javad Kadkhodapour and published by Elsevier. This book was released on 2022-11-30 with total page 858 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 Additive Manufacturing of Metallic Materials with Controlled Microstructures written by Zackery B. McClelland and published by . This book was released on 2019 with total page 148 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Multiscale Modeling to Predict Induced Residual Stress Distortion and Material Properties in Metal Additively Manufactured Components written by Sumair F. Sunny and published by . This book was released on 2021 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This work introduces numerical frameworks that enable the prediction of residual stress (RS), distortion, and microstructure from the metal additive manufacturing (AM) process, to reveal new insights that offer a deeper understanding towards the influence these factors have on RS and distortion induced during subsequent post-process operations. Electron backscatter diffraction (EBSD) imaging reported in the literature has provided evidence of microstructural inhomogeneity in metal AM parts that can strongly influence the resultant anisotropic mechanical response. Unfortunately, EBSD imaging only provides 2D observations of microstructure, and hence assumptions regarding the out-of-plane size and shape of individual grains have to be made. While multiple 0́−slices0́+ of EBSD images can be digitally stitched together, such experimental procedures would be very time-intensive, especially for larger AM builds. Over the past decade, numerous 3D microstructure modeling techniques have emerged and/or evolved to address this difficulty. One such approach involves the Kinetic Monte Carlo (KMC) method. A limitation of the existing KMC method, however, is that its modeling technique only allows for static melt pool and heat affected zone; and it thereby neglects important effects of transient thermal history in metal AM processes. Aside from microstructure, considering the thermomechanical nature of metal AM, rapid thermal cycles can cause large magnitudes of RS and distortion to develop within a fused part during the build. Prior investigations documented in the literature report experimental measurement of tensile residual stresses (TRS) in the bulk AM material, along with several types of surface defects. While TRS can result in poor fatigue life of a component, excessive distortions can lead to part rejection or necessitate expensive and time-consuming post-process correction. It should be noted, however, that the preliminary experimental measurement and characterization of RS via techniques such as slitting, x-ray and/or neutron diffraction are either extremely time consuming, costly, or possess a considerable degree of volumetric averaging. Nonetheless, a poor understanding of the RS fields, distortion, and mechanical response of a metal AM part will adversely influence how the part is post-processed. In addition, the final part geometry may not conform to dimensional requirements or possess the load bearing capacity for the desired application. The foregoing issues motivate the need for a physics-based numerical approach by which the AM microstructure, as well as RS and distortion, can be suitably predicted based on the AM process parameters. Furthermore, such a physics-based model may be of great value in assessing the influence of the initial RS and distortion in the AM part on the subsequent RS and distortion that is induced during post-processing operations such as machining or laser shock peening. In this work, several numerical frameworks are presented and deployed to test hypotheses related to the influences of metal AM RS and inhomogeneous microstructure. First, a Dynamic Kinetic Monte Carlo (DKMC) microstructure prediction framework is developed to capture interlayer and intralayer heat accumulation effects when predicting metal AM microstructure. Unlike the existing KMC approach, the DKMC method captures the influence of the AM process parameter dependent transient thermal history on the printed structure0́9s grain morphology. This is followed by a study that incorporates the 3D inhomogeneous microstructure for AM metal, predicted via DKMC, in post-process simulations of micromilling as well as laser shock peening (LSP). The work illuminates key insights into how the 3D microstructure consideration influences material response during post-process operations, and it effectively demonstrates a process-structure-property relationship. An investigation into how the initial RS in the bulk AM material influences the post-process induced RS and distortion is subsequently presented with a high-speed machining case study. Furthermore, the extent by which the machining strategy affects the degree of influence of initial RS on the machining-induced RS and distortion is also investigated. The study offers a comprehensive understanding towards the importance of inclusion of initial RS in the AM bulk material when simulating post-process operations. While the aforementioned studies either focus on the effects of initial RS in the AM bulk material or microstructure, they do not combine the two. Hence, an additional study implementing both metal AM microstructure modeling and its initial RS fields is also presented. A parametric examination on the influence of initial RS fields, microstructure, and the printing environment temperature when applying interlayer burnishing during a laser powder bed fusion process reveals new insights regarding their combined effect. Finally, a research application study is presented which demonstrates how numerical prediction of the vertical distortion along the upper surface of the AM build can be used to devise an in-situ LSP strategy to correct for excessive amounts of such surface distortion. While the frameworks presented in this research are implemented using selective laser melting case studies, they are readily extensible to other powder bed fusion metal AM methods, as well as directed energy deposition and binder jetting technologies. New insights from the tools developed in this research facilitate improved understanding through more realistic predictions of residual stress, distortion, and mechanical response of the AM bulk material when subject to post-process treatments.

Download or read book Fundamentals of Multiscale Modeling of Structural Materials written by Wenjie Xia and published by Elsevier. This book was released on 2022-11-26 with total page 450 pages. Available in PDF, EPUB and Kindle. Book excerpt: Fundamentals of Multiscale Modeling of Structural Materials provides a robust introduction to the computational tools, underlying theory, practical applications, and governing physical phenomena necessary to simulate and understand a wide-range of structural materials at multiple time and length scales. The book offers practical guidelines for modeling common structural materials with well-established techniques, outlining detailed modeling approaches for calculating and analyzing mechanical, thermal and transport properties of various structural materials such as metals, cement/concrete, polymers, composites, wood, thin films, and more.Computational approaches based on artificial intelligence and machine learning methods as complementary tools to the physics-based multiscale techniques are discussed as are modeling techniques for additively manufactured structural materials. Special attention is paid to how these methods can be used to develop the next generation of sustainable, resilient and environmentally-friendly structural materials, with a specific emphasis on bridging the atomistic and continuum modeling scales for these materials. - Synthesizes the latest cutting-edge computational multiscale modeling techniques for an array of structural materials - Emphasizes the foundations of the field and offers practical guidelines for modeling material systems with well-established techniques - Covers methods for calculating and analyzing mechanical, thermal and transport properties of various structural materials such as metals, cement/concrete, polymers, composites, wood, and more - Highlights underlying theory, emerging areas, future directions and various applications of the modeling methods covered - Discusses the integration of multiscale modeling and artificial intelligence

Download or read book Multiscale Modeling of Metal Additive Manufacturing Investigation Into Dendritic Solidification Meltpool Dynamics and Microstructure Evolution written by Kunal Pratap Bhagat and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Microstructure evolution in metal additive manufacturing (AM) is a complex multi-physics and multi-scale problem. Understanding the impact of AM process conditions on the microstructure evolution and the resulting mechanical properties of the printed part is an active area of research. The investigation into understanding the microstructure evolution under AM conditions, at different length scales, is done as a three-part research program that is presented in this thesis. In the first part, a high-fidelity numerical method at the mesoscale to model varied dendritic solidification morphologies is developed. A numerical framework encompassing the modeling of Stefan problem formulations relevant to dendritic evolution using a phase-field approach and a finite element method implementation is presented. Using this framework, numerous complex dendritic morphologies that are physically relevant to the solidification of pure melts and binary alloys are modeled. To the best of our knowledge, this is a first-of-its-kind study of numerical convergence of the phase-field equations of dendritic growth in a finite element method setting. Further, using this numerical framework, various types of physically relevant dendritic solidification patterns like single equiaxed, multi-equiaxed, single-columnar, and multi-columnar dendrites are modeled in two-dimensional and three-dimensional computational domains. In the second part, the complex dynamics of meltpool formation during metal additive manufacturing are modeled using a thermo-fluidic numerical model. Statistical-based method of least-squares is exploited to characterize the role of dimensional numbers in the microstructure evolution process. A novel strategy using dimensional analysis and the method of linear least-squares regression to numerically investigate the thermo-fluidic governing equations of the Laser Powder Bed Fusion AM process is presented. First, the governing equations are solved using the finite element method, and the model predictions are validated with experimental and numerical results from the literature. Then, through dimensional analysis, an important dimensionless quantity - interpreted as a measure of heat absorbed by the powdered material and the meltpool, is identified. Key contributions of this work include the demonstration of the correlation between the dimensionless measure of heat absorbed, and classical dimensionless quantities such as Peclet, Marangoni, and Stefan numbers, with advective transport in the meltpool for different alloys, meltpool morphologies, and microstructure evolution-related variables In the third part, the influence on the morphology of evolving dendritic microstructure due to the rapid thermal cycle and fluid convection in the meltpool during metal additive manufacturing is investigated. A finite-element formulation that solves a coupled Navier-Stokes flow model and a phase-field model of dendritic solidification is developed. Microstructure evolution modeled using purely heat and mass diffusion process may not capture the entire spectrum of the dendrite morphology observed in metal additive manufacturing. The impact of flow dynamics on the thermal gradients and momentum transfer that modulate dendritic shapes, along with the associated remelting are modeled using a coupled phase-field model of solidification. Further, the morphological changes to dendrites in the solidifying region beneath the meltpool fusion line are modeled by accounting for convective effects in the mass and heat diffusion process in equiaxed, aligned equiaxed, and columnar dendrite growth for a pure metal and binary alloys. It is observed that for a meltpool formed under high laser power and scan speed conditions, where Marangoni convection is significant, enhanced growth of the secondary arms of columnar dendrite occurs as compared to dendrite growth observed in low convection regions of the meltpool.

Download or read book Additive Manufacturing Applications for Metals and Composites written by Balasubramanian, K.R. and published by IGI Global. This book was released on 2020-06-19 with total page 348 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) of metals and composites using laser energy, direct energy deposition, electron beam methods, and wire arc melting have recently gained importance due to their advantages in fabricating the complex structure. Today, it has become possible to reliably manufacture dense parts with certain AM processes for many materials, including steels, aluminum and titanium alloys, superalloys, metal-based composites, and ceramic matrix composites. In the near future, the AM material variety will most likely grow further, with high-performance materials such as intermetallic compounds and high entropy alloys already under investigation. Additive Manufacturing Applications for Metals and Composites is a pivotal reference source that provides vital research on advancing methods and technological developments within additive manufacturing practices. Special attention is paid to the material design of additive manufacturing of parts, the choice of feedstock materials, the metallurgical behavior and synthesis principle during the manufacturing process, and the resulted microstructures and properties, as well as the relationship between these factors. While highlighting topics such as numerical modeling, intermetallic compounds, and statistical techniques, this publication is ideally designed for students, engineers, researchers, manufacturers, technologists, academicians, practitioners, scholars, and educators.

Download or read book Data Driven Modeling for Additive Manufacturing of Metals written by National Academies of Sciences, Engineering, and Medicine and published by National Academies Press. This book was released on 2019-11-09 with total page 79 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) is the process in which a three-dimensional object is built by adding subsequent layers of materials. AM enables novel material compositions and shapes, often without the need for specialized tooling. This technology has the potential to revolutionize how mechanical parts are created, tested, and certified. However, successful real-time AM design requires the integration of complex systems and often necessitates expertise across domains. Simulation-based design approaches, such as those applied in engineering product design and material design, have the potential to improve AM predictive modeling capabilities, particularly when combined with existing knowledge of the underlying mechanics. These predictive models have the potential to reduce the cost of and time for concept-to-final-product development and can be used to supplement experimental tests. The National Academies convened a workshop on October 24-26, 2018 to discuss the frontiers of mechanistic data-driven modeling for AM of metals. Topics of discussion included measuring and modeling process monitoring and control, developing models to represent microstructure evolution, alloy design, and part suitability, modeling phases of process and machine design, and accelerating product and process qualification and certification. These topics then led to the assessment of short-, immediate-, and long-term challenges in AM. This publication summarizes the presentations and discussions from the workshop.

Download or read book Fatigue in Additive Manufactured Metals written by Filippo Berto and published by Elsevier. This book was released on 2023-09-20 with total page 321 pages. Available in PDF, EPUB and Kindle. Book excerpt: Fatigue in Additive Manufactured Metals provides a brief overview of the fundamental mechanics involved in metal fatigue and fracture, assesses the unique properties of additive manufactured metals, and provides an in-depth exploration of how and why fatigue occurs in additive manufactured metals. Additional sections cover solutions for preventing it, best-practice design methods, and more. The book recommends cutting-edge evidence-based approaches for designing longer lasting additive manufactured metals, discusses the latest trends in the field and the various aspects of low cycle fatigue, and looks at both post-treatment and manufacturing process-based solutions. By providing international standards and testing procedures of additive manufactured metal parts and discussing the environmental impacts of additive manufacturing of metals and outlining simulation and modeling scenarios, this book is an ideal resource for users in industry. - Discusses the underlying mechanisms controlling the fatigue behavior of additive manufactured metal components as well as how to improve the fatigue life of these components via both manufacturing processes and post-processing - Studies the variability of properties in additive manufactured metals, the effects of different process conditions on mechanical reliability, probabilistic versus deterministic aspects, and more - Outlines nondestructive failure analysis techniques and highlights the effects of unique microstructural characteristics on fatigue in additive manufactured metals

Download or read book A Multiscale Thermomechanical Metal Additive Manufacturing Simulation and the Impact of Geometry on Residual Stress and Distortion written by Luis Fernando Silva Velasco and published by . This book was released on 2020 with total page 86 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal additive manufacturing is an enabling technology for the rapid prototyping and manufacturing of geometrically complex parts that would otherwise be difficult or impossible to manufacture. However, the manufacturing process can produce undesired residual stresses and distortions. The first part of the work describes the implementation of a multiscale, thermo-mechanical simulation modeling the metal powder bed fusion additive manufacturing process. NASA’s Micromechanics Analysis Code was is to incorporate the microscale effects of an evolving material porosity on the predicted macroscale residual fields. The simulation shows that modeling an evolving material porosity, as the material transitions from a metal powder to a solid, significantly affects the magnitude of the residual stresses and distortions, compared to a constant porosity model. The second part of this work uses the developed simulations to assess the effects of geometrical features. A linear regression shows that there is a correlation between the residual fields and the geometry. This suggests that it may be feasible to predictably influence the residual fields by modifying the geometry. This work is part of a larger work aimed at optimizing the geometry to minimize the residual stresses and distortions.

Download or read book Metal Additive Manufacturing written by Dyuti Sarker and published by John Wiley & Sons. This book was released on 2021-10-26 with total page 624 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 Modeling and Optimization in Manufacturing written by Catalin I. Pruncu and published by John Wiley & Sons. This book was released on 2021-07-19 with total page 338 pages. Available in PDF, EPUB and Kindle. Book excerpt: Discover the state-of-the-art in multiscale modeling and optimization in manufacturing from two leading voices in the field Modeling and Optimization in Manufacturing delivers a comprehensive approach to various manufacturing processes and shows readers how multiscale modeling and optimization processes help improve upon them. The book elaborates on the foundations and applications of computational modeling and optimization processes, as well as recent developments in the field. It offers discussions of manufacturing processes, including forming, machining, casting, joining, coating, and additive manufacturing, and how computer simulations have influenced their development. Examples for each category of manufacturing are provided in the text, and industrial applications are described for the reader. The distinguished authors also provide an insightful perspective on likely future trends and developments in manufacturing modeling and optimization, including the use of large materials databases and machine learning. Readers will also benefit from the inclusion of: A thorough introduction to the origins of manufacturing, the history of traditional and advanced manufacturing, and recent progress in manufacturing An exploration of advanced manufacturing and the environmental impact and significance of manufacturing Practical discussions of the economic importance of advanced manufacturing An examination of the sustainability of advanced manufacturing, and developing and future trends in manufacturing Perfect for materials scientists, mechanical engineers, and process engineers, Modeling and Optimization in Manufacturing will also earn a place in the libraries of engineering scientists in industries seeking a one-stop reference on multiscale modeling and optimization in manufacturing.

Download or read book Multiscale Modeling Framework for Defect Generation in Metal Powder Bed Fusion Process to Correlate Process Parameters and Structural Properties written by Suchana Akter Jahan and published by . This book was released on 2018 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Powder Bed Fusion (PBF) is one of the most popular additive manufacturing methods employed extensively to fabricate complex parts especially in industries with stringent standard criteria, including aerospace, medical, and defense. DMLS/PBF fabrication of parts that is free of defects represents major challenges. A comprehensive study of thermal defects, contributing parameters, and their correlation is necessary to better understand how process specifications initiate these defects. Monitoring & controlling temperature and its distribution throughout a layer under fabrication is an effective and efficient proxy to controlling process thermal evolution, which is a completely experimental technique. This being highly costly specifically for metal printing, computer-based numerical simulation can significantly help the identification of temperature distribution during the printing process. In this paper, a multiscale modeling technique is demonstrated with commercially available software tools to correlate the defect generation in metal PBF process and significant process parameters. This technique can help efficiently design the process setting in addition to or even absence of experimental monitoring data. This research work is a part of a larger project of closed-loop control strategy development using physics-based modeling and graph-based artificial neural network implementation for reducing thermally induced part defects in metal 3D printed process.

Download or read book Additive Manufacturing Technology written by Kun Zhou and published by John Wiley & Sons. This book was released on 2022-12-20 with total page 405 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing Technology Highly comprehensive resource covering all key aspects of the current developments of additive manufacturing Additive Manufacturing Technology: Design, Optimization, and Modeling provides comprehensive and in-depth knowledge of the latest advances in various additive manufacturing technologies for polymeric materials, metals, multi-materials, functionally graded materials, and cell-laden bio-inks. It also details the application of numerical modeling in facilitating the design and optimization of materials, processes, and printed parts in additive manufacturing. The topics covered in this book include: Fundamentals and applications of 4D printing, 3D bioprinting of cell-laden bio-inks, and multi-material additive manufacturing Alloy design for metal additive manufacturing, mechanisms of metallurgical defect formation, and the mechanical properties of printed alloys Modified inherent strain method for the rapid prediction of residual stress and distortion within parts fabricated by additive manufacturing Modeling of the different stages in polymer and metal additive manufacturing processes, including powder spreading, melting, and thermal stress evolution By providing extensive coverage of highly relevant concepts and important topics in the field of additive manufacturing, this book highlights its essential role in Industry 4.0 and serves as a valuable resource for scientists, engineers, and students in materials science, engineering, and biomedicine.

Download or read book Multiscale Modelling in Sheet Metal Forming written by Dorel Banabic and published by Springer. This book was released on 2016-10-20 with total page 416 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book gives a unified presentation of the research performed in the field of multiscale modelling in sheet metal forming over the course of more than thirty years by the members of six teams from internationally acclaimed universities. The first chapter is devoted to the presentation of some recent phenomenological yield criteria (BBC 2005 and BBC 2008) developed at the CERTETA center from the Technical University of Cluj-Napoca. An overview on the crystallographic texture and plastic anisotropy is presented in Chapter 2. Chapter 3 is dedicated to multiscale modelling of plastic anisotropy. The authors describe a new hierarchical multi-scale framework that allows taking into account the evolution of plastic anisotropy during sheet forming processes. Chapter 4 is focused on modelling the evolution of voids in porous metals with applications to forming limit curves and ductile fracture. The chapter details the steps needed for the development of dissipation functions and Gurson-type models for non-quadratic anisotropic plasticity criteria like BBC 2005 and those based on linear transformations. Chapter 5 describes advanced models for the prediction of forming limit curves developed by the authors. Chapter 6 is devoted to anisotropic damage in elasto-plastic materials with structural defects. Finally, Chapter 7 deals with modelling of the Portevin-Le Chatelier (PLC) effect. This volume contains contributions from leading researchers from the Technical University of Cluj-Napoca, Romania, the Catholic University of Leuven, Belgium, Clausthal University of Technology, Germany, Amirkabir University of Technology, Iran, the University of Bucharest, Romania, and the Institute of Mathematics of the Romanian Academy, Romania. It will prove useful to postgraduate students, researchers and engineers who are interested in the mechanical modeling and numerical simulation of sheet metal forming processes.

Download or read book Fundamentals of Laser Powder Bed Fusion of Metals written by Igor Yadroitsev and published by Elsevier. This book was released on 2021-05-23 with total page 678 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing. Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward. - Presents laser powder bed fusion fundamentals, as well as their inherent challenges - Provides an up-to-date summary of this advancing technology and its potential - Provides a comprehensive textbook for universities, as well as a reference for industry - Acts as quick-reference guide

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