Download or read book Simulation of Additive Manufacturing Process Physics and Properties in Powder Bed Electron beam Melting of Ti 6Al 4V written by Mark Hedreen and published by . This book was released on 2020 with total page 153 pages. Available in PDF, EPUB and Kindle. Book excerpt: Electron-Beam Melting (EBM) is a novel additive manufacturing process that is capable of producing production-quality parts. However, part quality and microstructure are still highly variable. In order to improve the ability to develop better process parameters, experimental and numerical methods were preliminarily developed to better understand the process physics and phenomena. The state of the art in EBM process and process simulation is discussed and areas in need of further development are identified. An infrared camera is calibrated and used to attempt to measure temperatures in situ. A coupled computational fluid dynamics-thermal model is implemented in ANSYS Fluent in order to simulate the meltpool dynamics and heat transfer. This modeling approach allows for accurate resolution of process physics while avoiding excessive computational cost or time. Predicted and experimental melt pool topologies are compared for differing process and component conditions and with similar data. The effects of part geometry and process parameters on solidification rates and other microstructural characteristics are discussed and compared with experimental data. The experimental and numerical data from this work is compared with similar data from the literature and future improvements and developments are discussed.

Download or read book Origins of Variability in Electron Beam Powder Bed Fusion of Ti6Al4V written by Sean S. Ghods and published by . This book was released on 2021 with total page 173 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing (AM) processes for metals are advancing at a rapid pace. Among manyattractive qualities, AM relaxes design constraints, enables customization and can significantly reduce material waste in comparison to subtractive manufacturing processes. However, there are some fundamental issues that must be addressed for metal AM to become prevalent in aerospace. Most critical is the reliability of the mechanical properties of the metal and an identification of contributions (i.e., the root causes) to the mechanical variability. In powder bed fusion (PBF) AM, powder reuse from previous build cycles is desired to improve process economics. However, there is limited understanding of the contributions from feedstock reuse to particle-powder-properties and part quality. The first half of this dissertation investigates this topic in electron beam melting (EBM) powder fusion AM of a titanium alloy(Ti6Al4V) over 30 cycles of build and powder reuse. Results show that nearly all aspects of the process are influenced by powder reuse. Specifically, the particle size distribution tightens with reuse, but particle damage increases, which includes surface deformation (reduction in sphericity), partial melting and/or particle fusion and fracture. While no changes in the concentration of Al, V, Fe, H and N occur, there is a significant increase in Oxygen with reuse, which exceeded the concentration limit (0.20%) in just 11 build cycles. Results showed that the strength of the metal increased with powder reuse, whereas the ductility decreased significantly, both relevant to the damage tolerance of the metal. Powder reuse covers inter-build variability but not address the intra-build variability. Establishing an understanding of the mechanical response variation within a build is also necessary for quality control in metal AM. A design of experiments approach was adopted to determine the relative effects of part location, geometry, and proximity on quasi-static and cyclic properties of the metal. Significant effects were found from the radial distance from the center of the build plate and from the thickness of the parts to the ductility and fatigue life. The highest ductility and fatigue life can be obtained from part placement near the center of the build plate and with increasing thickness. This knowledge makes a fundamental contribution and supports successful application of EBM additive manufacturing for stress-critical components in aerospace and beyond. Nevertheless, more expansive efforts are necessary to further mature the technology, such that it can be integrated into aerospace manufacturing as a reliable production process.

Download or read book Achivements in Additive Manufacturing written by Mihail Ionescu and published by Trans Tech Publications Ltd. This book was released on 2023-11-23 with total page 172 pages. Available in PDF, EPUB and Kindle. Book excerpt: Special topic volume with invited peer-reviewed papers only

Download or read book Additive Manufacturing Technology written by Kun Zhou and published by John Wiley & Sons. This book was released on 2023-02-28 with total page 405 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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 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 Metal Powder Based Additive Manufacturing written by Kun Zhou and published by John Wiley & Sons. This book was released on 2023-05-17 with total page 325 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal Powder—Based Additive Manufacturing Highly comprehensive resource covering all key aspects of the current developments of metal powder—based additive manufacturing Metal Powder—Based Additive Manufacturing provides valuable knowledge and critical insights regarding the recent advances in various metal powder—based additive manufacturing techniques. This book also reviews typical powder preparation processes and highlights the significance of metal powder—based additive manufacturing for various industrial applications. The key features covered in this book: A rigorous overview of the underlying theories and practical applications of metal powder—based additive manufacturing techniques, including laser powder bed fusion, electron beam melting, laser-based directed energy deposition, and metal binder jetting. An expansive introduction of each technique and its significance pertaining to the printing processes, metallurgical defects, powder materials, equipment, and the microstructures and mechanical properties of the printed parts. A deep exploration of the preparation processes of metal powders for additive manufacturing and the effects of different processes on the powder properties. Comprehensive case studies of parts printed by metal powder—based additive manufacturing for various industrial applications. By providing extensive coverage of relevant concepts in the field of metal powder—based 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, powder metallurgy, physics, and chemistry. The rich research experience of the authors in additive manufacturing ensures that the readers are provided with both an in-depth understanding and informative technical guidance of metal powder—based additive manufacturing.

Download or read book Additive Manufacturing Handbook written by Adedeji B. Badiru and published by CRC Press. This book was released on 2017-05-19 with total page 928 pages. Available in PDF, EPUB and Kindle. Book excerpt: Theoretical and practical interests in additive manufacturing (3D printing) are growing rapidly. Engineers and engineering companies now use 3D printing to make prototypes of products before going for full production. In an educational setting faculty, researchers, and students leverage 3D printing to enhance project-related products. Additive Manufacturing Handbook focuses on product design for the defense industry, which affects virtually every other industry. Thus, the handbook provides a wide range of benefits to all segments of business, industry, and government. Manufacturing has undergone a major advancement and technology shift in recent years.

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 Laser Based Additive Manufacturing written by Narendra B. Dahotre and published by John Wiley & Sons. This book was released on 2022-08-01 with total page 308 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-Based Additive Manufacturing Explore laser-based additive manufacturing processes via multi-scale modeling and computer simulation In Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments, a distinguished team of researchers delivers an incisive framework for understanding materials processing using laser-based additive manufacturing (LAM). The book describes the use of computational modeling and simulation to explore and describe the LAM technique, to improve the compositional, phase, and microstructural evolution of the material, and to enhance the mechanical, chemical, and functional properties of the manufactured components. The accomplished authors combine a comprehensive overview of multi-scale modeling and simulation with experimental and practical observations, offering a systematic review of laser-material interactions in advanced LAM processes. They also describe the real-world applications of LAM, including component processing and surface functionalization. In addition to explorations of residual stresses, three-dimensional defects, and surface physical texture in LAM, readers will also find: A thorough introduction to additive manufacturing (AM), including the advantages of AM over conventional manufacturing and the challenges involved with using the technology A comprehensive exploration of computation materials science, including length- and time-scales in materials modeling and the current state of computational modeling in LAM Practical discussions of laser-material interaction in LAM, including the conversion of light energy to heat, modes of heat dissipation, and the dynamics of the melt-pool In-depth examinations of the microstructural and mechanical aspects of LAM integrated with modeling Perfect for materials scientists, mechanical engineers, and physicists, Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments is perfect for anyone seeking an insightful treatment of this cutting-edge technology in the areas of alloys, ceramics, and composites.

Download or read book Additive Manufacturing Processes written by Sanjay Kumar and published by Springer Nature. This book was released on 2020-05-26 with total page 212 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book provides a single-source reference to additive manufacturing, accessible to anyone with a basic background in engineering and materials science. Unlike other books on additive manufacturing that include coverages of things such as machine architecture, applications, business and present market conditions, this book focuses on providing comprehensive coverage of currently available additive manufacturing processes. All processes are explained with the help of various, original diagrams, useful for beginners and advanced researchers alike. Provides comprehensive coverages of all current processes available in additive manufacturing; Explains processes with the help of various original diagrams; Explains future process development at the last chapter, providing research outlook; Includes extensive references at the end of each chapter for further reading of original research.

Download or read book Effects of the Microstructure and Porosity on Properties of Ti 6Al 4V ELI Alloy Fabricated by Electron Beam Melting EBM written by and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology that makes possible the fabrication of three dimensional near-net-shaped parts directly from computer models. EBM technology has been in continuously updating, obtaining optimized properties of the processed alloys. Ti-6Al-4V titanium alloy is the most widely used and studied alloy for this technology and is the focus of this work. Several research works have been completed to study the mechanisms of microstructure formation as well as its influence on mechanical properties. However, the relationship is not completely understood, and more systematic research work is necessary in order to attain a better understanding of these features. In this work, samples fabricated at different locations, orientations, and distances from the build platform have been characterized, studying the relationship of these variables with the resulting material intrinsic characteristics and properties (surface topography, microstructure, porosity, micro-hardness and static mechanical properties). This study has revealed that porosity is the main factor controlling mechanical properties relative to the other studied variables. Therefore, in future process developments, decreasing of the porosity should be considered as the primary goal in order to improve mechanical properties.

Download or read book Additive Manufacturing of Emerging Materials written by Bandar AlMangour and published by Springer. This book was released on 2018-08-01 with total page 353 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book provides a solid background for understanding the immediate past, the ongoing present, and the emerging trends of additive manufacturing, with an emphasis on innovations and advances in its use for a wide spectrum of manufacturing applications. It contains contributions from leading authors in the field, who view the research and development progress of additive manufacturing techniques from the unique angle of developing high-performance composites and other complex material parts. It is a valuable reference book for scientists, engineers, and entrepreneurs who are seeking technologically novel and economically viable innovations for high-performance materials and critical applications. It can also benefit graduate students and post-graduate fellows majoring in mechanical, manufacturing, and material sciences, as well as biomedical engineering.

Download or read book Post processing Techniques for Additive Manufacturing written by Zafar Alam and published by CRC Press. This book was released on 2023-07-21 with total page 292 pages. Available in PDF, EPUB and Kindle. Book excerpt: This text defines and covers different themes of post-processing techniques based on mechanical, chemical/electrochemical, and thermal energy. It will serve as an ideal reference text for senior undergraduate and graduate students in diverse engineering fields including manufacturing, industrial, aerospace, and mechanical. This book: covers the fundamentals and advancements in the post-processing techniques for additive manufacturing; explores methods/techniques for post-processing different types of materials used in additive manufacturing processes; gives insight into the process selection criteria for post-processing of additive manufactured products made from different types of materials; discusses hybrid processes used for post-processing of additive manufacturing parts; and highlights post-processing techniques for properties enhancement. The primary aim of the book is to give the readers a well-informed layout of the different post-processing techniques that range from employing mechanical energy to chemical, electrochemical, and thermal energy to perform the intended task.

Download or read book Phase field method and integrated computing materials engineering written by Yu-Hong Zhao and published by Frontiers Media SA. This book was released on 2023-04-19 with total page 126 pages. Available in PDF, EPUB and Kindle. Book excerpt:

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 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 Additive Manufacturing of Metal Alloys 1 written by Patrice Peyre and published by John Wiley & Sons. This book was released on 2022-09-07 with total page 276 pages. Available in PDF, EPUB and Kindle. Book excerpt: Over the last decade or so, additive manufacturing has revolutionized design and manufacturing methods by allowing more freedom in design and functionalities unattainable with conventional processes. This has generated extraordinarily high interest in both industrial and academic communities. Additive Manufacturing of Metal Alloys 1 puts forward a state of the art of additive manufacturing and its different processes, from metallic raw materials (in the form of powder or wire) to their properties after elaboration. It analyzes the physics and the modelling of existing AM processes as well as future elaboration processes. Using a balanced approach encapsulating basic notions and more advanced aspects for each theme, this book acts as a metal additive manufacturing textbook, as useful to professionals in the field as to the general public.