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 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 Fundamentals of Additive Manufacturing for the Practitioner written by Sheku Kamara and published by John Wiley & Sons. This book was released on 2021-05-25 with total page 194 pages. Available in PDF, EPUB and Kindle. Book excerpt: Fundamentals of Additive Manufacturing for the Practitioner Discover how to shift from traditional to additive manufacturing processes with this core resource from industry leaders Fundamentals of Additive Manufacturing for the Practitioner delivers a vital examination of the methods and techniques needed to transition from traditional to additive manufacturing. The book explains how traditional manufacturing work roles change as various industries move into additive manufacturing and describes the flow of the typical production process in additive manufacturing. Detailed explorations of the processes, inputs, machine and build preparation, post-processing, and best practices are included, as well as real-world examples of the principles discussed within. Every chapter includes a problems and opportunities section that prompts readers to apply the book’s techniques to their own work. Diagrams and tables are distributed liberally throughout the work to present concepts visually, and key options and decisions are highlighted to assist the reader in understanding how additive manufacturing changes traditional workflows. Readers will also benefit from the inclusion of A thorough introduction on how to move into additive manufacturing, including the identification of a manufacturing opportunity and its characteristics An exploration of how to determine if additive manufacturing is the right solution, with descriptions of the origins of additive manufacturing and the current state of the technology An examination of the materials used in additive manufacturing, including polymers, composites, metals, plasters, and biomaterials A discussion of choosing an additive manufacturing technology and process Perfect for mechanical engineers, manufacturing professionals, technicians, and designers new to additive manufacturing, Fundamentals of Additive Manufacturing for the Practitioner will also earn a place in the libraries of technical, vocational, and continuing education audiences seeking to improve their skills with additive manufacturing workflows.

Download or read book Investigation of High speed Directed Energy Deposition DED for High Geometric Accuracy and Productivity written by Leslie Leung and published by . This book was released on 2019 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Directed energy deposition (DED) is an attractive metal additive manufacturing process that can be used to make complex parts in less time than with conventional powder bed fusion (PBF). However, the dimensional accuracy of the final part and the process efficiency of DED are limited by current process parameters. High deposition speeds are proposed and tested as an alternative to 1) increase the productivity of the process and 2) create individual clad layers with minimal sloping to reduce the accumulated dimensional errors per layer. A full-factorial design of experiment with three factors—feed rate, laser power, and powder flow rate—was performed for individual clads, from which their geometries were measured and used to optimize the process parameters. Thin walls made of 316L stainless steel were fabricated to test the effects of these optimized process parameters in addition to machine dynamics on the dimensional accuracy of a multi-layered part. Mechanical properties and pore fraction content were compared to those of conventional DED and wrought 316L stainless steel from tensile testing results and scanning electron microscopy images. Results from this study indicated that higher feed rates at or above 1800mm/min have the potential of producing parts with outstanding material properties but must be balanced with other process parameters to ensure that the desired productivity and part qualities are met.

Download or read book Advances in Metal Additive Manufacturing written by Sachin Salunkhe and published by Elsevier. This book was released on 2022-10-10 with total page 255 pages. Available in PDF, EPUB and Kindle. Book excerpt: Advances in Metal Additive Manufacturing explains fundamental information and the latest research on new technologies, including powder bed fusion, direct energy deposition using high energy beams, and hybrid additive and subtractive methods. This book introduces readers to the technology, provides everything needed to understand how the different stages work together, and inspires to think beyond traditional metal processing to capture new ideas in metal. Chapters offer an introduction on metal additive manufacturing, processes, and properties and standards and then present surveys on the most significant international advances in metal additive manufacturing. Throughout, the book presents a focus on the effect of important process parameters on the microstructure, mechanical properties and wear behavior of additively manufactured parts. - Covers the entire process chain of metal additive manufacturing, from input data preparation to part certification - Describes a wide range of the latest design tools and options, including generative design, topology optimization, and lattice and surface optimization - Addresses additive manufacturing, with a comprehensive list of metals including titanium, aluminum, iron-and nickel-based alloys and Inconel 718

Download or read book Experimental Design for Process Parameter Correlation to Dimensional Inaccuracies in Additive Manufacturing Processes written by David Corbin and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The objective of this work is to develop a comprehensive set of experiments for the investigation of the effects of Directed Energy Deposition (DED) processing parameters on dimensional accuracy. Dimensional accuracy, defined as the quantitative assessment of the agreement between the intended geometry and the final geometry of the deposited part, is understood to be one of the most important aspects of quality of an Additive Manufacturing (AM) process. This outcome is generally defined by the heat input affecting dimensions of the process including the capture efficiency of the injected powder, melt-pool size, and thermal cycling of the deposited part. Experiments were designed to generalize the effects of common DED processing parameters and their interactions on dimensional accuracy measured in situ and post-process. The experimental measurements assisted the development of validated, thermo-mechanical models that determined deformation-causing mechanisms in ways that traditional, measurement strategies fail. These models can act as a predictive tool in the assessment of the dimensional accuracy of subsequent directed energy depositions.

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 of High Performance Metallic Materials written by Robert Pederson and published by Elsevier. This book was released on 2023-09-19 with total page 580 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing of High-Performance Metallic Materials outlines the state-of-the-art on AM in high performance materials utilizing the two most industrially interesting routes of powder bed fusion (PBF) and directed energy deposition (DED). The book delves into Feedstock, Processing, Monitoring and control, Modeling and simulation, and Surface and thermal post-treatments. It specifically addresses materials and the most relevant and high performance applications, namely Ni-based alloys and Titanium alloys, and also provides insights into potential applications through illustrative case studies. With each chapter contributed by experts in the field, this work will serve as a comprehensive resource for graduate students and practitioners alike. - Covers the entire value chain relevant to additive manufacturing spanning feedstock, processing, monitoring, post-treatment, testing and applications - Includes the fundamental understanding of varied associated aspects derived from both extensive experimental knowledge and theoretical investigations - Addresses key materials relevant to varied high performance applications, namely Superalloys and Ni-based alloys

Download or read book Handbook of Post Processing in Additive Manufacturing written by Gurminder Singh and published by CRC Press. This book was released on 2023-10-04 with total page 210 pages. Available in PDF, EPUB and Kindle. Book excerpt: Handbook of Post-Processing in Additive Manufacturing is a key resource on postprocessing treatments available for additive manufactured products. It provides broad coverage of the theory behind emerging technology, material development, functional characterization, and technical details required to investigate novel applications and methods and put them to use. The handbook presents experimental breakthroughs of novel methodologies that treat additively manufactured parts, which are suitable for demanding engineering applications. This handbook emphasizes the various types of post-processing technologies that can effectively eliminate the inferiorities of additively manufactured components. It also provides a collection of key principles, literature, methodologies, experimental results, case studies, and theoretical aspects of the different types of postprocessing techniques, along with different classes of materials and end-applications. This book is an ideal reference for libraries and post-graduate courses as well as the professional market, including, but not limited to manufacturing, mechanical and industrial engineering, and materials science.

Download or read book In Situ Process Monitoring of Directed Energy Deposition Powder Flow to Detect Anomalies written by Sheila Moroney and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Directed energy deposition (DED) is a category of additive manufacturing (AM) that employs one of a variety of energy sources, (such as electron beam, laser, arc) to melt and deposit either powder or wire feedstock to build up standalone features or resurface existing components making DED a practical option for repair. Laser based directed energy deposition (LDED) additive manufacturing process is attractive for repair because of the ability to tailor process parameters to effectively restore part geometry while using the least amount of energy necessary to limit residual stress, distortion, and degradation of the base material. The use of LDED to repair parts in the aerospace and defense industries has helped to reduce costs of replacement parts. Currently, however, LDED lacks the reliability of other manufacturing processes. Many researchers have developed methods to monitor key process parameters of the LDED process in-situ. However, few studies have focused on a method to monitor the powder flow, a parameter that is critical to the success of a DED repair. And none have related variations in powder flow directly to deposition geometry and quality with data collected in-situ. The work presented in this thesis presents methods to monitor the powder flow rate and spatial powder flow distribution below the nozzle exit. In-situ powder flow monitoring analysis methods are developed and used to identify anomalies in the powder flow from nozzle exit through the powder focal plane. The ability for the system to detect a powder flow anomaly that impacts deposition quality is validated by performing a set of experiments that show the effect of irregular powder flow on build height.

Download or read book Process Planning for Additive Manufacturing of Metallic Functionally Graded Materials written by Frederick Lia and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: A decision making algorithm for process planning for laser-based directed energy deposition (DED) additive manufacturing (AM) to produce metallic functionally graded materials (FGM) components is proposed in this research. The challenge of processing and modeling the FGM component depends on the local compositions throughout the gradient and directly impact the microstructure development and material properties. The objective in utilizing the algorithm was to minimize the brittle intermetallic phases within the gradient transition regions of the FGM component, which could be caused by dilution effects occurring at the locations of the gradient transition regions during the laser deposition process. Two models were developed for the algorithm: an energy balance model and a dilution model. The energy balance model was a combination of an analytical method and empirical model, which predicted the dimensions of the deposit track, such as: melt pool width, deposit height, and melt pool penetration depth. The dilution model utilized the track dimensions from the energy balance model to predict the chemical compositions of the FGM gradients. Two FGM systems were explored to validate the developed models. A material system based on AISI stainless steel 316L (SS 316L) and nickel aluminum bronze (NAB) system was used to verify the consistency and accuracy of the energy balance model and the dilution model. The stainless steel alloy 316L and Inconel 625® FGM system was also used to demonstrate the capability of the models for producing FGM material with alloys having practical applications. The energy balance model relied on critical laser deposition process parameters, such as laser power, laser scan speed, and laser spot size; as well as material physical properties such as, thermal properties and two empirical variables: powder capture efficiency, Pe, and melt pool aspect ratio, r. This approach for the energy balance model was required to predict the FGM compositions as a function of processing parameters and condition, which would provide predictive capabilities quickly and less expensively as a control algorithm. The energy balance model was utilized to estimate deposit track dimensions and showed strong agreement with the experimentally measured results for the SS 316L and NAB FGM system. The dilution model successfully predicted the gradient compositions and showed correlation with electron diffraction spectroscopy (EDS) data obtained from measured track dimensions and the energy balance model predictions for track dimensions. The dilution model was also used to investigate the gradient transitions along the vertical and horizontal directions for both SS 316L and NAB FGM and SS 316L and Inconel 625® FGM systems, and this analysis indicated that the model was capable of accurately predicting concentrations within these regions.

Download or read book A Novel Benchtop Open Architecture Direct Energy Deposition System BenchDED written by John Cloutier and published by . This book was released on 2021 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) promises to change the way manufacturing companies do business in terms of product to market, complexity of manufactured parts, waste reduction, etc. AM technologies, which include laser-based powder-bed fusion (PBF) and direct energy deposition (DED), have been used successfully for producing near net shape complex metal parts; however, the cost of equipment, the cycle time, and the cost of parts can be prohibitively high. As a result, AM is not considered to be a sufficiently mature process for production. DED technology can be used in unique applications, such as part repair and cladding, and 3D printing of functional grading materials. Further investigations into the design and operation of DED are required to optimize equipment and cycle costs. The primary objective of this research is to investigate the feasibility of developing a low-powered, low-cost DED system. Phase one of this work involved designing and manufacturing a DED experimental setup to enable research and development. The BenchDED is a 200-watt DED modular and open architecture laser printer that was built in house at the Advanced Manufacturing Lab (AML). The BenchDED enables data collection and process monitoring. The knowledge and experience gained from the BenchDED were invaluable and helped to better understand the mechanics of the DED process. The second phase involved optimizing and tuning the BenchDED so that it would be able to create 3D printed parts. This phase involved refining the main components of the BenchDED. It also involved identifying the operating range for these components. The third phase of this research involved the microstructural analysis and mechanical characterization of the test coupons manufactured using both the BenchDED and commercial AM machines. A comparison of the microstructure of the different coupons confirmed the functionality of the BenchDED. The microstructural analysis of SS316L steel revealed that the grain structure and the hardness values for both the industrial and the BenchDED samples were comparable. The primary discrepancy was seen in the irregularity in the grain size, due to the difference in spot size used for the industrial samples ( 3 mm ) and the BenchDED samples ( 0.5 mm ).

Download or read book Investigation of Additive Manufacturing Process Parameters for Sustainability to Optimize Energy and Material Consumption written by Marwan Khalid and published by . This book was released on 2020 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing (AM) offers many advantages to make objects over traditional subtractive manufacturing methods. For example, complex geometries can be easily fabricated, and light weight parts can be formed while maintaining the parts strength for the low carbon footprint, low material consumption and waste. But there are few areas in AM to improve i.e., sustainability, reliability, productivity, robustness, material diversity and part quality. Life Cycle Assessment studies have identified that the AM printing stage has a big impact on the life cycle sustainability of 3D printed products. AM building parameters can be properly selected to improve the sustainability of AM. This thesis presents an investigation of the Fused Deposition Modelling (FDM) process parameters for sustainability i.e., to reduce the energy and material consumption. Investigated parameters include the printing layer height, number of shells, material infilling percentage, infilling type, and building orientation. The impact of these parameters on the energy consumption, part weight, scrap weight and production time has been studied. The study uses both simulation and experimental methods to improve the accuracy of results. Taguchi Design of Experiments approach and statistical analysis tools are used to find optimal FDM parameter settings for sustainability. The building orientation and layer height have been found as major influencers on the energy consumption, part weight, scrap weight, and production time, whereas the number of shells, infilling type and infill percentage have the less impact. It is concluded that the building orientation and layer height can be optimized to reduce the energy and material consumption. It is found that the energy consumption is proportional to production time. The significance of this research lies on the factor that it investigates five AM process parameters at 3 levels. Models formulated in this research can be easily extended to other AM processes.

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 Additive Manufacturing written by Juan Pou and published by Elsevier. This book was released on 2021-05-27 with total page 768 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing explains the background theory, working principles, technical specifications, and latest developments in a wide range of additive manufacturing techniques. Topics addressed include treatments of manufactured parts, surface characterization, and the effects of surface treatments on mechanical behavior. Many different perspectives are covered, including design aspects, technologies, materials and sustainability. Experts in both academia and industry contribute to this comprehensive guide, combining theoretical developments with practical improvements from R&D. This unique guide allows readers to compare the characteristics of different processes, understand how they work, and provide parameters for their effective implementation. This book is part of a four-volume set entitled Handbooks in Advanced Manufacturing. Other titles in the set include Advanced Machining and Finishing, Advanced Welding and Deformation, and Sustainable Manufacturing Processes. Provides theory, operational parameters, and latest developments in 20 different additive manufacturing processes Includes contributions from experts in industry and academia with a wide range of disciplinary backgrounds, providing a comprehensive survey of this diverse and influential subject Includes case studies of innovative additive manufacturing practices from industry

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 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