Download or read book Laser Powder Bed Fusion Process Characterization written by Rachael M. Flam and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal Laser Powder Bed Fusion (M-LPBF) is a method of additive manufacturing that enables the fabrication of complex components that would not otherwise be possible through conventional manufacturing techniques. M-LPBF is well suited for aerospace applications because of its ability to fabricate geometrically complex and efficient components. It can also enable the reduction of costs and the schedule of programs. The recent advancements in material development have the potential to widen the design space even further for aerospace applications, but the initial process of evaluating a new material on a M-LPBF printer can be time-consuming and costly. In this thesis, a framework to improve the efficiency and structure of M-LPBF process development is proposed. First, simulations of the melt pool were performed to understand the impact of primary process parameters on the dimensions of the melt pool. Then, tools to model the melt pool were tested and used in combination with analytical equations to identify an acceptable processing window for the M-LPBF process. Following this process parameter filtering, physical experiments were executed that investigated the impact of process and design parameters on various outputs connected to the melt pool, density, dimensional accuracy, and surface roughness of the coupons printed. Optimal parameter ranges can then be determined according to different design and process priorities. The framework developed in this project enables a material and machine agnostic approach to process parameter selection in less time and at a lower cost.

Download or read book In situ Characterization of Transient Dynamics in Laser Powder Bed Fusion Additive Manufacturing Process written by Qilin Guo and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion (LPBF) is one of the dominating techniques in metal additive manufacturing (AM). It enables the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, understanding the complex transient dynamics during the LPBF process is greatly hindered by the lack of experimental characterizations, mainly due to two reasons: (a) It is challenging to monitor the dynamics inside metals due to their opacity to visible light. (b) The transient dynamics occur in a small space within a short time, which requires the monitoring tools to have both high temporal and spatial resolution. This work studied the multi-level transient dynamics during the LPBF process by addressing the above challenges with in-situ high-energy synchrotron X-ray imaging & diffraction. The mechanisms and driving forces of the powder spattering process-one of the significant causes of defect formation in LPBF-were identified and quantified in Chapter 3. The spattering behaviors in terms of environmental pressures and locations were explicitly characterized. Chapter 4 answers why an identical input energy density could lead to various melt pool sizes and shapes by exploring the mechanism of melt pool variation under different processing conditions. In Chapters 5 and 6, a flow-tracing approach was developed to study the melt flow dynamics during the LPBF process. The regular melt pool patterns within the conduction-mode and keyhole-mode melt pools were experimentally revealed and quantified for the first time in Chapter 5, while the unstable melt flow formation mechanisms and consequences were illustrated in Chapter 6. Chapter 7 revealed the phase transformation dynamics in 17-4PH stainless steel during the rapid solidification of the melt pool. Informed by the phase transformation dynamics, a 17-4PH composition was developed specifically for AM process to consistently deliver the desired phase under a wide range of cooling rates and withstand common environment impurities. Overall, this work provides critical insights into the transient process dynamics during LPBF, which serves as a foundation to guide the mitigation of part defects and the optimization of processing conditions. The direct observation of the process dynamics is also important for developing and validating high-fidelity computational models.

Download or read book Additive Manufacturing of Metals The Technology Materials Design and Production written by Li Yang and published by Springer. This book was released on 2017-05-11 with total page 172 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leading experts in this field at universities and in industry, it provides a comprehensive textbook for students and an invaluable guide for practitioners

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 In situ Characterization of Transient Dynamics in Laser Powder Bed Fusion Additive Manufacturing Process written by Qilin Guo (Ph.D.) and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion (LPBF) is one of the dominating techniques in metal additive manufacturing (AM). It enables the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, understanding the complex transient dynamics during the LPBF process is greatly hindered by the lack of experimental characterizations, mainly due to two reasons: (a) It is challenging to monitor the dynamics inside metals due to their opacity to visible light. (b) The transient dynamics occur in a small space within a short time, which requires the monitoring tools to have both high temporal and spatial resolution. This work studied the multi-level transient dynamics during the LPBF process by addressing the above challenges with in-situ high-energy synchrotron X-ray imaging & diffraction. The mechanisms and driving forces of the powder spattering process-one of the significant causes of defect formation in LPBF-were identified and quantified in Chapter 3. The spattering behaviors in terms of environmental pressures and locations were explicitly characterized. Chapter 4 answers why an identical input energy density could lead to various melt pool sizes and shapes by exploring the mechanism of melt pool variation under different processing conditions. In Chapters 5 and 6, a flow-tracing approach was developed to study the melt flow dynamics during the LPBF process. The regular melt pool patterns within the conduction-mode and keyhole-mode melt pools were experimentally revealed and quantified for the first time in Chapter 5, while the unstable melt flow formation mechanisms and consequences were illustrated in Chapter 6. Chapter 7 revealed the phase transformation dynamics in 17-4PH stainless steel during the rapid solidification of the melt pool. Informed by the phase transformation dynamics, a 17-4PH composition was developed specifically for AM process to consistently deliver the desired phase under a wide range of cooling rates and withstand common environment impurities. Overall, this work provides critical insights into the transient process dynamics during LPBF, which serves as a foundation to guide the mitigation of part defects and the optimization of processing conditions. The direct observation of the process dynamics is also important for developing and validating high-fidelity computational models.

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 Characterization of the Surface Roughness of Overhangs Manufactured by Laser Powder Bed Fusion Process Using Design of Experiments written by Xuan Yi Lim and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal Laser Powder Bed Fusion (M-LPBF) is a method of additive manufacturing that enables the fabrication of complex components that would not be possible through conventional manufacturing methods. M-LPBF is well suited for aerospace applications not only because of its ability to fabricate complex and efficient components, but it also can enable the reduction of cost and the schedule of programs. The recent advancements in material development could open the design space even further for aerospace applications, but the initial development process of evaluating a new material on a M-LPBF printer can be time consuming and costly. In this work, a framework to improve the efficiency and structure of M-LPBF process development is proposed. First, simulations of the melt pool were performed to understand the impact of primary process parameters on the dimensions of the melt pool. Then, tools to model the melt pool were tested and used in combination with analytical equations to identify an acceptable processing window for the M-LPBF process. Following this process parameter filtering, physical experiments were executed that investigated the impact of process and design parameters on various outputs connected to the melt pool, density, dimensional accuracy, and surface roughness of the coupons printed. Optimal parameter ranges can then be determined according to different design and process priorities. The framework developed in this project enables a material and machine agnostic approach to process parameter selection in less time and at a lower cost.

Download or read book Physics of Laser Materials Processing written by Gennady G. Gladush and published by Springer Science & Business Media. This book was released on 2011-08-05 with total page 549 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book describes the basic mechanisms, theory, simulations and technological aspects of Laser processing techniques. It covers the principles of laser quenching, welding, cutting, alloying, selective sintering, ablation, etc. The main attention is paid to the quantitative description. The diversity and complexity of technological and physical processes is discussed using a unitary approach. The book aims on understanding the cause-and-effect relations in physical processes in Laser technologies. It will help researchers and engineers to improve the existing and develop new Laser machining techniques. The book addresses readers with a certain background in general physics and mathematical analysis: graduate students, researchers and engineers practicing laser applications.

Download or read book Additive Manufacturing of High Performance Oxide Ceramics Via Selective Laser Melting written by Yves-Christian Hagedorn and published by . This book was released on 2014 with total page 258 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Aerospace Alloys written by Stefano Gialanella and published by Springer Nature. This book was released on 2019-10-30 with total page 583 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents an up-to-date overview on the main classes of metallic materials currently used in aeronautical structures and propulsion engines and discusses other materials of potential interest for structural aerospace applications. The coverage encompasses light alloys such as aluminum-, magnesium-, and titanium-based alloys, including titanium aluminides; steels; superalloys; oxide dispersion strengthened alloys; refractory alloys; and related systems such as laminate composites. In each chapter, materials properties and relevant technological aspects, including processing, are presented. Individual chapters focus on coatings for gas turbine engines and hot corrosion of alloys and coatings. Readers will also find consideration of applications in aerospace-related fields. The book takes full account of the impact of energy saving and environmental issues on materials development, reflecting the major shifts that have occurred in the motivations guiding research efforts into the development of new materials systems. Aerospace Alloys will be a valuable reference for graduate students on materials science and engineering courses and will also provide useful information for engineers working in the aerospace, metallurgical, and energy production industries.

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 Laser Additive Manufacturing written by Milan Brandt and published by Woodhead Publishing. This book was released on 2016-09-01 with total page 500 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser Additive Manufacturing: Materials, Design, Technologies, and Applications provides the latest information on this highly efficient method of layer-based manufacturing using metals, plastics, or composite materials. The technology is particularly suitable for the production of complex components with high precision for a range of industries, including aerospace, automotive, and medical engineering. This book provides a comprehensive review of the technology and its range of applications. Part One looks at materials suitable for laser AM processes, with Part Two discussing design strategies for AM. Parts Three and Four review the most widely-used AM technique, powder bed fusion (PBF) and discuss other AM techniques, such as directed energy deposition, sheet lamination, jetting techniques, extrusion techniques, and vat photopolymerization. The final section explores the range of applications of laser AM. Provides a comprehensive one-volume overview of advances in laser additive manufacturing Presents detailed coverage of the latest techniques used for laser additive manufacturing Reviews both established and emerging areas of application

Download or read book Analysis of the Laser Powder Bed Fusion Additive Manufacturing Process Through Experimental Measurement and Finite Element Modeling written by Alexander Dunbar and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The objective in this work is to provide rigourous experimental measurements to aid in the development of laser powder bed fusion (LPBF) additive manufacturing (AM). A specialized enclosed instrumented measurement system is designed to provide in situ experimental measurements of temperature and distortion. Experiments include comparisons of process parameters, materials and LPBF machines. In situ measurements of distortion and temperature made throughout the build process highlight inter-layer distortion effects previously undocumented for laser powder bed fusion. Results from these experiments are also be implemented in the development and validation of finite element models of the powder bed build process. Experimental analysis is extended from small-scale to larger part-scale builds where experimental post-build measurements are used in analysis of distortion profiles. Experimental results provided from this study are utilized in the validation of a finite element model capable of simulating production scale parts. The validated finite element model is then implemented in the analysis of the part to provide information regarding the distortion evolution process. A combination of experimental measurements and simulation results are used to identify the mechanism that results in the measured distortion profile for this geometry. Optimization of support structure primarily focuses on the minimization of material use and scan time, but no information regarding failure criteria for support structure is available. Tensile test samples of LPBF built support structure are designed, built, and tested to provide measurements of mechanical properties of the support structure. Experimental tests show that LPBF built support structure has only 30-40\% of the ultimate tensile strength of solid material built in the same machine. Experimental measurement of LPBF built support structure provides clear failure criteria to be utilized in the future design and implementation of support structure.

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

Download or read book Surfaces and their Measurement written by David J. Whitehouse and published by Elsevier. This book was released on 2004-07-01 with total page 425 pages. Available in PDF, EPUB and Kindle. Book excerpt: The importance of surface metrology has long been acknowledged in manufacturing and mechanical engineering, but has now gained growing recognition in an expanding number of new applications in fields such as semiconductors, electronics and optics. Metrology is the scientific study of measurement, and surface metrology is the study of the measurement of rough surfaces. In this book, Professor David Whitehouse, an internationally acknowledged subject expert, covers the wide range of theory and practice, including the use of new methods of instrumentation. · Written by one of the world's leading metrologists · Covers electronics and optics applications as well as mechanical · Written for mechanical and manufacturing engineers, tribologists and precision engineers in industry and academia

Download or read book 3D Printing for Energy Applications written by Albert Tarancón and published by John Wiley & Sons. This book was released on 2021-03-03 with total page 400 pages. Available in PDF, EPUB and Kindle. Book excerpt: 3D PRINTING FOR ENERGY APPLICATIONS Explore current and future perspectives of 3D printing for the fabrication of high value-added complex devices 3D Printing for Energy Applications delivers an insightful and cutting-edge exploration of the applications of 3D printing to the fabrication of complex devices in the energy sector. The book covers aspects related to additive manufacturing of functional materials with applicability in the energy sector. It reviews both the technology of printable materials and 3D printing strategies itself, and its use in energy devices or systems. Split into three sections, the book covers the 3D printing of functional materials before delving into the 3D printing of energy devices. It closes with printing challenges in the production of complex objects. It also presents an interesting perspective on the future of 3D printing of complex devices. Readers will also benefit from the inclusion of: A thorough introduction to 3D printing of functional materials, including metals, ceramics, and composites An exploration of 3D printing challenges for production of complex objects, including computational design, multimaterials, tailoring AM components, and volumetric additive manufacturing Practical discussions of 3D printing of energy devices, including batteries, supercaps, solar panels, fuel cells, turbomachinery, thermoelectrics, and CCUS Perfect for materials scientists, 3D Printing for Energy Applications will also earn a place in the libraries of graduate students in engineering, chemistry, and material sciences seeking a one-stop reference for current and future perspectives on 3D printing of high value-added complex devices.

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.