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.
Author(s): Sachin Salunkhe, Sergio T. Amancio-Filho, J. Paulo Davim
Series: Woodhead Publishing Reviews: Mechanical Engineering Series
Publisher: Woodhead Publishing
Year: 2022
Language: English
Pages: 247
City: Cambridge
Advances in Metal Additive Manufacturing
Preface
List of contributors
Copyright
Contents
1 Powder bed fusion processes: main classes of alloys, current status, and technological trends
1.1 Additive manufacturing of aluminum alloys
1.1.1 General challenges
1.1.2 Overview over aluminum alloys produced by additive manufacturing
1.1.2.1 AlSi10Mg
1.1.2.2 AlSi12
1.1.2.3 Sc, Zr-based aluminum alloys
1.1.2.4 Al-Cu alloys
1.1.2.5 AA7075 alloys
1.1.2.6 AA6061 alloys
1.2 Laser powder bed fusion of tool steels
1.2.1 Hot work tool steels
1.2.2 High-speed steels and cold work tool steels
1.3 Laser metal deposition of steels
1.3.1 Introduction
1.3.2 LMD of tool steels
1.3.3 Conclusion
1.4 Powder-based additive manufacturing of shape memory alloys
1.4.1 Introduction
1.4.2 Powder-based additive manufacturing of shape memory alloys: current technologies in use
1.4.3 Processing of NiTi-based alloys: fields of application
1.4.4 Processing of other SMA alloys by powder-based additive manufacturing
1.5 Powder-based additive manufacturing of high-entropy alloys
1.5.1 Introduction
1.5.2 Technological overview
1.5.3 Powder for HEA development
1.5.4 Techniques for 3D printing of HEAs
1.5.5 Mechanical properties of 3D-printed HEAs
1.6 Powder-based additive manufacturing of magnetic materials
1.6.1 Additive manufacturing of hard magnetic materials
1.6.2 Nd-Fe-B
1.6.3 Fe-Co-based magnetic alloys
1.6.4 Additive manufacturing of soft magnetic materials
1.7 In situ alloying
1.7.1 Introduction
1.7.2 Powder quality and mixing
1.7.3 The temperature of melting, energy input, and homogeneity
1.8 AM of recycled Ti-64 powder
1.8.1 Introduction: why reuse the powder?
1.8.2 Influence on the powder
1.8.3 Influence on build parts
1.8.4 Influence on the mechanical properties
1.9 Outlook: new powder-based additive manufacturing processes
1.9.1 Selective LED-based melting
1.10 Sintering-debinding additive manufacturing
1.10.1 Binder Jetting
1.10.2 Metal extrusion additive manufacturing of highly filled polymers
1.10.3 Lithography-based metal manufacturing
1.11 Cold spray additive manufacturing
References
2 Directed energy deposition processes and process design by artificial intelligence
2.1 Wire-arc additive manufacturing
2.1.1 Introduction
2.1.2 Arc welding techniques in WAAM: cold metal transfer in comparison to gas metal arc welding
2.1.3 Materials development using filler wire: solid wire compared to metal cored wires
2.2 Wire-based electron beam additive manufacturing of titanium alloys and NiTi shape memory alloys
2.2.1 Introduction
2.2.2 Wire-based electron beam additive manufacturing
2.2.3 Wire-based electron beam additive manufacturing of titanium alloys
2.2.4 Wire-based electron beam additive manufacturing of NiTi shape memory alloys
2.3 Outlook: new wire-based additive manufacturing processes
2.3.1 Resistance welding additive manufacturing (or Joule Printing)
2.3.2 Liquid metal additive manufacturing
2.4 Friction-based additive manufacturing
2.5 Ultrasonic metal additive manufacturing
2.6 Artificial intelligence in additive manufacturing
2.6.1 Introduction
2.6.2 Learning methodology
2.6.3 Machine learning
2.6.3.1 Regression
2.6.3.2 Linear and polynomial regressions
2.6.3.3 Formulation
2.6.3.4 Gaussian process regression
2.6.3.4.1 Formulation
2.6.3.4.2 Applications
2.6.4 Deep Learning
2.6.4.1 Multilayer perceptrons
2.6.4.2 Formulation
2.6.4.3 Applications
2.6.5 Future trends in AI for AM
2.6.5.1 Topology optimization
2.6.5.2 Microstructural characterization
2.6.5.3 Hybrid modeling
References
3 Current trends of metal additive manufacturing in the defense, automobile, and aerospace industries
3.1 Introduction
3.2 Metal additive manufacturing systems
3.3 AM materials for aerospace applications
3.4 Aerospace applications of AM
3.5 Challenges and future prospectus of metal AM in aerospace industry
3.5.1 Challenges of AM in aerospace applications
3.5.1.1 Certification and standards
3.5.1.2 Structural integrity
3.5.1.3 Design for AM
3.5.1.4 Material characteristics
3.5.1.5 Process control
3.5.2 Potential future applications of AM in aerospace
References
4 Review of Microstructure and Mechanical properties of materials manufactured by direct energy deposition
4.1 Introduction
4.2 Direct energy deposition
4.3 Advantages and disadvantages
4.4 Applications in different fields
4.5 Microstructure and mechanical properties of different materials
4.5.1 Steels
4.5.1.1 Influence of powder characteristics on direct energy deposition process
4.5.1.2 Effect of laser rescanning strategy on the microstructure and mechanical properties
4.5.1.3 Microstructure and mechanical properties of different steels
4.5.1.4 Process parameters influence on functionally graded steels by direct energy deposition
4.5.2 Ti alloys
4.5.3 Ni base alloys
4.5.4 Al-alloys
4.5.4.1 Direct energy deposition process parameters and their influence on the functionality of the parts
4.5.4.2 Microstructure and mechanical properties improvement in Al alloy parts
Improvement of fatigue behavior of direct energy deposition parts
Enhancement in the corrosion resistance of direct energy deposition parts
Current challenges in direct energy deposition of Al alloys
4.5.4.3 Future scope for direct energy deposition of Al alloys
Postprocessing technique for improving the quality of direct energy deposition parts
Development of direct energy deposition amenable unconventional class of material system
Induction of grain refinement mechanism in direct energy deposition process
4.6 Conclusions
References
5 Postprocessing challenges in metal AM: Strategies for achieving homogeneous microstructure in Ni-based superalloys
5.1 Introduction
5.2 Direct energy deposition
5.3 Powder bed fusion
5.4 Crystal growth theory
5.5 Grain morphology control
5.6 Hotter metal
5.7 Effect of additive manufacturing processing parameters on metallurgy
5.7.1 Laser parameters
5.7.2 Scan strategy
5.7.3 Rotation of scan vectors
5.7.4 Length of scanning vectors
5.8 Effect of heat treatment on metallurgy
5.9 Solution treatment
5.10 Double ageing
5.11 Intrinsic heat treatment
5.12 Suitable processing strategies
5.13 Conclusion
References
6 Design and topology optimization for additive manufacturing of multilayer (SS316L and AlSi10Mg) piston
6.1 Introduction
6.2 Product design and development for additive manufacturing
6.3 Design for additive manufacturing (DfAM)
6.4 Methodology and DfAM project design process for automotive piston
6.5 Generative design for additive manufacturing of automotive piston
6.6 Topology optimization for additive manufacturing of automotive piston
6.7 The automotive piston modeling techniques and simulation processes
6.8 Simulating additive manufacturing with additive software
6.9 Experimental optimization based on machine configuration
6.10 Part printing by a metal-based additive manufacturing process
6.10.1 Powder bed fusion
6.10.2 Direct energy deposition
6.11 A case study of using additive manufacturing technology to manufacture automotive piston
6.11.1 Numerical validation
6.12 Conclusions
References
7 Mechanical properties of titanium alloys additive manufacturing for biomedical applications
7.1 Selective laser melting
7.1.1 Selective laser melting of titanium alloys
7.2 Electron beam melting
7.2.1 Biocomposites materials reinforced with multiwalled carbon nanotubes
7.3 Electron beam melting of titanium alloys
7.4 Conclusion
References
Index
