Innovations in Additive Manufacturing

Preface
Introduction
Contents
Editors and Contributors
Abbreviations
Part I Introduction to Additive Manufacturing
1 Metal Additive Manufacturing: From History to Applications
1.1 History
1.2 Fundamentals of Additive Manufacturing
1.2.1 Preparation of CAD File and Saving to STL Format
1.2.2 Pre-Processing of Design
1.2.3 Slicing of the Part
1.2.4 Machine Configuration
1.2.5 Build-Up Process
1.2.6 Part Removal and Post-Processing
1.2.7 End Product
1.3 Material Compatibility in Metal Additive Manufacturing
1.3.1 Melting Point
1.3.2 Optical Interactions
1.4 Processing Techniques for Metal Additive Manufacturing
1.4.1 Powder Bed Fusion (PBF) Process
1.4.2 Binder Jetting Technology (BJT)
1.4.3 Powder or Wire Fed Fusion Process
1.5 Applications of Metal Additive Manufacturing
1.5.1 Aeronautical Industry
1.5.2 Biomedical Industry
1.5.3 Automobile Industry
References
2 Development in Additive Manufacturing Techniques
2.1 Evolutions in Additive Manufacturing
2.1.1 History of Additive Manufacturing
2.1.2 Types of Additive Manufacturing with Materials
2.1.3 Developments in Additive Manufacturing
2.1.4 Applications
2.1.5 Advancement in 3D Printing Technology
2.2 Summary
References
Part II Additive Manufacturing and Materials Development
3 Challenges in Additive Manufacturing for Metals and Alloys
3.1 Introduction
3.2 Comparison of Metal Additive Manufacturing Processes
3.3 Printable Metals and Alloys for Metal AM
3.4 Challenges of Metal Additive Manufacturing
3.4.1 Anisotropic Behavior and Mechanical Properties
3.4.2 Material Heterogeneity and Structural Reliability
3.4.3 Void Formation
3.4.4 Difficulty in Powder Preparation, Powder Splash, Crack Formation, Porosity
3.4.5 Stair Stepping, Dimensional Inaccuracy, Generation of Balling, Evaporation of Volatile Elements
3.5 Wear Failure in AM Products
3.6 Conclusion
References
4 Laser Additive Manufacturing of Aluminium Matrix Composites
4.1 Introduction
4.2 Methods for Preparing AMMC
4.3 LAM Processed Aluminium Composites
4.4 Mechanical Behaviour of Aluminium Composites
4.5 Challenges in Metal Additive Manufacturing
4.6 Conclusion
References
5 Additive Manufacturing of Non-ferrous Metals
5.1 Introduction
5.2 Fabrication of NMs with SLM
5.2.1 Properties of SLMed Ti and Ti Alloys with Challenges
5.2.2 Properties of SLMed Ni and Ni Alloys with Challenges
5.2.3 Properties of SLMed Co and Co Alloys with Challenges
5.2.4 Properties of SLMed Al and Al Alloys with Challenges
5.2.5 Properties of SLMed Cu and Cu Alloys with Challenges
5.3 Conclusions
References
6 Development and Optimization Study of Poly-Lactic Acid Blended Carbon Particles by Fused Deposition Modelling Method
6.1 Introduction
6.2 Fused Deposition Modelling
6.3 Materials and Methodology
6.4 Design of Experiment (DoE)
6.5 Results and Discussion
6.5.1 Compressive Property Analysis
6.5.2 Tensile Property Analysis
6.5.3 Flexural Property Analysis
6.5.4 Shore Hardness Analysis
6.5.5 Taguchi Analysis for Obtained Responses
6.5.6 Regression Analysis
6.6 Conclusion
References
7 Role of Additive Manufacturing in Biomedical Engineering
7.1 Introduction to Additive Manufacturing
7.2 Additive Manufacturing Techniques
7.3 Application of Additive Manufacturing in Medical Field
7.3.1 Biomedical Materials, Mechanical Properties and Their Applications
7.4 Rapid Prototyping Techniques for Additive Manufacturing Applications
7.4.1 Fused Deposition Modelling
7.4.2 Selective Laser Sintering
7.4.3 Sintered Laser Melting
7.4.4 Electron Beam Melting
7.5 Developments in Additive Manufacturing for Clinical Applications
7.6 Role of Rapid Prototyping in Tissue Engineering
7.7 3D Printing for Personalised Protective Equipments Despite During COVID-19
7.7.1 Face Shields and Masks
7.8 Conclusions
References
Part III Post-Processing and Investigations on 3D Built Materials
8 Surface Finishing Post-treatments for Additive Manufactured Metallic Components
8.1 Introduction
8.2 Mechanical Surface Finishing Methods
8.2.1 Tumble/barrel Finishing
8.2.2 Finish Machining
8.2.3 Blasting
8.2.4 Shot Peening, Cavitation Peening and Laser Shock Peening
8.2.5 Surface Mechanical Attrition Treatment
8.2.6 Ultrasonic Nanocrystal Surface Modification
8.3 Abrasive Finishing Methods
8.3.1 Abrasive Flow Machining
8.3.2 Magnetic Field Assisted Abrasive Finish Machining
8.3.3 Abrasive Fluidized Bed Machining
8.3.4 Ultrasonic and Hydrodynamic Cavitation Abrasive Finishing
8.4 Chemical and Electrochemical Processes
8.4.1 Chemical Etching
8.4.2 Chemical Polishing
8.4.3 Combined Chemical and Abrasive Flow Polishing
8.4.4 Electropolishing
8.4.5 Jet Electrochemical Machining
8.5 Laser and Electron Beam Processes
8.5.1 Laser Polishing
8.5.2 Laser Re-Melting
8.5.3 Large Pulsed Electron-Beam Irradiation
8.6 Hybrid Additive/subtractive Manufacturing
8.7 Concluding Remarks
8.8 Future Perspectives
References
9 Surface Treatments and Surface Modification Techniques for 3D Built Materials
9.1 Introduction
9.1.1 Post Processing Works in AM
9.1.2 Importance of Post Processes in AM
9.2 Post Processing Stages in AM
9.2.1 Cool the Built Part
9.2.2 Loose Powder Elimination
9.2.3 Heat Treatment Process
9.2.4 Eliminate the Supports
9.2.5 Surface Treatment Process
9.3 Surface Modification Methods
9.3.1 Mechanical Methods
9.3.2 Physical Methods
9.3.3 Chemical Methods
9.3.4 Electrochemical Methods
9.3.5 Thermal Methods
9.3.6 Laser Methods
9.4 Surface Modification Techniques
9.4.1 Introduction of Surface Modification
9.4.2 Surface Coating and Deposition
9.4.3 Surface Oxidation
9.4.4 Surface Texturing
9.5 Effects of Surface Modification
9.6 Issues in Surface Modification Techniques
9.7 Challenges in Surface Modification Techniques
9.8 Conclusions
9.9 Future Prospects
References
10 Surface Coatings and Surface Modification Techniques for Additive Manufacturing
10.1 Introduction
10.1.1 Metal Additive Manufacturing
10.1.2 Role of Surface Coatings (SC) and Surface Modification (SM) Techniques in AM
10.2 Surface Coating on Metal Additive Manufacturing
10.3 Surface Modification (SM) Techniques for MAM
10.4 Benefits of Surface Coatings and Surface Modification in AM
10.5 Summary
10.5.1 Future of Surface Coatings and Surface Modification (SM) Techniques in AM
References
11 Mechanical Testing of Additive Manufacturing Materials
11.1 Introduction to Additive Manufacturing Techniques
11.2 Classification of Metal Based AM Techniques
11.2.1 Laser Beam Melting (LBM)
11.2.2 Laser Metal Fusion
11.2.3 Electron Beam Melting (EBM)
11.2.4 Laser Metal Deposition (LMD)
11.3 Additive Manufacturing of Metal Based Products
11.3.1 Titanium and Its Alloys
11.3.2 Stainless Steel
11.3.3 Aluminum and Its Alloys
11.4 Metallurgical Characteristics of the AM Metallic Component
11.4.1 Microstructural Properties on AM (PBF) Components
11.4.2 Microstructural Properties on AM (DED) Components
11.5 Standards of Mechanical Testing
11.6 Mechanical Properties of Metal AM Components
11.6.1 Hardness
11.6.2 Tensile Properties of AM Developed Metal Components
11.6.3 Compressive Test Properties of AM Developed Metal Components
11.6.4 Surface Roughness Properties of AM Developed Metal Components
11.6.5 Fracture Toughness Properties of AM Developed Metal Components
11.6.6 Fatigue Strength in AM Metal
11.6.7 Creep in AM Metals
11.6.8 Analysis of Residual Stress in AM Developed Metal Parts
11.7 Conclusions
11.8 Future Trends
References
12 Electrochemical Corrosion Behavior of Heat Treated Inconel 718 Superalloy Manufactured by Direct Metal Laser Sintering (DMLS) in 3.5% NaCl Solution
12.1 Introduction
12.2 Materials and Method
12.2.1 Materials and Fabrication
12.2.2 Heat Treatment
12.2.3 Mechanical Property Evaluation
12.2.4 Electrochemical Property Evaluation
12.2.5 Surface Characterization
12.3 Results and Discussion
12.3.1 Micro Structural and XRD Examination
12.3.2 Mechanical Characterization
12.3.3 Fractograpy
12.3.4 Electrochemical Corrosion
12.4 Conclusion
References
13 Machinability of 3D Printed Materials
13.1 Introduction
13.2 Importance of AM
13.3 Theory of AM and Its Techniques
13.4 Machining of Components Produced Using AM
13.4.1 Machining of Ti-6Al-4V Alloy
13.4.2 Machining of Nickel-Based Alloys
13.4.3 Machining of Al-Si Based Alloys
13.4.4 Machining of Other AMed Workpieces
13.4.5 Machining Quality and Its Performance
13.5 Concluding Remarks
References
14 Challenges Involved in Framing Additive Manufacturing Standards
14.1 Introduction
14.2 Standardization of Additive Manufacturing Technology
14.2.1 Standards
14.2.2 Process
14.3 Challenges in Additive Manufacturing Process Chain
14.3.1 Materials Selection
14.3.2 Materials and Design Limitation
14.3.3 Cyber-Physical Security
14.3.4 Standards and Guidelines
14.4 Future Directions
14.5 Conclusions
References