Additive Manufacturing Of Metals The Technology Materials Design And Production

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

This textbook and reference provides a comprehensive treatment of additive manufacturing (AM) for metals, including design and digital work flows, process science and reliability, metallic systems, quality assurance, and applications. The book is rooted in the fundamental science necessary to develop and understand AM technologies, as well as the application of engineering principles covering several disciplines to successfully exploit this important technology. As additive manufacturing of metals is the fastest growing subset of this transformative technology, with the potential to make the widest impact to industrial production, Metals Additive Manufacturing: Design, Processes, Materials, Quality Assurance, and Applications is ideal for students in a range of engineering disciplines and practitioners working in aerospace, automotive, medical device manufacturing industries.

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.

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

Science, Technology and Applications of Metal Additive Manufacturing provides a holistic picture of metal Additive Manufacturing (AM) that encompasses the science, technology and applications for the use of metal AM. Users will find design aspects, various metal AM technologies commercially available, a focus on merits and demerits, implications for qualification and certification, applications, cost modeling of AM, and future directions. This book serves as an educational guide, providing a holistic picture of metal AM that encompasses science, technology and applications for the real-life use of metal AM. Includes an overall understanding of metal additive manufacturing, Including steps involved (process flow) Discusses available commercial metal AM technologies and their relative strengths and weaknesses Reviews the process of qualification of AM parts, various applications, cost modeling, and the future directions of metal AM

METAL ADDITIVE MANUFACTURING A comprehensive review of additive manufacturing processes for metallic structures Additive Manufacturing (AM)—also commonly referred to as 3D printing—builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise. Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource: Provides a thorough analysis of AM processes and their theoretical foundations Explains the classification, advantages, and applications of AM processes Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software Discusses the opportunities, challenges, and current and emerging trends within the field Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes Includes illustrative cases studies and numerous figures and tables Featuring material drawn from the lead author’s research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.

This book is a technical introduction to additive manufacturing (AM) with a focus on powder bed fusion and metals. It provides the theory and industry-based practices to design, make, and test metal components via AM. After outlining the methods and materials of powder bed methods, the book explains the workings and physical limitations of electron beam and laser melt technologies in manufacturing parts, using a variety of metal powders. In this context, the physics of powder melting is described, as well as the effects of temperature variables on the properties of a part. The critical elements of how powder feedstock is chosen and formulated are explained. Processing methods are described using original design and engineering parameters developed by the author. Information is provided on current test methods of metals produced by AM, as well as how to carry out quality control, monitor reliability, and implement safety standards. For process design, a section is devoted to modeling.Each chapter includes a set of problems for students and practitioners that reflect metals' fabrication in industry.

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.