Quality Analysis Of Additively Manufactured Metals

Quality Analysis of Additively Manufactured Metals: Simulation Approaches, Processes, and Microstructure Properties provides readers with a firm understanding of the failure and fatigue processes of additively manufactured metals. With a focus on computational methods, the book analyzes the process-microstructure-property relationship of these metals and how it affects their quality while also providing numerical, analytical, and experimental data for material design and investigation optimization. It outlines basic additive manufacturing processes for metals, strategies for modeling the microstructural features of metals and how these features differ based on the manufacturing process, and more.Improvement of additively manufactured metals through predictive simulation methods and microdamage and micro-failure in quasi-static and cyclic loading scenarios are covered, as are topology optimization methods and residual stress analysis techniques. The book concludes with a section featuring case studies looking at additively manufactured metals in automotive, biomedical and aerospace settings. Provides insights and outlines techniques for analyzing why additively manufactured metals fail and strategies for avoiding those failures Defines key terms and concepts related to the failure analysis, quality assurance and optimization processes of additively manufactured metals Includes simulation results, experimental data and case studies

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 book is an exciting collection of research articles that offer a unique view into the fast developing field of metal additive manufacturing, providing insights into this advanced manufacturing technology. The articles span recent advances in metal AM technologies, and their application to a wide range of metals, exploring how the processing parameters offer unique material properties. This book encapsulates the state of the art in this rapidly evolving field of technology and will be a valuable resource for researchers in the field, from Ph.D. students to professors, and through to industrial end users.

Metal fatigue is an essential consideration for engineers and researchers who are looking at factors that cause metals to fail through stress, corrosion, etc. This is an English translation of a book originally published in Japan in 1993, with an additional two chapters on the fatigue failure of steels and the effect of surface roughness on fatigue strength. The methodology is based on important and reliable results and may be usefully applied to other fatigue problems not directly treated in this book.

Freedoms in material choice based on combinatorial design, different directions of process optimization, and computational tools are a significant advantage of additive manufacturing technology. The combination of additive and information technologies enables rapid prototyping and rapid manufacturing models on the design stage, thereby significantly accelerating the design cycle in mechanical engineering. Modern and high-demand powder bed fusion and directed energy deposition methods allow obtaining functional complex shapes and functionally graded structures. Until now, the experimental parametric analysis remains as the main method during AM optimization. Therefore, an additional goal of this book is to introduce readers to new modeling and material's optimization approaches in the rapidly changing world of additive manufacturing of high-performance metals and alloys.

Additive manufacturing (AM) is a fast-growing sector with the ability to evoke a revolution in manufacturing due to its almost unlimited design freedom and its capability to produce personalised parts locally and with efficient material use. AM companies, however, still face technological challenges such as limited precision due to shrinkage, built-in stresses and limited process stability and robustness. Moreover, often post-processing is needed due to high roughness and remaining porosity. Qualified, trained personnel are also in short supply. In recent years, there have been dramatic improvements in AM design methods, process control, post-processing, material properties and material range. However, if AM is going to gain a significant market share, it must be developed into a true precision manufacturing method. The production of precision parts relies on three principles: Production is robust (i.e. all sensitive parameters can be controlled). Production is predictable (for example, the shrinkage that occurs is acceptable because it can be predicted and compensated in the design). Parts are measurable (as without metrology, accuracy, repeatability and quality assurance cannot be known). AM of metals is inherently a high-energy process with many sensitive and inter-related process parameters, making it susceptible to thermal distortions, defects and process drift. The complete modelling of these processes is beyond current computational power, and novel methods are needed to practicably predict performance and inform design. In addition, metal AM produces highly textured surfaces and complex surface features that stretch the limits of contemporary metrology. With so many factors to consider, there is a significant shortage of background material on how to inject precision into AM processes. Shortage in such material is an important barrier for a wider uptake of advanced manufacturing technologies, and a comprehensive book is thus needed. This book aims to inform the reader how to improve the precision of metal AM processes by tackling the three principles of robustness, predictability and metrology, and by developing computer-aided engineering methods that empower rather than limit AM design. Richard Leach is a professor in metrology at the University of Nottingham and heads up the Manufacturing Metrology Team. Prior to this position, he was at the National Physical Laboratory from 1990 to 2014. His primary love is instrument building, from concept to final installation, and his current interests are the dimensional measurement of precision and additive manufactured structures. His research themes include the measurement of surface topography, the development of methods for measuring 3D structures, the development of methods for controlling large surfaces to high resolution in industrial applications and the traceability of X-ray computed tomography. He is a leader of several professional societies and a visiting professor at Loughborough University and the Harbin Institute of Technology. Simone Carmignato is a professor in manufacturing engineering at the University of Padua. His main research activities are in the areas of precision manufacturing, dimensional metrology and industrial computed tomography. He is the author of books and hundreds of scientific papers, and he is an active member of leading technical and scientific societies. He has been chairman, organiser and keynote speaker for several international conferences, and received national and international awards, including the Taylor Medal from CIRP, the International Academy for Production Engineering.