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El. knyga: Science, Technology and Applications of Metals in Additive Manufacturing

(COO, DM3D Technology, LLC), (University of Tennessee, Knoxville, TN, USA), (Principal Member of the Technical Staff, Sandia National Laboratories)
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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
Acknowledgments ix
1 Metal additive manufacturing
1(10)
Abbreviations
1(1)
1.1 Introduction
1(8)
References
9(2)
2 Additive manufacturing technology
11(44)
Abbreviations
11(1)
2.1 Introduction
11(2)
2.2 Designing and toolpathing for additive manufacturing
13(2)
2.3 Additive manufacturing technologies
15(12)
2.4 Process control
27(20)
2.5 Postprocessing of additive manufacturing parts
47(2)
References
49(6)
3 Comparison of various additive manufacturing technologies
55(22)
Abbreviations
55(1)
3.1 Technology comparison
55(8)
3.2 Free form capability
63(3)
3.3 Repair and remanufacturing
66(2)
3.4 Hybrid manufacturing for large-part additive manufacturing
68(2)
3.5 Porous structural concepts
70(1)
3.6 Multimaterial manufacturing using additive manufacturing
70(2)
3.7 Special applications
72(2)
References
74(3)
4 Raw materials for metal additive manufacturing
77(16)
Abbreviations
77(1)
4.1 Introduction
77(1)
4.2 Powder preparation techniques
78(9)
4.3 Powder recycling and reuse
87(3)
4.4 Wire precursors
90(1)
References
90(3)
5 Microstructure and properties of additive manufacturing builds
93(52)
5.1 Introduction
93(2)
5.2 Overview of process optimization for defect mitigation
95(4)
5.3 Microstructure evolution and properties of fusion-based additive manufacturing
99(28)
5.4 Microstructure evolution and properties of solid state-based additive manufacturing
127(9)
5.5 Relevance to qualification
136(3)
References
139(6)
6 Metal additive manufacturing process modeling and simulation
145(48)
6.1 Overview of physical processes
145(3)
6.2 Scope for AM process modeling
148(2)
6.3 Integrated process-structure-property modeling
150(34)
6.4 Challenges and future directions
184(1)
References
185(8)
7 Design for metal additive manufacturing
193(52)
Abbreviations
193(1)
7.1 Motivation and opportunities
193(14)
7.2 Process constraints
207(16)
7.3 Materials
223(4)
7.4 Design tools
227(11)
References
238(7)
8 Qualification for metal additive manufacturing
245(64)
Abbreviations
245(1)
8.1 Qualification and product acceptance
246(11)
8.2 Approaches
257(10)
8.3 Function
267(2)
8.4 Geometry
269(5)
8.5 Feedstock
274(6)
8.6 Material
280(8)
8.7 Printing
288(10)
8.8 Postprocessing
298(1)
References
299(10)
9 Markets, applications, and costs
309(24)
Abbreviations
309(1)
9.1 Markets and applications for metal additive manufacturing
309(11)
9.2 Cost analysis of additive manufacturing
320(2)
9.3 Economic impact of additive manufacturing
322(9)
References
331(2)
Index 333
Bhaskar Dutta, Ph.D. has over 26 years of experience in the field of metallurgy and metal processing, including 11 years in the Additive Manufacturing (AM) industry. He has been directly involved in participating and directing AM research and technology development as well as commercial product development using AM. He has over 15 publications and more than 30 presentations in the field of AM. He also has 7 pending patents in this area. Dr. Sudarsanam Babu is the UT/ORNL Governors chair of advanced manufacturing at the University of Tennessee, Knoxville, TN. In this role he acts as a bridge to the ORNLs expertise and infrastructure including manufacturing demonstration facility to develop a collaborative research and education ecosystem locally and deploy engineering solutions to manufacturing industries. Dr. Babu has 23 years of experience in the area of advanced manufacturing, additive manufacturing, physical metallurgy, as well as, computational materials modeling. His work relates to welding metallurgy, solid-state joining, ultrasonic additive manufacturing, laser/electron beam assisted additive manufacturing, phase transformation issues related to low-alloy steels, inclusion formation, nonequilibrium solidification, and application of computational thermodynamics and kinetics to corrosion issues. He is also involved in the application of state-of-the-art characterization tools including atom probe tomography; synchrotron diffraction and neutron diffraction for understanding interaction between weld thermal cycles, phase stability and diffusion in complex alloys, as well as, energy storage materials. Dr. Babu has published 180 journal papers and numerous conference proceedings. He has received many awards in recognition of his technical and leadership service to the materials and manufacturing community. He is a fellow of AAAS, ASM International and AWS. Dr. Bradley H. Jared is a Principal Member of the Technical Staff at Sandia National Laboratories where he leads research and development efforts in advanced and additive manufacturing within the Materials Science and Engineering Center. He has over 20 years of experience in mechanical design and advanced manufacturing process development including precision machining, metrology, ultrafast pulsed laser processing and additive manufacturing. He is working with multiple Sandia teams evaluating the requirements and design aspects for qualification of additive components, materials and processes for high consequence applications. His additive research interests are focused on process-structure-property relationships in metal powder bed fusion, the metrology of additive equipment and processes, the application of advanced optimization design methodologies, and the development of computational tools for predicting material and process performance. Bradley has over 15 years of research experience and worked in the industrial sector for Corning Incorporated and 3M before joining Sandia working in precision fabrication, design and assembly. He has submitted over 15 technical advances for intellectual property at Sandia, three of which have accepted for patents.