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.

Ehsan Toyserkani, Professor, Multi-Scale Additive Manufacturing Lab, Department of Mechanical and Mechatronics Engineering, University of Waterloo, Ontario, Canada.

Dyuti Sarker, Research Scientist 1, Georgia Institute of Technology, Georgia, USA.

Osezua Obehi Ibhadode, Researcher, Multi-Scale Additive Manufacturing Lab, Department of Mechanical and Mechatronics Engineering, University of Waterloo, Ontario, Canada.

Farzad Liravi, Research Associate, Department of Mechanical and Mechatronics Engineering, University of Waterloo, Ontario, Canada.

Paola Russo, Applications Scientist, Angstrom Engineering Inc., Kitchener, ON, Canada.

Katayoon Taherkhani, Ph.D. Candidate, Multi-Scale Additive Manufacturing Lab, Department of Mechanical and Mechatronics Engineering, University of Waterloo, Ontario, Canada.

A comprehensive review of additive manufacturing processes for metallic structures

Additive Manufacturing (AM)also commonly referred to as 3D printingbuilds 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.

Inhalt

Preface xv

Abbreviations xvii

1 Additive Manufacturing Process Classification, Applications, Trends, Opportunities, and Challenges 1

1.1 Additive Manufacturing: A Long-Term Game Changer 1

1.2 AM Standard Definition and Classification 4

1.3 Why Metal Additive Manufacturing? 5

1.4 Market Size: Current and Future Estimation 11

1.5 Applications of Metal AM 12

1.5.1 Medical and Dental 14

1.5.2 Aerospace and Defense 15

1.5.3 Communication 17

1.5.4 Energy and Resources 18

1.5.5 Automotive 19

1.5.6 Industrial Tooling and Other Applications 20

1.6 Economic/Environmental Benefits and Societal Impact 20

1.7 AM Trends, Challenges, and Opportunities 23

1.8 Looking Ahead 27

References 28

2 Basics of Metal Additive Manufacturing 31

2.1 Introduction 31

2.2 Main Metal Additive Manufacturing Processes 32

2.2.1 Powder Bed Fusion (PBF) 32

2.2.2 Directed Energy Deposition (DED) 41

2.2.3 Binder Jetting (BJ) 49

2.2.4 Emerging Metal AM Processes 55

2.3 Main Process Parameters for Metal DED, PBF, and BJ 62

2.3.1 Main Output Parameters 64

2.3.2 Combined Thermal Energy Source Parameters (PBF and DED) 65

2.3.3 Beam Scanning Strategies and Parameters for PBF and DED 68

2.3.4 Powder Properties for PBF, DED, and BJ 71

2.3.5 Wire Properties for DED 76

2.3.6 Layer Thickness for PBF, DED, and BJ 77

2.3.7 Ambient Parameters for PBF, DED, and BJ 79

2.3.8 Geometry-Specific Parameters (PBF) 80

2.3.9 Support structures for PBF 82

2.3.10 Binder Properties for BJ 82

2.3.11 Binder Saturation for BJ 84

2.4 Materials 85

2.4.1 Ferrous Alloys 86

2.4.2 Titanium Alloys 86

2.4.3 Nickel Alloys 86

2.4.4 Aluminum Alloys 86

References 87

3 Main Sub-Systems for Metal AM Machines 91

3.1 Introduction 91

3.2 System Setup of AM Machines 92

3.2.1 Laser Powder Bed Fusion (LPBF) 92

3.2.2 Laser Directed Energy Deposition (LDED) Known as Laser Powder Fed (LPF) 92

3.2.3 Binder Jetting (BJ) 93

3.3 Laser Basics: Important Parameters Needed to be Known for AM 93

3.3.1 Laser Theory 93

3.3.2 Laser Components 100