The introduction of metal AM processes in such industrial sectors as the aerospace, automotive, defense, jewelry, medical and tool-making fields, has led to a significant reduction in waste material and in the lead times of the components, innovative designs with higher strength, lower weight, and fewer potential failure points from joining features. This Special Issue on "Additive Manufacturing (AM) of Metallic Alloys" contains a mixture of review articles and original contributions on some problems that limit the wider uptake and exploitation of metals in 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.
Lightweight alloys have become of great importance in engineering for construction of transportation equipment. At present, the metals that serve as the base of the principal light alloys are aluminum and magnesium. One of the most important lightweight alloys are the aluminum alloys in use for several applications (structural components wrought aluminum alloys, parts and plates). However, some casting parts that have low cost of production play important role in aircraft parts. Magnesium and its alloys are among the lightest of all metals and the sixth most abundant metal on earth. Magnesium is ductile and the most machinable of all metals. Many of these light weight alloys have appropriately high strength to warrant their use for structural purposes, and as a result of their use, the total weight of transportation equipment has been considerably decreased.
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.
Additive manufacturing (AM) of metals and composites using laser energy, direct energy deposition, electron beam methods, and wire arc melting have recently gained importance due to their advantages in fabricating the complex structure. Today, it has become possible to reliably manufacture dense parts with certain AM processes for many materials, including steels, aluminum and titanium alloys, superalloys, metal-based composites, and ceramic matrix composites. In the near future, the AM material variety will most likely grow further, with high-performance materials such as intermetallic compounds and high entropy alloys already under investigation. Additive Manufacturing Applications for Metals and Composites is a pivotal reference source that provides vital research on advancing methods and technological developments within additive manufacturing practices. Special attention is paid to the material design of additive manufacturing of parts, the choice of feedstock materials, the metallurgical behavior and synthesis principle during the manufacturing process, and the resulted microstructures and properties, as well as the relationship between these factors. While highlighting topics such as numerical modeling, intermetallic compounds, and statistical techniques, this publication is ideally designed for students, engineers, researchers, manufacturers, technologists, academicians, practitioners, scholars, and educators.
Additive Manufacturing of Titanium Alloys: State of the Art, Challenges and Opportunities provides alternative methods to the conventional approach for the fabrication of the majority of titanium components produced via the cast and wrought technique, a process which involves a considerable amount of expensive machining. In contrast, the Additive Manufacturing (AM) approach allows very close to final part configuration to be directly fabricated minimizing machining cost, while achieving mechanical properties at least at cast and wrought levels. In addition, the book offers the benefit of significant savings through better material utilization for parts with high buy-to-fly ratios (ratio of initial stock mass to final part mass before and after manufacturing). As titanium additive manufacturing has attracted considerable attention from both academicians and technologists, and has already led to many applications in aerospace and terrestrial systems, as well as in the medical industry, this book explores the unique shape making capabilities and attractive mechanical properties which make titanium an ideal material for the additive manufacturing industry. - Includes coverage of the fundamentals of microstructural evolution in titanium alloys - Introduces readers to the various Additive Manufacturing Technologies, such as Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) - Looks at the future of Titanium Additive Manufacturing - Provides a complete review of the science, technology, and applications of Titanium Additive Manufacturing (AM)
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.
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
The field of additive manufacturing has seen explosive growth in recent years due largely in part to renewed interest from the manufacturing sector. Conceptually, additive manufacturing, or industrial 3D printing, is a way to build parts without using any part-specific tooling or dies from the computer-aided design (CAD) file of the part. Today, mo
Capitalizing on the rapid growth and reduced costs of laser systems, laser cladding is gaining momentum, and in some instances replacing conventional techniques of depositing thin films because it can accommodate a great variety of materials, achieve uniform thickness and precise widths of layers, and provide improved resistance to wear and corrosion in the final product. Laser cladding technology also offers a revolutionary layered manufacturing and prototyping technique that can fabricate complex components without intermediate steps. Laser Cladding reviews the parameters, techniques and equipment, process modeling and control, and the physical metallurgy of alloying and solidification during laser cladding. The authors clarify the interconnections laser cladding has with CAD/CAM design; automation and robotics; sensors, feedback, and control; physics, material science, heat transfer, fluid dynamics, and powder metallurgy to promote further development and improved process quality of this growing technology. As the first book entirely dedicated to the topic, it also offers a history of its development and a guide to applications and market opportunities. While a considerable part of Laser Cladding is dedicated to industrial applications, this volume brings together valuable information illustrated with real case studies based on the authors' vast experience, and research and analysis in the field to provide a timely source for both academia and industry.
