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.
Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing. Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward. - Presents laser powder bed fusion fundamentals, as well as their inherent challenges - Provides an up-to-date summary of this advancing technology and its potential - Provides a comprehensive textbook for universities, as well as a reference for industry - Acts as quick-reference guide
Metallic Powders for Additive Manufacturing Overview of successful pathways for producing metal powders for additive manufacturing of high-performance metallic parts and components with tailored properties Metallic Powders for Additive Manufacturing introduces the readers to the science and technology of atomized metal powders beyond empirical knowledge and the fundamental relationships among the chemistry, microstructure, and morphology of atomized metallic powders and their behavior during additive manufacturing. The text sets a foundation of the underlying science that controls the formation and microstructure of atomized metallic droplets, including the relations among the properties of metallic powders, their performance during the manufacturing processes, and the resulting products. Other topics covered include the influence of powder on defect formation, residual stress, mechanical behavior, and physical properties. The concluding two chapters encompass considerations of broader societal implications and overarching themes, including the exploration of alternative feedstock materials, economic analysis, and sustainability assessment. These chapters offer valuable perspectives on the prospective trajectory of the field. Written by a team of experienced and highly qualified professors and academics, Metallic Powders for Additive Manufacturing includes information on: Atomization techniques such as Vacuum Induction Gas Atomization (VIGA), Electrode Induction Melting Gas Atomization (EIMGA), and Plasma Rotating Electrode Process (PREP) Atomization science and technology, covering control of atomization parameters, powder size distribution, effect of processing variables, and theoretical models of atomization Heat transfer and solidification of droplets, covering nucleation, microstructure development, and important thermal and solidification conditions during atomization Atomization of Al, Fe, Ni, Co, Ti, and high entropy alloys, as well as composite powders for additive manufacturing, and guidelines for atomization equipment and powder handling Fundamental processing principles in a variety of metal additive manufacturing processes Powder characteristics and requirements for different additive manufacturing processes Effect of powder chemistry and physical characteristics on additive manufacturing processes, and the microstructure and properties of the built parts Evaluation of alternative feedstock sources for metal additive manufacturing, beyond gas atomized powder Economic and sustainability perspectives on powder production and additive manufacturing Metallic Powders for Additive Manufacturing is an excellent combination of rigorous fundamentals and a practice-oriented and forward-looking resource on the subject for materials scientists and practicing engineers seeking to understand, optimize, and further develop the field of powder production and additive manufacturing.
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.
The manufacture and use of the powders of non-ferrous metals has been taking place for many years in what was previously Soviet Russia, and a huge amount of knowledge and experience has built up in that country over the last forty years or so. Although accounts of the topic have been published in the Russian language, no English language account has existed until now.Six prominent academics and industrialists from the Ukraine and Russia have produced this highly-detailed account which covers the classification, manufacturing methods, treatment and properties of the non-ferrous metals ( aluminium, titanium, magnesium, copper, nickel, cobalt, zinc, cadmium, lead, tin, bismuth, noble metals and earth metals).The result is a formidable reference source for those in all aspects of the metal powder industry. - Covers the manufacturing methods, properties and importance of the following metals: aluminium, titanium, magnesium, copper, nickel, cobalt, zinc, cadmium, noble metals, rare earth metals, lead, tin and bismuth - Expert Russian team of authors, all very experienced - English translation and update of book previously published in Russian
This report is the second in a series of reports from the National Institute of Standards and Technology's (NIST's) Engineering Laboratory project titled Materials Standards for Additive Manufacturing. This project provides the measurement science for the additive manufacturing (AM) industry to measure material properties in a standardized way. Currently there are few consensus-based standards in this area. This project, in conjunction with NIST's Fundamental Measurement Science for Additive Processes project, will provide the technical foundation necessary to develop new consensus-based standards. Development of standards will be done via ASTM-International's (hereafter referred to as 'ASTM') Committee F42 on Additive Manufacturing Technologies and the newly formed International Organization for Standardization (ISO) TC261 committee on Additive Manufacturing.
Metal Powder—Based Additive Manufacturing Highly comprehensive resource covering all key aspects of the current developments of metal powder—based additive manufacturing Metal Powder—Based Additive Manufacturing provides valuable knowledge and critical insights regarding the recent advances in various metal powder—based additive manufacturing techniques. This book also reviews typical powder preparation processes and highlights the significance of metal powder—based additive manufacturing for various industrial applications. The key features covered in this book: A rigorous overview of the underlying theories and practical applications of metal powder—based additive manufacturing techniques, including laser powder bed fusion, electron beam melting, laser-based directed energy deposition, and metal binder jetting. An expansive introduction of each technique and its significance pertaining to the printing processes, metallurgical defects, powder materials, equipment, and the microstructures and mechanical properties of the printed parts. A deep exploration of the preparation processes of metal powders for additive manufacturing and the effects of different processes on the powder properties. Comprehensive case studies of parts printed by metal powder—based additive manufacturing for various industrial applications. By providing extensive coverage of relevant concepts in the field of metal powder—based additive manufacturing, this book highlights its essential role in Industry 4.0 and serves as a valuable resource for scientists, engineers, and students in materials science, powder metallurgy, physics, and chemistry. The rich research experience of the authors in additive manufacturing ensures that the readers are provided with both an in-depth understanding and informative technical guidance of metal powder—based additive manufacturing.
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
Theoretical and practical interests in additive manufacturing (3D printing) are growing rapidly. Engineers and engineering companies now use 3D printing to make prototypes of products before going for full production. In an educational setting faculty, researchers, and students leverage 3D printing to enhance project-related products. Additive Manufacturing Handbook focuses on product design for the defense industry, which affects virtually every other industry. Thus, the handbook provides a wide range of benefits to all segments of business, industry, and government. Manufacturing has undergone a major advancement and technology shift in recent years.
