The advent of additive manufacturing (AM) processes applied to the fabrication of structural components creates the need for design methodologies supporting structural optimization approaches that take into account the specific characteristics of the process. While AM processes enable unprecedented geometrical design freedom, which can result in significant reductions of component weight, on the other hand they have implications in the fatigue and fracture strength due to residual stresses and microstructural features. This is linked to stress concentration effects and anisotropy that still warrant further research. This Special Issue of Applied Sciences brings together papers investigating the features of AM processes relevant to the mechanical behavior of AM structural components, particularly, but not exclusively, from the viewpoints of fatigue and fracture behavior. Although the focus of the issue is on AM problems related to fatigue and fracture, articles dealing with other manufacturing processes with related problems are also be included.
The advent of additive manufacturing (AM) processes applied to the fabrication of structural components creates the need for design methodologies supporting structural optimization approaches that take into account the specific characteristics of the process. While AM processes enable unprecedented geometrical design freedom, which can result in significant reductions of component weight, on the other hand they have implications in the fatigue and fracture strength due to residual stresses and microstructural features. This is linked to stress concentration effects and anisotropy that still warrant further research. This Special Issue of Applied Sciences brings together papers investigating the features of AM processes relevant to the mechanical behavior of AM structural components, particularly, but not exclusively, from the viewpoints of fatigue and fracture behavior. Although the focus of the issue is on AM problems related to fatigue and fracture, articles dealing with other manufacturing processes with related problems are also be included.
Timely summary of state-of-the-art solid-state metal 3D printing technologies, focusing on fundamental processing science and industrial applications Solid-State Metal Additive Manufacturing: Physics, Processes, Mechanical Properties, and Applications provides detailed and in-depth discussion on different solid-state metal additive manufacturing processes and applications, presenting associated methods, mechanisms and models, and unique benefits, as well as a detailed comparison to traditional fusion-based metal additive manufacturing. The text begins with a high-level overview of solid-state metal additive manufacturing with an emphasis on its position within the metal additive manufacturing spectrum and its potential for meeting specific demands in the aerospace, automotive, and defense industries. Next, each of the four categories of solid-state additive technologies—cold spray additive manufacturing, additive friction stir deposition, ultrasonic additive manufacturing, and sintering-based processes—is discussed in depth, reviewing advances in processing science, metallurgical science, and innovative applications. Finally, the future direction of these solid-state processes, especially the material innovation and artificial intelligence aspects, are discussed. Sample topics covered in Solid-State Metal Additive Manufacturing include: Physical processes and bonding mechanisms in impact-induced bonding and microstructures and microstructural evolution in cold sprayed materials Process fundamentals, dynamic microstructure evolution, and potential industrial applications of additive friction stir deposition Microstructural and mechanical characterization and industrial applications of ultrasonic additive manufacturing Principles of solid-state sintering, binder jetting-based metal printing, and sintering-based metal additive manufacturing methods for magnetic materials Critical issues inherent to melting and solidification, such as porosity, high residual stress, cast microstructure, anisotropic mechanical properties, and hot cracking Solid-State Metal Additive Manufacturing is an essential reference on the subject for academic researchers in materials science, mechanical, and biomedicine, as well as professional engineers in various manufacturing industries, especially those involved in building new additive technologies.
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.
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
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 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.
Over the last decade or so, additive manufacturing has revolutionized design and manufacturing methods by allowing more freedom in design and functionalities unattainable with conventional processes. This has generated extraordinarily high interest in both industrial and academic communities. Additive Manufacturing of Metal Alloys 1 puts forward a state of the art of additive manufacturing and its different processes, from metallic raw materials (in the form of powder or wire) to their properties after elaboration. It analyzes the physics and the modelling of existing AM processes as well as future elaboration processes. Using a balanced approach encapsulating basic notions and more advanced aspects for each theme, this book acts as a metal additive manufacturing textbook, as useful to professionals in the field as to the general public.
This book presents select proceedings of the 8th International and 29th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2021). It discusses the latest advances in miniature manufacturing, machining of miniature components, surface engineering, nanomaterials, nanotechnology, Industry 4.0, optimization techniques, micro-electric discharge machining, electrochemical micro-machining, thin films, optimization of micro-machining process parameters, machining of nano-composites, characterization using atomic force microscopy, micro-tool fabrications, characterization of nano-composites, surface roughness analysis, tribological performance of surface coated materials and sustainability in manufacturing. The contents of this book are useful for students, researchers and as well as industry professionals in the various fields of mechanical engineering.
Advances in Metal Additive Manufacturing explains fundamental information and the latest research on new technologies, including powder bed fusion, direct energy deposition using high energy beams, and hybrid additive and subtractive methods. This book introduces readers to the technology, provides everything needed to understand how the different stages work together, and inspires to think beyond traditional metal processing to capture new ideas in metal. Chapters offer an introduction on metal additive manufacturing, processes, and properties and standards and then present surveys on the most significant international advances in metal additive manufacturing. Throughout, the book presents a focus on the effect of important process parameters on the microstructure, mechanical properties and wear behavior of additively manufactured parts. Covers the entire process chain of metal additive manufacturing, from input data preparation to part certification Describes a wide range of the latest design tools and options, including generative design, topology optimization, and lattice and surface optimization Addresses additive manufacturing, with a comprehensive list of metals including titanium, aluminum, iron-and nickel-based alloys and Inconel 718
