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Solid-State Metal Additive Manufacturing

E-BookEPUB2 - DRM Adobe / EPUBE-Book
416 Seiten
Englisch
Ernst & Sohnerschienen am16.04.20241. Auflage
Solid-State Metal Additive Manufacturing
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 directions 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.


Hang Z. Yu, PhD, is an Associate Professor in the Department of Materials Science and Engineering at Virginia Tech, USA. His research focuses on materials processing and manufacturing science, emphasizing the underlying process physics, mechanics, and kinetics. His work also aims to leverage the process fundamentals to drive material sustainability to new heights, e.g., via solid-state metal recycling, structural repair, and austere condition-resilient manufacturing.
Nihan Tuncer, PhD, is a Principal Scientist at Desktop Metal Inc. since 2016, where she has been developing solid-state 3D printing technologies and equipment. She holds several patents in addition to research papers and review articles. Her expertise includes powder metallurgy, processing-microstructure-property relationships in ferrous and non-ferrous alloys, porous metals, and shape memory alloys.
Zhili Feng, PhD, currently leads the Materials Joining Group and is a Distinguished R&D Staff Member of Oak Ridge National Laboratory, USA. His research covers various aspects of thermal-mechanical-metallurgical behaviors of materials in materials joining.mehr
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Produkt

KlappentextSolid-State Metal Additive Manufacturing
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 directions 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.


Hang Z. Yu, PhD, is an Associate Professor in the Department of Materials Science and Engineering at Virginia Tech, USA. His research focuses on materials processing and manufacturing science, emphasizing the underlying process physics, mechanics, and kinetics. His work also aims to leverage the process fundamentals to drive material sustainability to new heights, e.g., via solid-state metal recycling, structural repair, and austere condition-resilient manufacturing.
Nihan Tuncer, PhD, is a Principal Scientist at Desktop Metal Inc. since 2016, where she has been developing solid-state 3D printing technologies and equipment. She holds several patents in addition to research papers and review articles. Her expertise includes powder metallurgy, processing-microstructure-property relationships in ferrous and non-ferrous alloys, porous metals, and shape memory alloys.
Zhili Feng, PhD, currently leads the Materials Joining Group and is a Distinguished R&D Staff Member of Oak Ridge National Laboratory, USA. His research covers various aspects of thermal-mechanical-metallurgical behaviors of materials in materials joining.
Details
Weitere ISBN/GTIN9783527839346
ProduktartE-Book
EinbandartE-Book
FormatEPUB
Format Hinweis2 - DRM Adobe / EPUB
FormatFormat mit automatischem Seitenumbruch (reflowable)
Erscheinungsjahr2024
Erscheinungsdatum16.04.2024
Auflage1. Auflage
Seiten416 Seiten
SpracheEnglisch
Artikel-Nr.14448021
Rubriken
Genre9201

Inhalt/Kritik

Inhaltsverzeichnis
Introduction and Overview
Impact-Induced Bonding: Physical Processes and Bonding Mechanisms
Microstructures and Microstructural Evolution in Cold Sprayed Materials
Mechanical Properties of Cold Spray Deposits
Cold Spray Applications
Process Fundamentals of Additive Friction Stir Deposition
Dynamic Microstructure Evolution in Additive Friction Stir Deposition
Mechanical Properties of Additive Friction Stir Deposits
Potential Industrial Applications of Additive Friction Stir Deposition
Process Fundamentals of Ultrasonic Additive Manufacturing
Ultrasonic Additive Manufacturing: Microstructural and Mechanical Characterization
Industrial Applications of Ultrasonic Additive Manufacturing
Principles of Solid-State Sintering
Material Extrusion Additive Manufacturing
Binder Jetting-Based Metal Printing
Sintering-Based Metal Additive Manufacturing Methods for Magnetic Materials
Future Perspectivesmehr
Leseprobe

1
Introduction and Overview

Hang Z. Yu1, Nihan Tuncer2, and Zhili Feng3

1Virginia Tech, 445 Old Turner Street, Blacksburg, VA, 24061, USA

2Desktop Metal Inc., 63 3rd Ave, Burlington, MA, 01803, USA

3Oak Ridge National Laboratory, 1 Bethel Valley Rd, Oak Ridge, TN, 37831, USA

Additive manufacturing generally denotes scalable fabrication (printing) of 3D components and structures for industrial production. Employing a layer-by-layer or voxel-by-voxel approach, additive manufacturing has started to shift the manufacturing paradigm and revolutionize the way components are produced. It not only offers unparalleled design freedom and efficiency for creating complex geometries, but also opens the door to the production of lighter, stronger, multifunctional, and multimaterial parts [1]. Its versatility knows almost no bounds; nearly all types of materials can be transformed into intricate 3D components through additive manufacturing, including polymers, ceramics, metals, composites, and even natural materials. With the vast global market of metal component production and the extensive use of metallic materials in diverse industrial sectors, there has been a surge in interest of metal additive manufacturing particularly over the past decade [2-4].

Metal additive manufacturing approaches can come in two key forms: fusion-based (i.e., beam-based) and solid-state (i.e., nonbeam-based) methods, both with their distinctive advantages. The former fundamentally relies on selective melting and rapid solidification to progressively build a structure, while the latter harnesses a high strain rate, extensive plastic deformation, or thermally induced atomic diffusion to metallurgically bond the material to build a structure. Fusion-based approaches, including powder bed fusion (e.g., selective laser melting [SLM] and e-beam melting [EBM]) and directed energy deposition (DED) (e.g., laser engineered net shaping [LENS] and wire arc additive manufacturing [WAAM]) have been the primary focus of industry and academia at the time of writing. This is not surprising, as much of the processes and equipment are based on similar fusion-based welding processes widely applied in the industry for decades. Similar to casting [5] and fusion welding [6], both of which are bulk-scale melting-solidification manufacturing processes, fusion-based additive manufacturing is challenged by porosity, residual stress, and hot cracking [7]. Compared to casting, the additive nature exacerbates these issues because of the small molten pool size, large thermal gradient, and rapid cooling rates. Additionally, epitaxial solidification leads to the natural formation of textured, columnar grain structures along the build direction, presenting a hurdle for microstructure and isotropy control [8]. These issues also limit melt-based methods to weldable alloys.

These critical issues stem from the melting and solidification nature of fusion-based additive manufacturing and can be avoided if melting is not present in the process. This motivates the development of a series of emerging nonbeam-based, solid-state processes for metal additive manufacturing - which is the focus of this book. The cutting-edge solid-state technologies explored in this book encompass cold spray additive manufacturing (CSAM), additive friction stir deposition (AFSD), ultrasonic additive manufacturing (UAM), and sintering-based processes like binder jetting additive manufacturing (BJAM) and material extrusion-enabled metal additive manufacturing (MEAM).

This relatively new field of manufacturing technologies is continuing to develop at a fast pace along with a growing wealth of research articles and white papers. The aim of this book is to present the principles and effects of the physical phenomena that each solid-state additive manufacturing method is built upon, as well as an in-depth picture of the process fundamentals, the resulting microstructures and properties, and the key industrial applications. Starting with an overview and historical perspective of metal additive manufacturing, this chapter proceeds to offer frameworks for categorizing solid-state additive manufacturing methods based on bonding mechanisms and relationship between building and consolidation. It then discusses the potential and limitations of nonbeam-based, solid-state metal additive manufacturing methods, which are implemented through deformation-based or sintering-based approaches. Furthermore, the chapter outlines the structure of the book, providing a glimpse of the topics of all the following chapters.
1.1 Overview and History of Metal Additive Manufacturing

Offering a disruptive concept that enables greater design freedom, rapid prototyping, and the production of complex geometries that were previously unachievable, metal additive manufacturing has enormous potential for enhancing performance such as strength and durability, weight and waste reduction, customization, as well as on-demand production and supply chain risk reduction. It has found applications in aerospace, space, automotive, defense, healthcare, and many other industries, driving innovation and reshaping the manufacturing landscape. Based on different material feeding and bonding mechanisms, metal additive manufacturing can be implemented by SLM, selective EBM, LENS, WAAM, CSAM, BJAM, UAM, and AFSD. Depending on the process, the feedstock can be in the form of powder, wire, sheet/foil, and solid bar. The first four technologies are based on melting and rapid solidification, and are thus termed fusion-based or beam-based. The last four are based on solid-state processes without melting; they are the focus of this book.

Figure 1.1 A brief history of metal additive manufacturing development over the last 40 years.

As illustrated in Figure 1.1, the history of metal additive manufacturing dates to the 1980s when additive manufacturing, in general, was in its early stages. Similar to the case with other technologies, different terminologies were invented and used for different additive manufacturing processes as they developed. Selective laser sintering (SLS) was patented by Carl Deckard in 1986 [9], the first 3D printed parts were demonstrated by Manriquez-Frayre and Bourell in 1990 [10], and Electro Optical Systems (EOS) introduced its initial SLS machine in 1995. On the other hand, the first SLM patent was issued in 1995 by the Fraunhofer Institute Institut für Lasertechnik (ILT) in Germany, eventually leading to SLM Solutions Gesellschaft mit beschränkter Haftung (GmbH) in the early 2000s [11]. SLM or SLS falls under the category of powder bed fusion additive manufacturing.

Another significant technology within the powder bed fusion category is selective EBM, patented by Larson in 1993 [12]. In 2002, the first commercial EBM machine was launched by Arcam, which was later acquired by General Electric (GE) in 2016. Enabling the fabrication of complex geometries with high spatial resolution, powder bed fusion has emerged as one of the leading metal additive manufacturing technologies today.

LENS represents another important example that leverages high-energy laser beam for metal additive manufacturing [13]. LENS involves melting and fusing nozzle-delivered metal powder onto a substrate in a layer-by-layer fashion to create intricate 3D components. The technology was patented by Sandia National Laboratories in 1994 and later commercialized by Optomec in the early 2000s. LENS belongs to the category of DED, where the material is fed in powder form.

Another notable technology in this category is WAAM. The roots of WAAM can be traced back to the 1920s when Baker proposed using an electric arc and filler wires to deposit metal ornaments [14]. In the welding industry, arc welding, laser welding, and electron-beam welding are widely used for cladding of large-scale structures and rebuild of aircraft turbine rotor tips. They are early on primitive WAAM. In recent years, advancements in robotics, sensors, and control systems have propelled the progress of WAAM technology. Precise control of welding parameters and robotic movement has improved accuracy and repeatability, not to mention the high build rate and excellent scalability offered by WAAM.

Now let us briefly review the history of solid-state metal additive manufacturing processes, wherein the feedstock is not melted. Our first focus is on cold spray, a technology with a long history dating back to the early twentieth century. The modern cold spray phenomenon was discovered by Papyrin and Alkhimov in the 1980s [15, 16]. Subsequently, in 1994, the National Center for Manufacturing Sciences consortium, including companies like Ford Motor Company, GE Aircraft Engines, General Motors Corporation, the Naval Aviation Depot, and...
mehr

Autor

Hang Yu obtained his Ph.D. degree in materials science and engineering from MIT in 2013 and B.S. degree in physics from Peking University in 2007, and is currently an assistant professor in the Department of Materials Science and Engineering and a key member of the Advanced Manufacturing Team at Virginia Tech. Dr. Yu's research has been focused on solid-state metal additive manufacturing using additive friction stir deposition, which is an emerging large-scale technology giving rise to forging mechanical properties in the as-printed state.
Nihan Tuncer, Ph.D., completed her BS in Metallurgical and Materials Engineering in Middle East Technical University in 2002 and her MSc and PhD in Anadolu University in 2011 in Turkey. Following her PhD, she worked as a visiting scientist in Forschungszentrum Juelich IEK-1 in Germany on metal injection molding of porous Titanium implants. She conducted her postdoctoral research at MIT between 2012-2016 on Cu-based shape memory alloys. She has been working at Desktop Metal since 2016 as a Principal Scientist, where she authored a number of papers and patents. Her expertise includes powder metallurgy of steel, titanium, hard metals, nickel-based alloys, ceramic-metal composites, shape memory alloys, porous metals, microstructure development and mechanical properties of materials.
Zhili Feng obtained his Ph.D. degree in welding engineering from Ohio State University, and M.S. degree in mechanical engineering and B.S. degree in mechanical engineering both from Tsinghua University. Dr. Zhili Feng currently leads the Materials Joining Group and is a Distinguished R&D Staff of Oak Ridge National Laboratory. He is also a Joint Faculty of University of Tennessee, Knoxville. Dr. Feng's research covers various aspects of thermal-mechanical-metallurgical behaviors of materials in materials joining. He has broad interactions with industry and demonstrated experience in solving critical industry problems.
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