Additive Manufacturing of High-Performance Metallic Materials

1st Edition - September 19, 2023
Authors: Robert Pederson, Joel Andersson, Shrikant Joshi
Language: English
Paperback ISBN:
9 7 8 - 0 - 3 2 3 - 9 1 8 8 5 - 5
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 9 1 3 8 2 - 9

Additive Manufacturing of High-Performance Metallic Materials outlines the state-of-the-art on AM in high performance materials utilizing the two most industrially intere… Read more

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Additive Manufacturing of High-Performance Metallic Materials outlines the state-of-the-art on AM in high performance materials utilizing the two most industrially interesting routes of powder bed fusion (PBF) and directed energy deposition (DED). The book delves into Feedstock, Processing, Monitoring and control, Modeling and simulation, and Surface and thermal post-treatments. It specifically addresses materials and the most relevant and high performance applications, namely Ni-based alloys and Titanium alloys, and also provides insights into potential applications through illustrative case studies. With each chapter contributed by experts in the field, this work will serve as a comprehensive resource for graduate students and practitioners alike.

Cover image
Title page
Table of Contents
Copyright
Contributors
Preface
Chapter 1: Metal additive manufacturing: Motivation, process portfolio, and application potential
Abstract
Motivation for AM and materials for metal AM
Nickel-based alloys
Chemistry
Phase constituents
Titanium alloys
Advantages and challenges in metal AM
Processes for metal AM—Powder bed fusion and directed energy deposition techniques
References
Chapter 2: Metal powders for additive manufacturing of superalloys and titanium alloys
Abstract
Introduction
Powder manufacturing
Powder characteristics
References
Chapter 3: Wires for metal additive manufacturing
Abstract
Acknowledgment
Introduction
Wires for AM
Classification of wires
Procurement, testing, and delivery of wires
Summary
References
Chapter 4: Processing of high-performance materials by electron beam-powder bed fusion
Abstract
Introduction
Description of the EB-PBF process
Description of critical process parameters
Geometry and position-related parameters
Overview of EB-PBF process physical phenomena
Nickel-based superalloys in EB-PBF process
Titanium alloys
Summary
References
Chapter 5: Processing of high-performance materials by laser beam-powder bed fusion
Abstract
Introduction
Process description
Process parameters
Defects
Materials used for LB-PBF process
Concluding remarks: Challenges, opportunities, and future trends
References
Chapter 6: Processing of high-performance materials by laser-directed energy deposition with powders
Abstract
Introduction
Process description
Interaction between material and L-DED-P process
Nickel-based superalloys
Titanium alloys
Final remarks: Challenges, trends, and opportunities
References
Chapter 7: Processing of high-performance materials by laser directed energy deposition with wire
Abstract
Introduction
Process description
L-DEDw processed metallic materials
Sustainability of L-DEDw processed materials
Future directions for Laser DED-w
References
Chapter 8: Surface post-treatment of additively manufactured components
Abstract
Introduction
Surface anatomy of AM components and main features
Surface posttreatment of AM components
Surface finishing of AM components and their impact on their application performance
Closing remarks
References
Chapter 9: Thermal post-treatment of additively manufactured components
Abstract
Introduction
Motivation for thermal post-treatments
Stages of post-treatment
Case studies
Case studies on post-treatment of nickel-based superalloy
Case studies on post-treatment of titanium-based alloy
Summary of chapter
References
Chapter 10: Mechanical properties of high-performance AM materials
Abstract
Introduction
Strengthening mechanisms in AM metals
Anisotropy in deformation and fracture mechanisms
Fatigue
Creep and high-temperature properties
Summary and conclusions
References
Chapter 11: Modeling and simulation of microstructures in metal additive manufacturing
Abstract
Introduction
Phenomenological phase transformation modeling
Cellular automata modeling
Phase-field modeling
Mean-field modeling
General challenges in microstructure modeling
Summary
References
Chapter 12: Process modeling of powder bed and directed energy deposition
Abstract
Introduction
The heat source and its interaction with the metal
Thermal modeling of metal alloy
Thermo-fluid modeling of metal alloy
Concluding remarks
References
Chapter 13: Monitoring and control of directed energy deposition using a laser beam
Abstract
Introduction
In-process monitoring of directed energy deposition using a laser beam
Automatic control of directed energy deposition using a laser beam
Conclusions and perspectives
References
Chapter 14: Nondestructive evaluation of additively manufactured components
Abstract
Introduction
Process defects addressed by NDE
NDT methods
Standards related to AM and NDT and probability of detection
Probability of detection
Mathematical modeling and application of NDE simulations
Outlook
References
Chapter 15: Applications of additive manufacturing: Selected case studies and future prospects
Abstract
Introduction
CASE 1—Demonstration of laser beam powder bed fusion in space turbine applications
A low-cost turbine design
Design for additive manufacturing
Manufacturing and inspection of burst test hardware
Burst test as a step in turbine design verification
Acknowledgments and disclaimer
CASE 2—Turbine rear structure (TRS) retrofit using the L-DED-p method
CASE 3—Ariane 6 nozzle extension using the L-DEDw method
CASE 4—Trent XWB intermediate compressor case using the L-DEDw method
CASE 5—Fabricated fan case mount ring using the L-DEDw technology
CASE 6—Milling head in titanium produced via the powder bed fusion-laser beam process
References
Index

Robert Pederson

Professor Robert Pederson is professor in Engineering Materials and head of Division of Subtractive and Additive Manufacturing at University West. Robert has 20 years of experience within research and development of advanced metallic materials for aerospace and space applications. He received his PhD in 2004 in a project on titanium alloys in close collaboration with Volvo Aero Corporation (which became GKN Aerospace Engines Systems Sweden in 2012). Between 2004-2016, Robert worked at Volvo/GKN as research cluster leader, company specialist in materials technology, project leader, project manager, and responsible materials application engineer in a number of projects related with civilian aero engines as well as space rocket applications. In 2013 he became Associate Professor (Docent) at Chalmers University of Technology, and in 2015 he became Adjunct Professor at Luleå University of Technology. He has supervised 6 PhD students to doctors degree and is currently supervising 3 PhD students. The research work is focused on exploring and improving the understanding of the relationship between thermo-mechanical processing - microstructure - mechanical properties for titanium alloys and other metallic alloys and the key technologies of welding and additive manufacturing processes used by the aerospace and space industry.

Affiliations and expertise

Professor, Engineering Materials; Head of Division, Subtractive and Additive Manufacturing, University West, Sweden

Joel Andersson

Professor Joel Andersson is a Professor in Materials Science and Head of Division of Welding Technology at University West and has extensive experience in superalloy metallurgy. Dr. Andersson has been responsible for research and development of high temperature materials from 2011-2015 at GKN Aerospace Engine Systems in Sweden, while having a part-time senior research position at Chalmers University of Technology in Gothenburg Sweden. Since the beginning of 2016, he has been at University West and currently also holds an adjunct professorship at University of Manitoba, Canada. He has co-authored around 100 papers in peer-reviewed journals and conference contributions and has up-to-date supervised 7 PhD students to doctors degree and is currently supervising 6 PhD students.

Affiliations and expertise

Professor, Materials Science; Head of Division, Welding Technology, University West, Sweden

Shrikant Joshi

Professor Shrikant Joshi has been at University West since Aug 2015, after long stints as a scientist in premier R&D institutions in India following his PhD at University of Idaho, USA in 1989. He has nearly 30 years of experience in fields spanning Surface Engineering, Laser Materials Processing and Additive Manufacturing. Shrikant has led numerous R&D projects that have culminated in many industrial applications, over a dozen patent applications and more than 185 publications in peer-reviewed journals. His current research interests focus on various powder and solution-based thermal spray techniques for varied applications including aerospace coatings, and on additive manufacturing with specific emphasis on post-treatment of Ni-based superalloys.

Affiliations and expertise

Professor, University West, Sweden

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Additive Manufacturing of High-Performance Metallic Materials

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Robert Pederson

Joel Andersson

Shrikant Joshi