Quality Analysis of Additively Manufactured Metals

Simulation Approaches, Processes, and Microstructure Properties

1st Edition - November 30, 2022
Editors: Javad Kadkhodapour, Siegfried Schmauder, Felix Sajadi
Language: English
Paperback ISBN:
9 7 8 - 0 - 3 2 3 - 8 8 6 6 4 - 2
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 8 8 6 4 9 - 9

Quality Analysis of Additively Manufactured Metals: Simulation Approaches, Processes, and Microstructure Properties provides readers with a firm understanding of the failure and fa… Read more

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Quality Analysis of Additively Manufactured Metals: Simulation Approaches, Processes, and Microstructure Properties provides readers with a firm understanding of the failure and fatigue processes of additively manufactured metals. With a focus on computational methods, the book analyzes the process-microstructure-property relationship of these metals and how it affects their quality while also providing numerical, analytical, and experimental data for material design and investigation optimization. It outlines basic additive manufacturing processes for metals, strategies for modeling the microstructural features of metals and how these features differ based on the manufacturing process, and more.

Improvement of additively manufactured metals through predictive simulation methods and microdamage and micro-failure in quasi-static and cyclic loading scenarios are covered, as are topology optimization methods and residual stress analysis techniques. The book concludes with a section featuring case studies looking at additively manufactured metals in automotive, biomedical and aerospace settings.

Cover
Title page
Table of Contents
Copyright
Contributors
Part One: Fundamentals
Chapter One: Standards for metal additive manufacturing: Quality and quality control procedures
Abstract
1: Introduction
2: Additive manufacturing techniques for metals
3: Standards for metal additive manufacturing
4: Quality management framework for metal additive manufacturing
5: Potential and challenges in qualification and certification of metal additive manufacturing
6: Conclusions
References
Chapter Two: Processing-microstructure-property relationship for AM metals and the effect of thermal properties
Abstract
1: Introduction
2: Processing-microstructure formation
3: Microstructure-property relation
References
Chapter Three: Process-dependent material characteristics of DMLS-manufactured specimens
Abstract
Acknowledgments
1: Direct metal laser sintering
2: Parameter-dependent material characteristics: A case study
3: Technical considerations
References
Chapter Four: Structural defects and mechanical properties of additively manufactured parts
Abstract
1: Introduction
2: Sources of defects
3: Types and mechanisms of defect formations
4: Defects in lattice structures
5: Conclusions
References
Chapter Five: Microstructural features in metallic parts made by AM
Abstract
1: Introduction
2: General microstructural features in MAM
3: Microstructural features of common alloy systems in MAM
4: Microstructural features of MAM attribute by feed stock and postprocessing
5: Conclusion
References
Chapter Six: Additive manufacturing processes for metals
Abstract
1: Introduction
2: Additive manufacturing
3: Metal additive manufacturing
4: Powder bed fusion
5: Directed energy deposition
6: Metal jetting
7: Binder jetting
8: Sheet lamination
9: Summary
References
Part Two: Process, microstructure, property for AM metals: Experimental investigations
Chapter Seven: Postprocess treatments for surface quality improvement, mitigation of defects, and microstructural control
Abstract
1: Microstructural control and defect mitigation via thermal and thermomechanical posttreatments
2: Surface treatments for roughness reduction and tensile residual stresses mitigation
Glossary
References
Chapter Eight: Linking materials systems approach to alloy design and part qualification for laser powder bed fusion additive manufacturing
Abstract
1: Materials systems approach in L-PBF AM
2: Variations in the important attributes of the hierarchical subsystems during L-PBF AM
3: A holistic approach: From alloy design to part qualification
4: Summary
References
Chapter Nine: Microstructure and mechanical property correlation for additively manufactured aluminum-silicon alloys
Abstract
1: Process—Microstructure relation
2: The mechanical properties of aluminum-silicon alloys fabricated via LPBF
3: Postheat treatments
4: Concluding remarks
References
Part Three: Improvement/optimization of AM part quality by predictive simulation methods
Chapter Ten: A multiscale simulation approach to parametric investigation of process parameters in the characteristics and mechanical properties of AlSi10Mg parts manufactured by LPBF
Abstract
1: Introduction
2: Grain structure and fatigue (microscale)
3: Porosities and fracture (mesoscale)
4: Residual stresses (macroscale)
5: Conclusions
References
Chapter Eleven: Residual stress analysis and geometrical tolerances in powder bed fusion and direct energy deposition processes
Abstract
1: Introduction
2: Metal additive manufacturing processes
3: Challenges in metal additive manufacturing
4: Manufacturing analysis
5: Manufacturing issue detection and mitigation
6: Examples
References
Chapter Twelve: Wire arc additive manufacturing of light metals: From experimental investigation to numerical process simulation and microstructural modeling
Abstract
Acknowledgments
1: Introduction
2: Modeling, simulation, and verification
3: Applications and potential
References
Chapter Thirteen: Predictive simulation of microstructural pattern in additively manufactured metallic materials
Abstract
Acknowledgments
1: Introduction
2: Experimental backgrounds and particularities of powder bed fusion affecting the component microstructure
3: Temperature history
4: Microstructure modeling
5: Summary
References
Chapter Fourteen: Rapid alloying in additive manufacturing using integrated computational materials engineering
Abstract
1: Introduction
2: Multiscale modeling using ICME
3: Integrating process, structure, property, and performance using ICME
4: ICME assessment in PBF additive manufacturing
5: Case study: Influencing the residual stresses and texture developments
6: Case study: Development of new high entropy alloy using ICME and additive manufacturing
7: Machine learning for materials developments in metals AM using ICME
8: Closure
References
Part Four: Future perspectives and applications of AM industrial products
Chapter Fifteen: Prospects of additively manufactured nickel aluminum bronzes for marine applications
Abstract
Acknowledgments
1: Introduction to wire-arc additive manufacturing
2: Background and metallurgy of nickel-aluminum bronzes
3: Experimental details
4: Microstructural features and tensile performance
5: Conclusions
References
Chapter Sixteen: Quality of AM implants in biomedical application
Abstract
1: Introduction
2: Implant design
3: Effects of process parameters on the quality of AM implants
4: Effects of postprocessing on the quality of AM implants
5: Materials
6: Mechanical properties
7: Conclusion and future directions
References
Chapter Seventeen: Quality of AM parts in automotive application: Design-process-property relation for automotive parts
Abstract
1: Introduction
2: Generative design for automotive applications
3: Examples of generative design in automotive applications
4: Process consideration
5: Laser powder-bed fusion
6: Electron beam powder-bed fusion
7: Direct energy deposition
8: Binder jetting
9: Material and property in AM process
10: Repeatability
11: Geometrical accuracy
12: Residual stresses
13: Mechanical strength
14: Porosity
15: Surface roughness
16: Challenges for major adoption of the technology
17: Concluding remark and future outlook
References
Chapter Eighteen: Metal-3D-printed permeable leading edges for airfoil noise reduction
Abstract
1: Introduction
2: Airfoils in disturbed inflow
3: Airfoil leading-edge design
4: Surface roughness and dimensional accuracy
5: Aerodynamic and aeroacoustic properties
6: Conclusions
References
Chapter Nineteen: Highly efficient and resource-saving function-integrated additively manufactured components for the mobility of tomorrow
Abstract
1: Introduction/motivation
2: Additive manufacturing
3: Especially selection process for additive manufactured components
4: Additive manufacturing in application
5: Example of a functionally integrated power electronics housing for electromobility
6: Summary/outlook
References
Index

Javad Kadkhodapour

Javad Kadkhodapour is currently Guest Professor at the University of Stuttgart, Germany, focusing on quality control of additively manufactured materials. He has previously worked as a research associate and project manager for research projects in several prestigious European and Iranian universities, gaining expert knowledge in the areas of multi-scale analysis for multiphase metallic and multi-material polymeric structures in different manufacturing processes, including additive manufacturing. His industry experience includes working on additive manufacturing of metals and polymers at Shining 3D Company in Hangzhou, China, as well as research and development roles with multiple companies in the automotive and biomedical sectors in Germany.

Affiliations and expertise

University of Stuttgart, Institute for Materials Testing, Materials Science, and Strength of Materials (IMWF), Stuttgart, Germany

Siegfried Schmauder

Siegfried Schmauder is Professor of Mechanical Engineering at University of Stuttgart, Germany. His research focuses on microstructure mechanics, multiscale modeling, additive manufacturing, material and component testing, material development and optimization, as well as component reliability and design. He applies experimental and numerical investigation techniques to steels, light alloys, fiber composite materials on a metal and polymer basis, metal/ceramic composite materials, hard metals and coatings. The investigative focus is on microstructure modeling and nanosimulation with a view to examining the correlation between material structure and material properties as well as shedding light on the phenomena that occur at grid level that are important in terms of elastic and place material and damage response.

Affiliations and expertise

Professor of Mechanical Engineering, University of Stuttgart, Germany

Felix Sajadi

Felix Sajadi is currently a PhD student at the University of Stuttgart, in Germany.

Affiliations and expertise

Institute for Materials Testing, Materials Science, and Strength of Materials (IMWF), University of Stuttgart, Germany