Additive Manufacturing: Design, Processes and Applications

Description

This book is a comprehensive guide to Additive Manufacturing (AM) product development. It offers a practical, reader-friendly approach to integrating the stages of product development. It covers current design and manufacturing strategies with a step-by-step approach, divided into three pillars: design, processes, and applications. The book addresses the challenges hindering the industrial application of AM and provides a roadmap for its successful implementation. It discusses specific AM case studies and hybrid AM cell and production line setups, with the goal of achieving high-quality, low-cost products that are both flexible and productive. The book concludes with an examination of Industry 4.0 capabilities in decentralized manufacturing. It is aimed to be read by researchers and professionals in industry who are interested in the development and potential of additive manufacturing, and will help to lead to wider adoption of AM. Preface References Contents Abbreviations 1 Introduction 1.1 Definition and Short Historical Review 1.2 AM Basic Steps and Process Families 1.3 AM Today, Challenges, and Shortcomings—Framework of This Book References 2 Design for AM 2.1 Introduction to Design for AM 2.2 Design Aspects 2.2.1 Geometric Features 2.2.2 Build Parameters 2.2.3 Process Capability Determination 2.3 Design Considerations 2.3.1 Accuracy (XY-Plane Versus Z-axis) 2.3.2 Anisotropic Mechanical Properties 2.3.3 Shrinkage and Warping 2.3.4 Surface Roughness 2.3.5 Build Time 2.4 Additive Manufacturability 2.5 Re-design for AM 2.6 Design Optimization 2.7 Design for Post-processing 2.8 AM Relevant Standards References 3 AM Processes 3.1 Process and Material Selection 3.2 AM Part Quality Issues 3.2.1 Surface Roughness and Layer-by-Layer Appearance 3.2.2 Porosity/Void Formation 3.2.3 Anisotropic Microstructure and Mechanical Properties 3.2.4 Thermal Residual Stresses and Deformations 3.3 Process Optimization Strategies 3.3.1 Heating 3.3.2 Scanner Head Speed and Scanning Strategy 3.3.3 Layer Thickness 3.4 Simulation for AM 3.4.1 Modeling Approaches and Scales 3.4.2 Simulations of Melt Pool-Related Phenomena 3.4.3 Thermo-Mechanical Simulations 3.4.4 Multi-scale Simulations 3.5 Monitoring, Control, and Quality Assessment 3.5.1 Monitoring and Control 3.5.2 Quality Diagnosis 3.6 Post-processing 3.6.1 Cleaning Processes 3.6.2 Mechanical Material-Removal Post-processes 3.6.3 Thermal Post-processes 3.6.4 Electrothermal Post-processes 3.6.5 Chemical Post-processes 3.6.6 Laser-Based Post-processes 3.7 Special Topics: Hybrid AM and Digitals Twins 3.7.1 Hybrid AM 3.7.2 Digital Twins References 4 AM Applications 4.1 Introduction to AM Applications 4.2 Production of End-Use AM Parts 4.3 Business Perspective and AM Case Studies 4.3.1 Aerospace Case 4.3.2 Dental Case 4.3.3 Power and Energy Sector Case References 5 Conclusions