Additive Manufacturing of Metal Alloys 1: Processes, Raw Materials and Numerical Simulation

Description

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. Cover Half-Title Page Title Page Copyright Page Contents Introduction 1. Metal Additive Manufacturing Processes 1.1. The DED-LMD process 1.1.1. Process overview 1.1.2. Basic elements 1.1.3. Overview of process parameters and their influence 1.1.4. Thermal cycles induced by the process 1.1.5. Types of materials involved 1.1.6. Microstructures of manufactured or repaired parts 1.1.7. Industrial systems 1.2. The L-PBF process 1.2.1. Distinction between sintering and laser melting 1.2.2. Manufacturer interests and requirements 1.2.3. Process principle and basic elements 1.2.4. Types of materials involved 1.2.5. Presentation and influence of the process operating parameters 1.2.6. Comparison of the L-PBF process and DED process 1.2.7. Design and manufacturing method of a part 1.2.8. Area of stable melt-pool suitable for construction 1.2.9. Optimization of L-PBF manufacturing of 3D parts 1.3. Electron powder bed fusion 1.3.1. Introduction 1.3.2. Implementation of the E-PBF process 1.3.3. Optimization of melting conditions and characteristic defects 1.3.4. Other characteristics of the E-PBF process 1.3.5. Partial conclusion regarding E-PBF 1.4. The deposition of matter via WAAM 1.4.1. Arc/wire additive manufacturing technologies 1.4.2. WAAM process parameters 1.4.3. Use of materials 1.4.4. Residual stresses and distortions 1.4.5. Finishing process 1.4.6. Digital chain: online control 1.4.7. Conclusion 1.5. Emerging processes 1.5.1. Indirect fabrication by selective laser sintering and infiltration 1.5.2. Indirect manufacture via metal binder jetting 1.5.3. Direct manufacture in the solid state without melting 1.6. Conclusion 1.7. References 2. Raw Materials: Metal Powders and Wires 2.1. Metal powders 2.1.1. Introduction 2.1.2. Producing powders 2.1.3. Physico-chemical properties of powders 2.1.4. Rheological properties of powders 2.1.5. Influence of powders on processes and final properties 2.1.6. Standardization 2.1.7. Summary 2.2. Metal wires 2.2.1. Introduction 2.2.2. Wire production 2.2.3. Use of filler wires in AM 2.2.4. Influence of wires on processes and final properties 2.2.5. Summary 2.3. References 3. The Physics of Metal Additive Manufacturing Processes 3.1. The energy–powder–fusion zone interaction in additive laser fusion processes 3.1.1. Introduction 3.1.2. Reminder of the essential physical variables 3.1.3. Radiation absorption and heat transfer: different interaction regimes for different processes 3.1.4. Local thermal cycles: influence of boundary conditions 3.1.5. Hydrodynamics of fusion zones and associated faults 3.1.6. Partial conclusion regarding the physics of laser additive manufacturing processes 3.2. The physics of the E-PBF process 3.2.1. Introduction 3.2.2. Reminder of the essential physical variables characteristic of the electron–matter interaction 3.2.3. The phenomena induced during the electron–matter interaction 3.2.4. Energy absorption in the powder in E-PBF 3.2.5. Description of the fusion zone in E-PBF and associated defects 3.2.6. Partial conclusion regarding E-PBF 3.3. Physics of the wire arc additive manufacturing process 3.3.1. Reminder of the essential physical variables 3.3.2. Arc–wire–deposit interaction 3.3.3. Form of deposits and associated defects 3.4. Conclusion 3.5. References 4. Numerical Simulation of Additive Manufacturing Processes 4.1. Thermo-hydrodynamic simulation 4.1.1. Description of physical phenomena 4.1.2. Modeling of heat source 4.1.3. Modeling of material input 4.1.4. Numerical methods for deposition modeling 4.1.5. Modeling of heat and mass transfer in the melt-pool 4.1.6. Examples of thermo-hydrodynamic simulations 4.2. Thermomechanical simulation 4.2.1. Whole-part simulation: different techniques 4.2.2. Heat transfer resolution 4.2.3. Metallurgical resolution 4.2.4. Mechanical resolution 4.2.5. Coupling 4.2.6. Application at the mesoscopic scale: local manufacturing stresses 4.2.7. Application at the macroscopic scale 4.2.8. Software and calculation codes dedicated to additive manufacturing 4.3. Conclusion 4.4. References Conclusion Abbreviations List of Authors Index