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151-0544-00L 4 Credits BSC , DR , MSC D-MAVT , D-MATL

Metal Additive Manufacturing - Mechanical Integrity and Process Simulation

Lecturers & Examiners: Dr. Ehsan Hosseini
Note: The previous course title until HS22 "Metal Additive Manufacturing - Mechanical Integrity and Numerical Analysis"
VVZ CR n/a

Last Updated: 2026-06-03 00:07:39

Abstract

An introduction to Metal Additive Manufacturing (MAM) (e.g. different techniques, the metallurgy of common alloy-systems, existing challenges) will be given. The focus of the lecture will be on the employment of different simulation approaches to address MAM challenges and to enable exploiting the full advantage of MAM for the manufacture of structures with desired property and functionality.

Objective

The main objectives of this lecture are: - Acknowledging the possibilities and challenges for MAM (with a particular focus on mechanical integrity aspects), - Understanding the importance of material science and metallurgical considerations in MAM, - Appreciating the importance of thermal, fluid, mechanical and microstructural simulations for efficient use of MAM technology, - Using commercial analysis tools (e.g. ABAQUS) for simulation of the MAM process.

Content

- Introduction to MAM (concept, application examples, pros & cons), - Powder-bed and powder-blown metal additive manufacturing, - Thermo-fluid analysis of additive manufacturing, - Continuum-based thermal modelling and experimental validation techniques, - Residual stress and distortion simulation and verification methods, - Microstructural simulation (basics, analytical, kinetic Monte Carlo, cellular automata), - Mechanical property prediction for MAM, - Microstructure and mechanical response of MAM material (stainless steel, Ti6Al4V, Inconel 718), - Design for additive manufacturing - Artificial intelligence for AM Exercise sessions use ABAQUS for analysis of MAM process. Detailed video instructions will be provided to enable students to set up their own simulations. Students can install the packages on their own systems.

Resources

Lecture Notes

Handouts of the presented slides.

General Information

Language
English
Levels
BSC , DR , MSC
Frequency
Yearly recurring

Examination

Type
end-of-semester examination
Mode
oral 20 minutes
The final grade consists of two components: a final oral examination, which accounts for 70% of the overall grade, and a compulsory continuous performance assessment, which contributes the remaining 30%.The compulsory continuous assessment itself consists of two parts: (i) in-class theory assessments (5%) and (ii) simulation assignments (25%). The in-class theory assessments are conducted in the form of multiple-choice quizzes during the first five minutes of selected lectures and cover material presented in the previous session. The simulation component comprises six small simulation tasks, which are introduced during exercise sessions starting from the third week of the semester. Students are expected to independently follow provided video instructions to set up simulation cases using ABAQUS. Each assignment is estimated to require approximately 1–4 hours of work.

Course Components

Type Title Time & Place Hours
lecture with exercise Metal Additive Manufacturing - Mechanical Integrity and Process Simulation No time listed 3 h weekly

Offered In