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151-0544-00L 4 Credits BSC , DR , MSC D-MATL , D-MAVT
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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: 2026-02-05 16:16:33

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 different commercial analysis tools (ANSYS, 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, phase-field), - 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 ANSYS, ABAQUS packages 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.

Literature

No textbook is available for the course (unfortunately), since it is a dynamic and relatively new topic. In addition to the material presented in the course slides, suggestions/recommendations for additional literature/publications will be given (for each individual topic).

General Information

Language
English
Levels
BSC , DR , MSC
Frequency
Yearly recurring

Examination

Type
end-of-semester examination
Mode
oral 20 minutes
In addition to the final oral examination, there is one compulsory continuous performance assessment. Eight small simulation assignments will be presented starting from the 3rd week of the semester in exercise sessions. The students are expected to follow video-instructions for setting up a simulation case per assignment (in COMSOL or ABAQUS or ANSYS) and submit a single-page report covering the simulation results and their personal interpretation of the results. There will be 3 weeks time for submission of the solution (report) for each assignment and the lecturer will be available for discussion and support within this time period. The reports will be graded and the average of the six best assignment grades will count 30% towards the final course grade. Not handing in an assignment at all will result in a grade 1 The remaining 70% of the final grade will be based on a 20-min oral exam.

Course Components

Type Title Time & Place Hours
lecture with exercise Metal Additive Manufacturing - Mechanical Integrity and Process Simulation
  • Fri 10:15-13:00 (CHN C 14)
3 h weekly

Offered In