Metal Additive Manufacturing – Fundamentals and Process Technology

Abstract

This lecture gives an introduction to the fundamentals and process technology of additive manufacturing processes with a focus on metals. The principles and technologies of laser powder bed fusion, directed energy deposition as well as sintering processes will be introduced.

Objective

The students will learn - the physics of the most important metal additive manufacturing processes including the interaction of energy sources (laser, electron beams, arc/plasma) and metals, the phenomena occurring during melting and solidification, the generation of stresses and defects - the capabilities and limits of these processes - the digital aspects of the process chains including preparation of geometries, slicing, hatching etc. including assessment of printability of a design - working principles of machines, equipment and technology - basics of sensors and process control - post processing steps and interaction with AM material - future trends in metal AM

Content

Unit 1: Introduction to the AM workflow at the example of FDM Unit 2: Overview of Metal AM processes Unit 3: Making parts from weld beads Unit 4: Heat Flow, Melt Pool Dynamics, and Heat Sources Unit 5: Residual Stress and Distortion Unit 6: Laser Powder Bed Fusion - Build Layout Unit 7: Laser Powder Bed Fusion - Process Optimization and Design of Experiments Unit 8: Cost Modeling Unit 9: Lightweight Design using AM Unit 10: Powder Fabrication and Characterization Unit 11: Directed Energy Deposition Unit 12: Post-processing Unit 13: Materials for Metal AM Unit 14: Binder Jetting and sinter-based AM Unit 15: Simulation of AM Processes Unit 16: Process monitoring and closed-loop control of AM processes

Resources