Fundamentals of Laser Powder Bed Fusion of Metals. Additive Manufacturing Materials and Technologies

Table of Contents

1. Historical background Joseph J. Beaman, University of Texas, Austin, Texas, USA 2. Basics of laser powder bed fusion Igor Yadroitsev and Ina Yadroitsava, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa 3. A step-by-step guide to the L-PBF process Igor Yadroitsev and Ina Yadroitsava, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; 4. Physics and modeling Andrey V. Gusarov, Moscow State University of Technology STANKIN, Moscow, Russia 5. Design principles Martin Leary, David Downing, and Bill Lozanovski, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia; Jonathan Harris, nTopology, New York, New York, USA 6. Porosity in laser powder bed fusion Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa 7. Surface roughness Martin Leary, Avik Sarker, Johnathan Tran, Kate Fox, and David Downing, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia; Mahyar Khorasani, School of Engineering, Deakin University, Waurn Ponds, Victoria, Australia; Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa 8. Microstructure of L-PBF alloys Pavel Krakhmalev, Department of Engineering and Physics, Karlstad University, Karlstad, Sweden; Nataliya Kazantseva, Institute of Metal Physics UB RAS, Ekaterinburg, Russia 9. Residual stress in laser powder bed fusion Lameck Mugwagwa, Ina Yadroitsava and Igor Yadroitsev, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; Nkutwane Washington Makoana, Council for Scientific and Industrial Research, National Laser Centre, Pretoria, South Africa 10. Non-destructive testing of parts produced by laser powder bed fusion Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa; Eric MacDonald, W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, Texas, USA; Jess M. Waller, NASA-Johnson Space Center White Sands Test Facility, Las Cruces, New Mexico, USA; Filippo Berto, Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology (NTNU), Trondheim, Norway 11. Process monitoring of laser powder bed fusion Marco Grasso and Bianca Maria Colosimo, Department of Mechanical Engineering, Polytechnic University of Milan, Milan, Italy; Kevin Slattery, The Barnes Global Advisors, Pittsburgh, Pennsylvania, USA; Eric MacDonald, W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, Texas, USA 12. Post-processing Sara Bagherifard and Mario Guagliano, Department of Mechanical Engineering, Polytechnic University of Milan, Milan, Italy 13. Structural integrity I: static mechanical properties Pavel Krakhmalev, Department of Engineering and Physics, Karlstad University, Karlstad, Sweden; Anna Martin Vilardell and Naoki Takata, Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Nagoya, Aich,?Japan 14. Structural integrity II: fatigue properties Uwe Zerbst and Mauro Madia, Federal Institute for Materials Research and Testing (BAM), Berlin, Germany 15. Structural integrity III: energy-based fatigue prediction for complex parts Seyed Mohammad Javad Razavi and Filippo Berto, Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology (NTNU), Trondheim, Norway; Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa 16. Lattice structures made by laser powder bed fusion Mohammad J. Mirzaali, Jie Zhou, and Amir A. Zadpoor, Department of Biomechanical Engineering, Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Delft, the Netherlands; Abolfazl Azarniya, Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore; Saeed Sovizi, Independent Researcher, Tehran, Iran 17. Bio-inspired design Yash Mistry, Daniel Anderson, and Dhruv Bhate, 3DX Research Group, The Polytechnic School, Arizona State University, Mesa, Arizona, USA 18. Powder characterization
methods, standards, and state of the art Robert Groarke, School of Mechanical Engineering, Dublin City University, Dublin, Ireland; R. K. Vijayaraghavan, School of Electronic Engineering, Dublin City University, Dublin, Ireland; Daniel Powell, Centre for Defense Engineering, Cranfield University, Shrivenham, United Kingdom; Allan Rennie, Engineering Department, Lancaster University, Lancaster, United Kingdom; Dermot Brabazon, I-Form, Advanced Manufacturing Research Centre, Dublin City University, Dublin, Ireland 19. New materials development Bonnie Attard, Abd El-Moez A. Mohamed, and Moataz M. Attallah, School of Metallurgy and Materials, University of Birmingham, Birmingham, United Kingdom 20. Recent progress on global standardization Johannes Gumpinger, ESA/ESTEC, European Space Research and Technology Center, Noordwijk, the Netherlands; Mohsen Seifi, ASTM International, Washington, District of Columbia, USA; Nima Shamsaei, National Center for Additive Manufacturing Excellence (NCAME), Auburn University, Auburn, Alabama, USA; Christian Seidel, Munich University of Applied Sciences, Munich, Germany; Richard W. Russell, NASA Engineering and Safety Center (NESC), Langley Research Center, Hampton, Virginia, USA 21. Industrial applications Elena Lopez, Frank Brueckner, and Samira Gruber, Fraunhofer IWS, Dresden, Germany 22. Economic feasibility and cost-benefit analysis Martin Leary, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia 23. Current state and future trends in laser powder bed fusion technology Andrey Molotnikov, Alex Kingsbury, and Milan Brandt, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia 24. Case study Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa; Igor Yadroitsev and Ina Yadroitsava, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; Johan Els, Centre of Rapid Prototyping and Manufacturing, Central University of Technology, Bloemfontein, Free State, South Africa; Eric MacDonald, W. M.

Authors

Igor Yadroitsev Research Chair, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa. Prof. Igor Yadroitsev is a Research Chair in Medical Product Development through Additive Manufacturing at the Central University of Technology launched by the National Research Foundation of South Africa in 2015. He has been involved in additive manufacturing with emphasis on laser powder bed fusion at the Vitebsk Institution of Technical Acoustics (Belarus) since 1995, when this technology was in its infancy. He continued his research in the field at the National School of Engineering (Saint-�tienne, France) and published a book on selective laser melting in 2009. His research interests include applied optics and laser technologies: additive manufacturing, laser powder bed fusion of metals and plastics, laser processing, materials science, and optics. He has authored over 100 articles in the field of laser powder bed fusion. Ina Yadroitsava Senior Researcher, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa. Dr. Ina Yadroitsava, PhD, has been involved in additive manufacturing since 2007 when she started to work in the Laboratory of Diagnostics and Engineering of Industrial Processes at the National School of Engineering (Saint-�tienne, France). At present, she is working as Senior Researcher at the Department of Mechanical and Mechatronic Engineering, Faculty of Engineering, Built Environment and Information Technology at the Central University of Technology, Free State. In 2019, she was recognized by the South Africa National Research Foundation as an established researcher in such areas as laser metal additive manufacturing, advanced materials and numerical modeling. Her research interests include laser powder bed fusion, material characterization, bio-medical applications, and properties of advanced additively manufactured materials. Anton Du Plessis Applications Scientist, Object Research Systems Inc, Montreal, Quebec, Canada; Associate Professor, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa. Prof. Anton Du Plessis is Associate Professor at Stellenbosch University (South Africa) and Applications Scientist at Object Research Systems (Canada). His research spans X-ray tomography applications, additive manufacturing and engineering materials. He has published over 150 journal papers and is on the editorial board of a number of journals, and acts as deputy editor of Additive Manufacturing Letters and editor in chief of Tomography of Materials and Structures. He holds extraordinary professor positions at Nelson Mandela University and Central University of Technology (South Africa). Eric MacDonald Professor and Murchison Chair, W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, Texas, USA. Prof. Eric MacDonald, PhD, is a Professor of Mechanical Engineering and the Murchison Chair at the University of Texas at El Paso, as well as deputy editor of the Elsevier journal 'Additive Manufacturing'. Dr. MacDonald received his PhD degree in Electrical Engineering from the University of Texas at Austin and has worked in industry for 12 years at IBM and Motorola, and subsequently co-founded a start-up - Pleiades, Inc., which was acquired by Magma Inc. (San Jose, CA) in 2003. Dr. MacDonald has held faculty fellowships at NASA's Jet Propulsion Laboratory, SPAWAR Navy Research (San Diego), and a State Department Fulbright Fellowship in South America. His research interests include 3D-printed multi-functional applications and advanced process monitoring in additive manufacturing.