Metal additive manufacturing stands as a revolutionary technology and a rapid prototype for engineering applications. In the realm of advanced manufacturing, it has long been a driving force in the development of AM metal technology. Moreover, it is now paving the way for high-value manufacturing components blended with sophisticated materials.
The book examines this rapidly evolving field and elucidates the foundations of metal additive manufacturing, including its various technologies, material design principles, and extrusion processes. Real-world applications are showcased, with examples from the aerospace, automotive, and healthcare industries, demonstrating the practical impact of metal AM. Chapters thoroughly discuss the evolution of manufacturing techniques, classifications of AM technologies, and the critical role of characterization in ensuring quality. The book emphasizes the importance of metal AM processes and their transformative potential for modern manufacturing. It concludes with coverage of future trends and advancements in additive manufacturing.
Audience
The book equips manufacturing and production engineers, researchers, and professionals with metal AM knowledge for the production of high-value components, driving innovation and efficiency in manufacturing.
Table of Contents
Preface xix
1 Technologies for Additive Manufacturing of Metals and Their Classification 1
Bhuvanesh Kumar M., Justus Panicker C. T. and Arivazhagan D.
1.1 Introduction 1
1.2 Metal Additive Manufacturing Process (MAMP) 2
1.3 Classification of MAMP Based on Technologies 4
1.4 Liquid-Based MAMP: Liquid Metal 3D Printing 4
1.5 Solid-Based MAMP: Ultrasonic Additive Manufacturing 6
1.6 Powder-Based MAMP 7
1.7 Wire-Based MAMP: Wire DED 14
1.8 Applications 20
1.9 Conclusion 21
2 Challenges and Complications in Metal Additive Manufacturing During Post Processing 27
Bhaskar Kumar, Amit Kumar and Sonu Rajak
2.1 Introduction 27
2.2 Various Post Processing Methods 32
2.3 Future Scope and Aspects 35
2.4 Conclusion 36
3 Mechanics and Modeling of Metal Additive Manufacturing Using Directed Energy Deposition Method 39
Amit Kumar, Bhaskar Kumar and Sonu Rajak
3.1 Introduction 39
3.2 Computational Modeling 44
3.3 Nucleation Modeling 48
3.4 Conclusion 51
4 Rapid Additive Manufacturing of Metals Using the Cold Spray Technology: Progress and Challenges 55
Rija Nirina Raoelison
4.1 Introduction 55
4.2 Progress in Cold Spraying Towards an Implementation as a Fast AM Route for Metals 56
4.3 Processing Science of Cold Spraying from Coating to Additive Manufacturing 60
4.4 Cold Spraying Modern System for an Additive Manufacturing Application 61
4.5 Robotic Technology and Computerized Program Execution in Cold Spraying 63
4.6 Robotic Programming and Deposition Strategy for CSAM 64
4.7 Current Achievements in CSAM of Metallic Parts 66
4.8 Porosity Issue Due to the Additive Growth and Methods for Pore Reduction 69
4.9 Issue of Clogging in CSAM and Concept of Aerospike Nozzle as Potential Solution 73
4.10 Future Research Directions 75
4.11 Conclusion 76
5 Principles of Material Extrusion in Metal Additive Manufacturing 83
Ishak Ertugrul and Osman Ulkir
5.1 Introduction 84
5.2 Additive Manufacturing Technology 84
5.3 Basic Additive Manufacturing Methods 85
5.4 Extrusion Principle 89
5.5 Metal Extrusion with Additive Manufacturing 92
5.6 Industrial Applications and Examples 93
5.7 Future Potential and Innovative Approaches 94
5.8 Conclusion 95
6 Material Design: A ‘Material’ Way to Improve Additive Manufacturing 99
Jiangqi Zhu, Cheng Chang, Shuohong Gao, Xingchen Yan and Min Liu
6.1 Introduction 99
6.2 Conventional Alloys for MAM 102
6.3 Limitations of Conventional Alloys for MAM 104
6.4 Material Design for Metal Additive Manufacturing 106
6.5 Alloys Designed for AM 112
6.6 Perspective and Future Directions 115
6.7 Summary 116
7 Metal Powder Feedstock Production for Additive Manufacturing 125
Palivela Bhargav Chandan, Devara Venkata Krishna and Mamilla Ravi Sankar
7.1 Introduction 125
7.2 Different Stages in Metal Powder Production 127
7.3 Feedstock Selection 128
7.4 Processes 130
7.5 Powder Processing 154
7.6 Discussion 154
7.7 Conclusion 160
8 Additive Manufacturing of Intermetallic-Based Alloys: A Review 169
Chaoyue Chen, Chaojun Xie, Tingwei Cao, Jiang Wang and Zhongming Ren
8.1 Introduction 169
8.2 Basic Properties of Intermetallic Alloy 171
8.3 Additive Manufacturing Techniques 177
8.4 NiAl-Based Alloys 179
8.5 Metallurgical Defects 179
8.6 Microstructure 181
8.7 Mechanical Properties 184
8.8 Ni3Al-Based Alloys 186
8.9 Metallurgical Defects 187
8.10 Microstructure 188
8.11 Mechanical Properties 192
8.12 TiAl-Based Alloy 194
8.13 Microstructure 197
8.14 Mechanical Properties 200
8.15 Conclusion and Perspectives 201
9 Mechanical Behavior of 3D Printed Parts 211
Sandhyarani Biswas, Himanshu Singh and Jagdish Uday Khatu
9.1 Introduction 211
9.2 Metal AM and its Classification 213
9.3 Metal AM Processes and the Mechanical Properties of Printed Parts 214
9.4 Effect of Post-Processing on the Mechanical Properties of 3D Printed Metal Parts 224
9.5 Challenges and Opportunities for Metal AM 225
9.6 Conclusion 228
10 Processing of Hydrogels with Metallic Additives in Additive Manufacturing 235
Magdalena B. Labowska, Maria Skrodzka, Adrianna Cieslak, Patrycja Szymczyk-Ziólkowska, Agnieszka Adamczyk and Jerzy Detyna
10.1 Introduction 235
10.2 Methods for Incorporating Metal Additives into Hydrogels 238
10.3 Metal Additives from Physical Cross-Linking Processes 238
10.4 Metal Additives as Metal Powder Feedstock 239
10.5 Metal Additives as Metal Nanoparticles 240
10.6 Application Areas for Hydrogels with Metallic Additives 242
10.7 Future Perspectives and Conclusions 249
11 Additive Manufacturing Simulation: Molten Pool Dynamics, Solidification Microstructure, and Powder Behavior 255
Songzhe Xu, Ling Shi, Chaoyue Chen, Jiang Wang and Zhongming Ren
11.1 Introduction 255
11.2 Simulation of Molten Pool Dynamics 256
11.3 Simulation of Grain Structure 260
11.4 Simulation of Dendrite Growth 265
11.5 Simulation of Powder Behavior 267
11.6 Conclusion and Future Prospects 270
12 Underlying Principles and Applications of Cold Spray Additive Manufacturing 279
Amritbir Singh, Himanshu Kumar and S. Shiva
12.1 Introduction 279
12.2 Emergence of Cold Spray Additive Manufacturing 281
12.3 Variables Affecting the CS Consolidations 282
12.4 Bonding Mechanism in CSAM 285
12.5 Locked Up Stresses in CSAM 286
12.6 Type of Structure Fabricated Using CSAM 288
12.7 Applications 289
13 Comparison of Different Metal Additive Manufacturing Techniques for Biomedical Application 297
Maria Skrodzka, Adrianna Cieslak, Patrycja Szymczyk-Ziólkowska, Magdalena B. Labowska, Maja Ducka and Jerzy Detyna
13.1 Introduction 297
13.2 Powder Bed Fusion (PBF) 299
13.3 Binder Jetting (BJ) 306
13.4 Material Extrusion (MEX) 308
13.5 Direct Energy Deposition (DED) 311
13.6 Sheet Lamination (SHL) 314
13.7 Material Jetting (MJ) 317
13.8 Conclusion 321
13.9 Future Direction and Challenges 322
14 Application of Metal Additive Manufacturing for Metal Matrix Composites 333
P. Lakshmikanthan, K. Senthilvel and B. Prabu
14.1 Introduction 333
14.2 Metal Matrix Composite (MMC) 335
14.3 Additive Manufacturing of MMCs 338
14.4 Techniques of Metal Matrix Composites-Based Additive Manufacturing (AM) 339
14.5 MMCs Processing by 3D Printing 344
14.6 Application of Additive Manufacturing Product 344
14.7 Key Challenges 351
14.8 Summary and Future Work 352
15 Transforming Supply Chains (SCs) with Additive Manufacturing (AM): A Paradigm Shift in Production 359
Vaishnavi Vadivelu, Prakash Nachimuthu and Parthasarathy Karthikeyan
15.1 Introduction 359
15.2 AM in Supply Chain Management 360
15.3 Impact of AM in Supply Chain 362
15.4 Smart Supply Chain with AM 363
15.5 AM Contribution to Flexibility in the Intelligent Supply Chain 365
15.6 Supply Chain Framework for AM 368
15.7 Supply Chain Structure Impacts of AM 376
15.8 Traditional Manufacturing (TM) 376
15.9 Spare Part Management 383
15.10 AM in Apparel Industry 389
15.11 Benefits of AM in Supply Chain 394
15.12 Cyber Risks in the AM Supply Chain 395
15.13 Barriers in AM Implementation in Supply Chain 396
15.14 Conclusion 398
16 Multi-Material Additive Manufacturing for Biomedical Applications 407
Devara Venkata Krishna, Palivela Bhargav Chandan and Mamilla Ravi Sankar
16.1 Introduction 407
16.2 Additive Manufacturing of Multi-Materials for Biomedical Applications 408
16.3 Additively Manufactured Multi-Material Components for Bio-Medical Applications 415
16.4 Conclusion 426
17 Digital Light Processing (DLP)--Based Three-Dimensional Printing for Biomedical Applications 433
Devera Venkata Krishna, Sunkara Venkata Naga Sai Surya, Palivela Bhargav Chandan and Mamilla Ravi Sankar
17.1 Introduction 433
17.2 Photocurable Materials 435
17.3 Photoinitiators 436
17.4 Synthesis of the Hydrogel 439
17.5 Applications in Biomedical Engineering 441
17.6 Conclusion and Future Aspects 449
18 Salient Aspects of 3D Printed Microfluidic Device--Based Organ-on-a-Chip Models for Futuristic Healthcare Applications 459
Devara Venkata Krishna, Palivela Bhargav Chandan, Deyyala Sai Venkat and Mamilla Ravi Sankar
18.1 Introduction 459
18.2 Biodegradable Materials for the Organ-on-a-Chip Model 462
18.3 Fabrication of MFDs Through 3D Printing 466
18.4 Evolution and Applications of Microfluidic Chips 473
18.5 Conclusion 485
19 Smart Hydrogels for Tissue Engineering Applications 497
Devara Venkata Krishna, Venneti Lakshmi Sri Vijay Srinivas, Palivela Bhargav Chandan, Mamilla Ravi Sankar and Thopireddy Nagendra Reddy
19.1 Introduction 497
19.2 Classification of Smart Hydrogels 499
19.3 Synthesis of Smart Hydrogels 505
19.4 Applications of Smart Hydrogels for Tissue Engineering 508
19.5 Conclusion 516
Acknowledgment 516
References 516
Index 527
