Metal Additive Manufacturing. Ehsan Toyserkani
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of surface wettability for a droplet of water as a func...Figure 6.6 Droplet impact regimes on dry surfaces.Figure 6.7 Droplet cross section changes as a function of time from impact t...Figure 6.8 Infiltration of the droplet into (a) dry and (b) ‐ (c) pre‐wetted...Figure 6.9 The wetted region imaged using micro‐CT for one droplet dispensed...Figure 6.10 The creation of crater geometry: (a) droplet approaching the sur...Figure 6.11 Schematic of liquid bridge between two identical spherical parti...Figure 6.12 The penetration of a droplet with the impact velocity of 5 m/s i...Figure 6.13 Droplet formation modeling using level‐set method showing the ef...Figure 6.14 (a) Sample D2Q9 LBM.(b) Lattice vectors in a D2Q9 cell.Figure 6.15 Streaming step in LBM.Figure 6.16 Collision step in LBM.Figure 6.17 (a) 2D view of droplet spreading on a smooth surface from initia...
7 Chapter 7Figure 7.1 Components of a typical printhead in a ME system.Figure 7.2 HF composite filament at different ME process stages: Metal–polym...Figure 7.3 The schematic view of liquefier and nozzle in ME.Figure 7.4 Schematic of heat transfer region in ME.Figure 7.5 Three pressure drop zones in the nozzle.Figure 7.6 (a) The gap (B) between the filament and liquefier walls filled w...Figure 7.7 (a) Nozzle configuration in a conventional ME (FDM) model and (b)...Figure 7.8 Die swell effect results in an increase in the diameter of the be...Figure 7.9 Schematics of the liquefier entrance.Figure 7.10 (a) Geometry and temperature zones of Serdeczny's model and (b) ...Figure 7.11 (a) Temperature distribution at the liquefier at different times...
8 Chapter 8Figure 8.1 The relationship between four major components of materials scien...Figure 8.2 Conventional manufacturing processes: e.g., casting.Figure 8.3 AM powder production steps [1].Figure 8.4 Schematic of cooling curves during solidification, (a) definition...Figure 8.5 Fe–C phase diagram.Figure 8.6 Continuous cooling transformation diagram for steel.Figure 8.7 Time–temperature profile of a single‐layer AM‐manufactured Ti‐6Al...Figure 8.8 Critical continuous cooling transformation diagram for welded or ...Figure 8.9 Time–temperature diagram presenting the nucleation onset of two d...Figure 8.10 A comparative presentation of the theoretical equilibrium (solid...Figure 8.11 Solidification during inadequate diffusion in liquid and no diff...Figure 8.12 Solute distribution without diffusion in the solid and dissimila...Figure 8.13 Schematic presentation of constitutional supercooling: (a) parti...Figure 8.14 Schematic presentation on the relation between the Gibbs free en...Figure 8.15 (a) The figure depicting the nucleation of a sphere‐shaped parti...Figure 8.16 (a) Solid nucleus connected with substrate metal and liquid. (b)...Figure 8.17 Schematic presentation of the Walton and Chalmers model showing ...Figure 8.18 The graphics showing the growth characteristics and constitution...Figure 8.19 Epitaxial growth of the solidified metal adjacent the fusion lin...Figure 8.20 The schematic diagrams illustrate the modes of solidification pa...Figure 8.21 Occurrence of various solidification structures related to const...Figure 8.22 Change of the temperature in time, throughout the solidification...Figure 8.23 Schematic of the dendrite formation/growth.Figure 8.24 Influence of temperature gradient G and growth rate R on size an...Figure 8.25 Formation mechanism of grains in AM: (a) single track, (b) multi...Figure 8.26 Schematic of (a) Keyhole porosity.(b) Process and gas‐induce...Figure 8.27 Process window for LPBF manufactured Ti‐6Al‐4V alloy.Figure 8.28 Schematic of balling incident appeared by coarsened sphere‐shape...Figure 8.29 Representation of balling phenomenon characterized by small shap...Figure 8.30 The mechanism of liquation cracking in the melt pool area.Figure 8.31 Schematic presentation of the microstructural development and ph...Figure 8.32 Transformation–time–temperature plot for IN718 alloy [79].Figure 8.33 Microstructure of Stellite 12 manufactured through laser‐based A...Figure 8.34 Effect of (a) α‐stabilizing, (b) β‐isomorphous, and (c...Figure 8.35 The graphical presentation of ternary titanium alloys having bot...Figure 8.36 The graphical illustration of thermal profiles.Figure 8.37 Continuous cooling transformation curve for Ti‐6Al‐4v alloy [99]...Figure 8.38 Micro‐hardness values with respect to the secondary arms spacing...Figure 8.39 The micro‐hardness values with respect to the secondary arms spa...Figure 8.40 Microstructure of Ti‐6Al‐4V manufactured by LPBF, (a) after stre...Figure 8.41 Micro‐hardness plot with respect to the alpha lath width for Ti6...Figure 8.42 The property window presents yield strength vs. elongation for v...Figure 8.43 The property window presents yield strength vs. elongation for T...Figure 8.44 The fatigue behavior of (a) 316L and (b) LPBF‐manufactured 17‐4 ...Figure 8.45 The schematic shows the breaking up of Laves phase and split‐up ...Figure 8.46 The fatigue plot shows strain amplitude vs. reversals to failure...
9 Chapter 9Figure 9.1 The production route of metal matrix composites in AM.Figure 9.2 Schematic illustration of the collision between grinding ball and...Figure 9.3 Geometrical presentation of the particle motion trajectory in an ...Figure 9.4 Formation mechanism of TiC reinforced 316L matrix composite, (a) ...Figure 9.5 Microstructure showing the morphology of matrix, interface, and W...Figure 9.6 The schematic diagram shows that the formation mechanism of ferro...Figure 9.7 Schematic presentation for the formation of TiB phase from in‐sit...Figure 9.8 Schematic depiction of the formation mechanism of quasi‐continuou...Figure 9.9 Schematic presentation of the microstructural development in pure...Figure 9.10 Schematic microstructure of the as‐printed Ti‐6Al‐4V/MG composit...Figure 9.11 SEM micrograph showing Ti‐6Al‐4V‐ 3% B4C composite.Figure 9.12 The schematic diagram illustrates the mechanism of Inconel–TiB2 ...Figure 9.13 Demonstration of various failure approaches during compressive l...Figure 9.14 (a) The influence of Marangoni flow, (b) TiC particles under int...
10 Chapter 10Figure 10.1 Topological and functional integrated design framework for AM....Figure 10.2 Multidiscipline optimization (MDO) for a multifunctional thermal...Figure 10.3 AM‐enable design framework.Figure 10.4 Design workflow for hybrid design solutions by topology optimiza...Figure 10.5 Multifunctional design methodology.Figure 10.6 AM model for product family design.Figure 10.7 Poor and good part orientation for the avoidance of the “curl ef...Figure 10.8 Types of support structures, from left to right: fill, lattice, ...Figure 10.9 Guidance on the use of support structures.Figure 10.10 Modification of circular profile to avoid “dropping effect.”...Figure 10.11 Hollow features printed with the hollow extrusion (a, b) perpen...Figure 10.12 Line‐of‐sight powder removal: (a) small radius, (b) large radiu...Figure 10.13 A feature with (a) sharp corners and (b) smooth corners.Figure 10.14 Design variations showing some thin sections that can encourage...Figure 10.15 The three classifications of structural optimization. (a) Sizin...Figure 10.16 Classification of topology optimization methods.Figure 10.17 How topology optimization transforms the structural form of (a)...Figure 10.18 Influence of volume fraction on interpolation function for SIMP...Figure 10.19 Linear filter for a 2D mesh.Figure 10.20 Classification of design‐dependent loads for topology optimizat...Figure 10.21 Thermomechanically loaded structures (a) with constant temperat...Figure 10.22 Workflow for density‐based topology optimization methods.Figure 10.23 Initial design domain and optimized bridge‐like designs with in...Figure 10.24 Different allowable minimum self‐supporting angles for satisfyi...Figure 10.25 Element density with supporting elements in a 2D FE mesh.Figure 10.26 Optimum designs showing difference in the topologies resulting ...Figure 10.27 Topology‐optimized half MBB beam with AM filter and Heaviside p...Figure 10.28 Optimized designs of an aerospace bracket. The right bracket wa...Figure 10.29 Neighboring elements to element e for a single layer.Figure 10.30 (a) Unconstrained and (b) constrained topology‐optimized cantil...Figure 10.31 Some examples of 2D unit cells.Figure 10.32 Some 3D unit cell types. (a) 3d Hexagon, (b) “X” shape, (c) oct...Figure 10.33 Relationship between a lattice structure and its framework.Figure 10.34 Lattice orientation showing Euler angles α, β, γFigure 10.35 Uniform lattice structure.Figure 10.36 Comparison between (a) uniform and (b) conformal lattices.Figure 10.37 Voronoi‐based lattice structures. (a) Normal Voronoi structure,...Figure 10.38 Design workflow of multiscale geometric modeling of lattice str...Figure 10.39 SIMP results for 0.5 volume fraction with penalty value (a) set...Figure 10.40 Representative structures with a volume fraction of 0.5. (a) So...Figure 10.41 Library of surface‐based unit cells: (a) G (Schoen's Gyroid), (...Figure 10.42 Schwarz's P surfaces (for value of t = 0.37); (a) fP (x,y,z) ≤ Figure 10.43 Example of a linear material grading for (a) strut‐based BCC la...Figure 10.44 Workflow for RDM method.Figure 10.45 Elements' centroids from strut j.Figure 10.46 Screening process for RDM.Figure 10.47 Effect of build orientation on a dogbone sample. (a) CAD model ...Figure 10.48 Orientation