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Metal Additive Manufacturing
Principles, Techniques and Applications
R. Rajasekar (Edited by), R Rajasekar (Author), Amir Mostafaei (Edited by), C. Moganapriya (Edited by), P. Sathish Kumar (Edited by)
9781394287628, Wiley
Hardback, published 21 May 2025
560 pages
25 x 15 x 1.5 cm, 1.191 kg
This informative and practical guide to metal additive manufacturing explores techniques, applications, and future advancements. 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.
Preface xix 1 Technologies for Additive Manufacturing of Metals and Their Classification 1 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 References 22 2 Challenges and Complications in Metal Additive Manufacturing During Post Processing 27 2.1 Introduction 27 2.2 Various Post Processing Methods 32 2.3 Future Scope and Aspects 35 2.4 Conclusion 36 References 36 3 Mechanics and Modeling of Metal Additive Manufacturing Using Directed Energy Deposition Method 39 3.1 Introduction 39 3.2 Computational Modeling 44 3.3 Nucleation Modeling 48 3.4 Conclusion 51 References 51 4 Rapid Additive Manufacturing of Metals Using the Cold Spray Technology: Progress and Challenges 55 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 References 77 5 Principles of Material Extrusion in Metal Additive Manufacturing 83 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 References 96 6 Material Design: A ‘Material’ Way to Improve Additive Manufacturing 99 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 References 117 7 Metal Powder Feedstock Production for Additive Manufacturing 125 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 Acknowledgments 160 References 160 8 Additive Manufacturing of Intermetallic-Based Alloys: A Review 169 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 Ni 3 Al-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 Acknowledgments 203 References 203 9 Mechanical Behavior of 3D Printed Parts 211 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 References 228 10 Processing of Hydrogels with Metallic Additives in Additive Manufacturing 235 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 References 250 11 Additive Manufacturing Simulation: Molten Pool Dynamics, Solidification Microstructure, and Powder Behavior 255 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 References 271 Appendix 275 12 Underlying Principles and Applications of Cold Spray Additive Manufacturing 279 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 References 291 13 Comparison of Different Metal Additive Manufacturing Techniques for Biomedical Application 297 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 References 323 14 Application of Metal Additive Manufacturing for Metal Matrix Composites 333 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 References 352 15 Transforming Supply Chains (SCs) with Additive Manufacturing (AM): A Paradigm Shift in Production 359 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 References 398 16 Multi-Material Additive Manufacturing for Biomedical Applications 407 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 Acknowledgment 426 References 427 17 Digital Light Processing (DLP)–Based Three-Dimensional Printing for Biomedical Applications 433 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 Acknowledgment 450 References 450 18 Salient Aspects of 3D Printed Microfluidic Device–Based Organ-on-a-Chip Models for Futuristic Healthcare Applications 459 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 Acknowledgment 487 References 487 19 Smart Hydrogels for Tissue Engineering Applications 497 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
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Subject Areas: Mechanical engineering & materials [TG]
