Additive Manufacturing Handbook

Adedeji B. Badiru is Dean Emeritus at the Graduate School of Engineering and Management, Air Force Institute of Technology (AFIT), Wright-Patterson Air Force Base, Ohio, UAS USA. He is a registered professional engineer (PE), a fellow of the Institute of Industrial & Systems Engineers (IISE), a fellow of the Nigerian Academy of Engineering, and a certified project management professional (PMP). Dr. Badiru has a PhD in industrial engineering from the University of Central Florida, Orlando, Florida, and is the author of several books and technical journal articles. His areas of interest include manufacturing systems, technology transfer, project management, mathematical modelling, simulation, economic analysis, learning curve analysis, quality engineering, and productivity improvement.Carl R. Hartfield is an Associate Professor of Aerospace Engineering and Director of the Center for Space Research and Assurance, in the Department of Aeronautics and Astronautics at the Air Force Institute of Technology (AFIT) Wright- Patterson Air Force Base, AFB Ohio, USA. He is a life Senior member of the American Institute of Aeronautics and Astronautics (AIAA), an associate member of the American Society of Civil Engineers (ASCE), and a member of the AIAA Small Satellites Technical Committee. Dr. Hartsfield is the author of several journal articles in the subject areas of propulsion, spacecraft thermal management and additive manufacturing.David Liu is an aerospace engineer and program manager with the United States Air Force (USAF). He previously served as a Materiel Leader in the Weapons Directorate, Air Force Lifecycle Management Center (AFLCMC) at Eglin Air Force Base, (AFB), Florida, USA. Dr. Liu also serves as an adjunct assistant professor of aerospace engineering at the Air Force Institute of Technology (AFIT), Wright-Patterson Air Force Base AFB, Ohio, USA. He is a Senior Member of the American Institute of Aeronautics and Astronautics (AIAA) and was the Technical Chair of the Survivability Technical Committee. Dr. Liu is the author of several technical journal articles about aircraft survivability, ballistic effects, propulsion, and additive manufacturing.

• Section I: General Introduction. 1. From Traditional Manufacturing to Additive Manufacturing. 2. Basic Guide to 3D Printing. 3. Project Management for Additive Manufacturing. 4. 3D-Printing Impacts on Systems Engineering in Defense Industry. 5. Systems Engineering in 3D Printing Design. 6. Additive Manufacturing Software Tools. 7. Additive Manufacturing R&D . 8. Operational and Regulatory Gaps. 9. Additive Manufacturing Implications for Military Ethics.10. Additive Manufacturing Technologies Trends. 11. A New Global Approach to Design for Additive Manufacturing. 12. Methodological Framework for Design for Additive Manufacturing . Section II: Research & Development. 13. Development and Implementation of Metals Additive Manufacturing. 14. Selective Laser Melting (SLM) of Ni-based Superalloys: A Mechanics of Materials Review. 15. Powder Bed Fusion Technology. 16. Additive Manufacturing of Titanium Alloys. 17. Ultrasonic Additive Manufacturing. 18. Printing Components for Reciprocating Engine Applications. 19. Developing Practical Additive Manufacturing Design Methods. 20. Optical Diagnostics for Real-Time Monitoring and Feedback. 21. 3D Printed Structures for Nano-Scale Research. 22. Additive Manufacturing at the Micron Scale. 23. Computer Modeling of Sol-Gel Thin Film Deposition Using Finite Element Analysis. 24. Additive Manufacturing Review. 25. Mechanical Property Optimization of Fused Deposition Modeled Polylactic Acid Components via Design of Experiments. 26. Powder-Bed Fusion Additive Manufacturing. 27. Calculation of Laser Absorption by Metal Powders in Additive Manufacturing. 28. Accuracy and Surface Roughness. 29. Surface Roughness of Electron Beam Melting Ti-6Al-4v Effect on Ultrasonic Testing. 30. Dynamic Failure Properties of Stainless Steel in Additive Manufactured. 31. Fatigue Life of Selective Laser Melted and Hot Isostatically Pressed Ti-6Al-4v Absent of Surface Machining. 32. Impact Response of Titanium. 33. Laser Powder Bed Fusion Additive Manufacturing. 34. Measurement Science for Additive Manufacturing Processes. 35. Denudation of Metal Powder Layers. 36. Tension–Compression Fatigue of an Oxide/Oxide Ceramic Composite at Elevated Temperature. 37. Effects of Steam Environment on Fatigue Behavior. Section III: Applications. 38. 3DEJI Systems Model for 3D-Printed Product Integration. 39. 3D Printing Case Example at ORNL. 40. 3D Printing Implications for STEM Education. 41. Additive Manufacturing in USAF Civil Engineer Operations. 42. Additive Manufacturing in Systems Engineering Spiral Process Model. 43. Additive Manufacturing in Ordnance Disposal Training. 44. Aircraft Wing Design Utilizing Additive Manufacturing. 45. Additive Manufacturing Application for Warhead Topology Optimization. 46. Direct Metal Laser Sintering Revolution. 47. Information Storage on Additive Manufactured Parts. 48. Education and Research of Additive Manufacturing at the US Air Force Institute of Technology. 49. Comprehensive Analysis and Evaluation of the Potential and Characterization of Recycled Polymers for FMD 3D Printing Applications. 50. Learning Curve Modeling for Additive Manufacturing. 51. Lattice Optimized Actively Cooled Additive Manufactured Nose Cone Design and Evaluation.