Additive Manufacturing of Metal Alloys 1

Patrice Peyre is a CNRS senior research scientist at the PIMM laboratory in Paris. He specializes in the study of the transformation of materials using lasers.Eric Charkaluk is a CNRS senior research scientist at the LMS laboratory at Ecole Polytechnique near Paris. His interests include the deformation and damage of metals in relation to their microstructure.

• Introduction ixPatrice Peyre and Éric CharkalukChapter 1 Metal Additive Manufacturing Processes 1Patrice Peyre1.1 The DED-LMD process 31.1.1 Process overview 31.1.2 Basic elements 41.1.3 Overview of process parameters and their influence 81.1.4 Thermal cycles induced by the process 131.1.5 Types of materials involved 151.1.6 Microstructures of manufactured or repaired parts 151.1.7 Industrial systems 161.2 The L-PBF process 211.2.1 Distinction between sintering and laser melting 211.2.2 Manufacturer interests and requirements 211.2.3 Process principle and basic elements 241.2.4 Types of materials involved 271.2.5 Presentation and influence of the process operating parameters 281.2.6 Comparison of the L-PBF process and DED process 311.2.7 Design and manufacturing method of a part 321.2.8 Area of stable melt-pool suitable for construction 371.2.9 Optimization of L-PBF manufacturing of 3D parts 381.3 Electron powder bed fusion 391.3.1 Introduction 391.3.2 Implementation of the E-PBF process 401.3.3 Optimization of melting conditions and characteristic defects 471.3.4 Other characteristics of the E-PBF process 521.3.5 Partial conclusion regarding E-PBF 571.4 The deposition of matter via WAAM 581.4.1 Arc/wire additive manufacturing technologies 581.4.2 WAAM process parameters 621.4.3 Use of materials 641.4.4 Residual stresses and distortions 671.4.5 Finishing process 681.4.6 Digital chain: online control 691.4.7 Conclusion 721.5 Emerging processes 721.5.1 Indirect fabrication by selective laser sintering and infiltration 721.5.2 Indirect manufacture via metal binder jetting 781.5.3 Direct manufacture in the solid state without melting 811.6 Conclusion 871.7 References 89Chapter 2 Raw Materials: Metal Powders and Wires 97Marc Thomas2.1 Metal powders 972.1.1 Introduction 972.1.2 Producing powders 992.1.3 Physico-chemical properties of powders 1152.1.4 Rheological properties of powders 1172.1.5 Influence of powders on processes and final properties 1252.1.6 Standardization 1282.1.7 Summary 1292.2 Metal wires 1302.2.1 Introduction 1302.2.2 Wire production 1322.2.3 Use of filler wires in AM 1352.2.4 Influence of wires on processes and final properties 1372.2.5 Summary 1462.3 References 147Chapter 3 The Physics of Metal Additive Manufacturing Processes 151Patrice Peyre3.1 The energy–powder–fusion zone interaction in additive laser fusion processes 1513.1.1 Introduction 1513.1.2 Reminder of the essential physical variables 1523.1.3 Radiation absorption and heat transfer: different interaction regimes for different processes 1533.1.4 Local thermal cycles: influence of boundary conditions 1633.1.5 Hydrodynamics of fusion zones and associated faults 1643.1.6 Partial conclusion regarding the physics of laser additive manufacturing processes 1713.2 The physics of the E-PBF process 1713.2.1 Introduction 1713.2.2 Reminder of the essential physical variables characteristic of the electron–matter interaction 1713.2.3 The phenomena induced during the electron–matter interaction 1733.2.4 Energy absorption in the powder in E-PBF 1773.2.5 Description of the fusion zone in E-PBF and associated defects 1803.2.6 Partial conclusion regarding E-PBF 1833.3 Physics of the wire arc additive manufacturing process 1833.3.1 Reminder of the essential physical variables 1843.3.2 Arc–wire–deposit interaction 1863.3.3 Form of deposits and associated defects 1933.4 Conclusion 1963.5 References 196Chapter 4 Numerical Simulation of Additive Manufacturing Processes 201Muriel Carin4.1 Thermo-hydrodynamic simulation 2014.1.1 Description of physical phenomena 2014.1.2 Modeling of heat source 2034.1.3 Modeling of material input 2064.1.4 Numerical methods for deposition modeling 2084.1.5 Modeling of heat and mass transfer in the melt-pool 2104.1.6 Examples of thermo-hydrodynamic simulations 2134.2 Thermomechanical simulation 2214.2.1 Whole-part simulation: different techniques 2234.2.2 Heat transfer resolution 2244.2.3 Metallurgical resolution 2254.2.4 Mechanical resolution 2304.2.5 Coupling 2324.2.6 Application at the mesoscopic scale: local manufacturing stresses 2334.2.7 Application at the macroscopic scale 2344.2.8 Software and calculation codes dedicated to additive manufacturing 2384.3 Conclusion 2384.4 References 239Conclusion 243Patrice Peyre and Éric CharkalukAbbreviations 245List of Authors 255Index 259