Metal Additive Manufacturing

R. Rajasekar, PhD, is a professor and dean of research and development in the Mechanical Engineering Department at Kongu Engineering College, Tamil Nadu, India. His research focuses on polymers, solar energy, nanocomposites, layer-by-layer assembly, thin films, anti-reflection coating materials, machining, welding, etc. He holds two patents. Amir Mostafaei, PhD, is an assistant professor in the Department of Mechanical, Materials, and Aerospace Engineering at the Illinois Institute of Technology, Chicago. He has published more than 65 research papers in international/national journals and six book chapters. C. Moganapriya, PhD, is an associate professor in the School of Mechanical Engineering at Vellore Institute of Technology, Chennai, Tamil Nadu, India. Her research focuses on material technology, manufacturing, cryogenic treatments, process optimization, and solar cells. She has published more than 40 research articles and 37 book chapters. P. Sathish Kumar, PhD, is a research scientist at King Mongkut’s University of Technology North Bangkok, Thailand. His research interests include polymer nanocomposites/composites, polymer blends and biomaterials, mechanical behavior of materials, thin film coating, etc.

• Preface xix1 Technologies for Additive Manufacturing of Metals and Their Classification 1Bhuvanesh Kumar M., Justus Panicker C. T. and Arivazhagan D.1.1 Introduction 11.2 Metal Additive Manufacturing Process (MAMP) 21.3 Classification of MAMP Based on Technologies 41.4 Liquid-Based MAMP: Liquid Metal 3D Printing 41.5 Solid-Based MAMP: Ultrasonic Additive Manufacturing 61.6 Powder-Based MAMP 71.7 Wire-Based MAMP: Wire DED 141.8 Applications 201.9 Conclusion 21References 222 Challenges and Complications in Metal Additive Manufacturing During Post Processing 27Bhaskar Kumar, Amit Kumar and Sonu Rajak2.1 Introduction 272.2 Various Post Processing Methods 322.3 Future Scope and Aspects 352.4 Conclusion 36References 363 Mechanics and Modeling of Metal Additive Manufacturing Using Directed Energy Deposition Method 39Amit Kumar, Bhaskar Kumar and Sonu Rajak3.1 Introduction 393.2 Computational Modeling 443.3 Nucleation Modeling 483.4 Conclusion 51References 514 Rapid Additive Manufacturing of Metals Using the Cold Spray Technology: Progress and Challenges 55Rija Nirina Raoelison4.1 Introduction 554.2 Progress in Cold Spraying Towards an Implementation as a Fast AM Route for Metals 564.3 Processing Science of Cold Spraying from Coating to Additive Manufacturing 604.4 Cold Spraying Modern System for an Additive Manufacturing Application 614.5 Robotic Technology and Computerized Program Execution in Cold Spraying 634.6 Robotic Programming and Deposition Strategy for CSAM 644.7 Current Achievements in CSAM of Metallic Parts 664.8 Porosity Issue Due to the Additive Growth and Methods for Pore Reduction 694.9 Issue of Clogging in CSAM and Concept of Aerospike Nozzle as Potential Solution 734.10 Future Research Directions 754.11 Conclusion 76References 775 Principles of Material Extrusion in Metal Additive Manufacturing 83Ishak Ertugrul and Osman Ulkir5.1 Introduction 845.2 Additive Manufacturing Technology 845.3 Basic Additive Manufacturing Methods 855.4 Extrusion Principle 895.5 Metal Extrusion with Additive Manufacturing 925.6 Industrial Applications and Examples 935.7 Future Potential and Innovative Approaches 945.8 Conclusion 95References 966 Material Design: A ‘Material’ Way to Improve Additive Manufacturing 99Jiangqi Zhu, Cheng Chang, Shuohong Gao, Xingchen Yan and Min Liu6.1 Introduction 996.2 Conventional Alloys for MAM 1026.3 Limitations of Conventional Alloys for MAM 1046.4 Material Design for Metal Additive Manufacturing 1066.5 Alloys Designed for AM 1126.6 Perspective and Future Directions 1156.7 Summary 116References 1177 Metal Powder Feedstock Production for Additive Manufacturing 125Palivela Bhargav Chandan, Devara Venkata Krishna and Mamilla Ravi Sankar7.1 Introduction 1257.2 Different Stages in Metal Powder Production 1277.3 Feedstock Selection 1287.4 Processes 1307.5 Powder Processing 1547.6 Discussion 1547.7 Conclusion 160Acknowledgments 160References 1608 Additive Manufacturing of Intermetallic-Based Alloys: A Review 169Chaoyue Chen, Chaojun Xie, Tingwei Cao, Jiang Wang and Zhongming Ren8.1 Introduction 1698.2 Basic Properties of Intermetallic Alloy 1718.3 Additive Manufacturing Techniques 1778.4 NiAl-Based Alloys 1798.5 Metallurgical Defects 1798.6 Microstructure 1818.7 Mechanical Properties 1848.8 Ni 3 Al-Based Alloys 1868.9 Metallurgical Defects 1878.10 Microstructure 1888.11 Mechanical Properties 1928.12 TiAl-Based Alloy 1948.13 Microstructure 1978.14 Mechanical Properties 2008.15 Conclusion and Perspectives 201Acknowledgments 203References 2039 Mechanical Behavior of 3D Printed Parts 211Sandhyarani Biswas, Himanshu Singh and Jagdish Uday Khatu9.1 Introduction 2119.2 Metal AM and its Classification 2139.3 Metal AM Processes and the Mechanical Properties of Printed Parts 2149.4 Effect of Post-Processing on the Mechanical Properties of 3D Printed Metal Parts 2249.5 Challenges and Opportunities for Metal AM 2259.6 Conclusion 228References 22810 Processing of Hydrogels with Metallic Additives in Additive Manufacturing 235Magdalena B. Łabowska, Maria Skrodzka, Adrianna Cieślak, Patrycja Szymczyk-Ziółkowska, Agnieszka Adamczyk and Jerzy Detyna10.1 Introduction 23510.2 Methods for Incorporating Metal Additives into Hydrogels 23810.3 Metal Additives from Physical Cross-Linking Processes 23810.4 Metal Additives as Metal Powder Feedstock 23910.5 Metal Additives as Metal Nanoparticles 24010.6 Application Areas for Hydrogels with Metallic Additives 24210.7 Future Perspectives and Conclusions 249References 25011 Additive Manufacturing Simulation: Molten Pool Dynamics, Solidification Microstructure, and Powder Behavior 255Songzhe Xu, Ling Shi, Chaoyue Chen, Jiang Wang and Zhongming Ren11.1 Introduction 25511.2 Simulation of Molten Pool Dynamics 25611.3 Simulation of Grain Structure 26011.4 Simulation of Dendrite Growth 26511.5 Simulation of Powder Behavior 26711.6 Conclusion and Future Prospects 270References 271Appendix 27512 Underlying Principles and Applications of Cold Spray Additive Manufacturing 279Amritbir Singh, Himanshu Kumar and S. Shiva12.1 Introduction 27912.2 Emergence of Cold Spray Additive Manufacturing 28112.3 Variables Affecting the CS Consolidations 28212.4 Bonding Mechanism in CSAM 28512.5 Locked Up Stresses in CSAM 28612.6 Type of Structure Fabricated Using CSAM 28812.7 Applications 289References 29113 Comparison of Different Metal Additive Manufacturing Techniques for Biomedical Application 297Maria Skrodzka, Adrianna Cieślak, Patrycja Szymczyk-Ziółkowska, Magdalena B. Łabowska, Maja Ducka and Jerzy Detyna13.1 Introduction 29713.2 Powder Bed Fusion (PBF) 29913.3 Binder Jetting (BJ) 30613.4 Material Extrusion (MEX) 30813.5 Direct Energy Deposition (DED) 31113.6 Sheet Lamination (SHL) 31413.7 Material Jetting (MJ) 31713.8 Conclusion 32113.9 Future Direction and Challenges 322References 32314 Application of Metal Additive Manufacturing for Metal Matrix Composites 333P. Lakshmikanthan, K. Senthilvel and B. Prabu14.1 Introduction 33314.2 Metal Matrix Composite (MMC) 33514.3 Additive Manufacturing of MMCs 33814.4 Techniques of Metal Matrix Composites-Based Additive Manufacturing (AM) 33914.5 MMCs Processing by 3D Printing 34414.6 Application of Additive Manufacturing Product 34414.7 Key Challenges 35114.8 Summary and Future Work 352References 35215 Transforming Supply Chains (SCs) with Additive Manufacturing (AM): A Paradigm Shift in Production 359Vaishnavi Vadivelu, Prakash Nachimuthu and Parthasarathy Karthikeyan15.1 Introduction 35915.2 AM in Supply Chain Management 36015.3 Impact of AM in Supply Chain 36215.4 Smart Supply Chain with AM 36315.5 AM Contribution to Flexibility in the Intelligent Supply Chain 36515.6 Supply Chain Framework for AM 36815.7 Supply Chain Structure Impacts of AM 37615.8 Traditional Manufacturing (TM) 37615.9 Spare Part Management 38315.10 AM in Apparel Industry 38915.11 Benefits of AM in Supply Chain 39415.12 Cyber Risks in the AM Supply Chain 39515.13 Barriers in AM Implementation in Supply Chain 39615.14 Conclusion 398References 39816 Multi-Material Additive Manufacturing for Biomedical Applications 407Devara Venkata Krishna, Palivela Bhargav Chandan and Mamilla Ravi Sankar16.1 Introduction 40716.2 Additive Manufacturing of Multi-Materials for Biomedical Applications 40816.3 Additively Manufactured Multi-Material Components for Bio-Medical Applications 41516.4 Conclusion 426Acknowledgment 426References 42717 Digital Light Processing (DLP)–Based Three-Dimensional Printing for Biomedical Applications 433Devera Venkata Krishna, Sunkara Venkata Naga Sai Surya, Palivela Bhargav Chandan and Mamilla Ravi Sankar17.1 Introduction 43317.2 Photocurable Materials 43517.3 Photoinitiators 43617.4 Synthesis of the Hydrogel 43917.5 Applications in Biomedical Engineering 44117.6 Conclusion and Future Aspects 449Acknowledgment 450References 45018 Salient Aspects of 3D Printed Microfluidic Device–Based Organ-on-a-Chip Models for Futuristic Healthcare Applications 459Devara Venkata Krishna, Palivela Bhargav Chandan, Deyyala Sai Venkat and Mamilla Ravi Sankar18.1 Introduction 45918.2 Biodegradable Materials for the Organ-on-a-Chip Model 46218.3 Fabrication of MFDs Through 3D Printing 46618.4 Evolution and Applications of Microfluidic Chips 47318.5 Conclusion 485Acknowledgment 487References 48719 Smart Hydrogels for Tissue Engineering Applications 497Devara Venkata Krishna, Venneti Lakshmi Sri Vijay Srinivas, Palivela Bhargav Chandan, Mamilla Ravi Sankar and Thopireddy Nagendra Reddy19.1 Introduction 49719.2 Classification of Smart Hydrogels 49919.3 Synthesis of Smart Hydrogels 50519.4 Applications of Smart Hydrogels for Tissue Engineering 50819.5 Conclusion 516Acknowledgment 516References 516Index 527