Metal Powder-Based Additive Manufacturing

Kun Zhou is a Professor of Mechanical Engineering in the School of Mechanical and Aerospace Engineering at Nanyang Technological University, Singapore. His research interests focus on mechanics of materials and additive manufacturing. He has founded the journal Smart Manufacturing and serves as its Editor-in-Chief. He is also a co-founder of Journal of Micromechanics and Molecular Physics and serves as its Co-Editor-in-Chief. He was elected Fellow of Institution of Mechanical Engineers, Royal Aeronautical Society, Royal Society of Chemistry, Institute of Physics, and Institute of Materials, Minerals & Mining. Changjun Han is an Associate Professor in the School of Mechanical and Automotive Engineering at South China University of Technology, China. He achieved his Ph.D. from Huazhong University of Science and Technology in 2018 and subsequently worked as a postdoctoral fellow in the School of Mechanical and Aerospace Engineering at Nanyang Technological University, Singapore for over two years. He has rich experience in additive manufacturing of metallic materials. He serves as an Associate Editor of Smart Manufacturing.

• Biography ixPreface xi1 Introduction 11.1 History and Fundamentals of AM 11.2 AM Techniques 21.3 Metal Powder–Based AM 81.4 Post-Processing 81.4.1 Surface Quality Improvement 91.4.2 Residual Stress Relief and Defect Reduction 111.4.3 Aesthetic Improvement 111.5 Powder Properties and Characterization Methods 121.5.1 Particle Morphology 121.5.2 Particle Size Distribution 141.5.3 Density 151.5.4 Flowability 161.5.5 Chemical Composition 181.5.5.1 Surface Analysis Methods 181.5.5.2 Bulk Analysis Methods 181.5.6 Microstructure 191.6 Challenges and Future Trends of Metal Powder–Based AM 211.7 Summary 23References 232 Metal Powder Preparation Processes 272.1 Atomization 272.1.1 Gas Atomization 282.1.2 Water Atomization 352.1.3 Plasma Atomization 382.1.4 Plasma Rotating Electrode Process 412.2 Mechanical Mixing 442.3 Reduction Process 502.3.1 Hydride–Dehydride Process 502.3.2 Oxide Reduction 532.3.3 Chloride Reduction 562.3.4 Carbonyl Reactions 572.4 Powder Modification 582.4.1 Plasma Spheroidization 582.4.2 Granulation–Sintering–Deoxygenation 612.4.3 Fluidized-bed Granulation 642.5 Summary 65References 673 Laser Powder Bed Fusion 753.1 History 753.2 Fundamentals 763.3 Printing Process 813.3.1 Melt Pool 823.3.2 Balling 863.3.3 Spattering 883.4 Metallurgical Defects 913.4.1 Porosity 913.4.2 Cracks and Warpage 963.5 Powder Materials 1023.6 Equipment 1063.7 Typical Materials Used in LPBF 1093.7.1 Titanium and Its Alloys 1093.7.2 Aluminum Alloys 1213.7.3 Nickel Alloys 1263.7.4 Iron Alloys 1293.7.5 Others 1323.7.5.1 Cobalt Alloys 1323.7.5.2 Copper Alloys 1323.7.5.3 Magnesium Alloys 1333.7.5.4 High-Entropy Alloys 1353.8 Mechanical Metamaterials for LPBF 1353.8.1 Fundamentals of Mechanical Metamaterials 1363.8.2 Mechanical Metamaterials with High Young’s Modulus 1373.8.3 Mechanical Metamaterials with High Shear and Bulk Moduli 1433.8.4 Mechanical Metamaterials with Zero or Negative Poisson’s Ratio 1463.9 Summary 148References 1504 Electron Beam Melting 1614.1 History 1614.2 Fundamentals 1624.3 Preheating and Melting Processes 1654.4 Metallurgical Defects 1684.5 Powder Materials 1714.6 Equipment 1724.7 Microstructures and Mechanical Properties 1734.7.1 Titanium and Its Alloys 1744.7.2 Nickel Alloys 1794.7.3 Cobalt Alloys 1804.7.4 Iron Alloys 1834.7.5 Others 1844.7.5.1 Copper and Its Alloys 1844.7.5.2 High-Entropy Alloys 1854.8 Summary 185References 1865 Laser-Based Directed Energy Deposition 1915.1 History 1915.2 Fundamentals 1925.3 Deposition Process 1955.4 Metallurgical Defects 1995.5 Powder Materials 2025.6 Equipment 2035.7 Microstructure and Mechanical Properties 2095.7.1 Titanium and Its Alloys 2095.7.2 Nickel Alloys 2145.7.3 Iron Alloys 2185.7.4 Others 2215.7.4.1 Aluminum Alloys 2215.7.4.2 Copper and Its Alloys 2235.7.4.3 High-Entropy Alloys 2295.8 Summary 230References 2316 Metal Binder Jetting 2376.1 History 2376.2 Fundamentals 2376.3 Printing Process 2396.4 Raw Materials 2456.5 Equipment 2476.6 Microstructure and Mechanical Properties 2496.6.1 Iron Alloys 2506.6.2 Nickel Alloys 2526.6.3 Titanium and Its Alloys 2546.6.4 Copper and Its Alloys 2556.6.5 Refractory Metals 2566.6.6 Others 2576.7 Summary 259References 2597 Applications 2637.1 Aerospace 2637.2 Biomedical 2707.3 Automotive 2757.4 Molding and Tooling 2777.5 Energy 2817.6 Jewelry 2857.7 Marine, Oil, and Gas 2877.8 Challenges and Risks 289References 290Index 295