10.1.3 Product Design Framework for AM with Integration of Topology Optimization 424
10.1.4 Multifunctional Optimization Methodology for DfAM 427
10.1.5 AM Process Model for Product Family Design 427
10.2 Design Rules and Guidelines 427
10.2.1 Laser Powder Bed Fusion (LPBF) 427
10.2.2 Electron Beam Powder Bed Fusion (EB-PBF) 431
10.2.3 Binder Jetting 433
10.2.4 Technologies Compared 434
10.3 Topology Optimization for Additive Manufacturing 434
10.3.1 Structural Optimization 435
10.3.2 Topology Optimization 436
10.3.3 Design-Dependent Topology Optimization 444
10.3.4 Efforts in AM-Constrained Topology Optimization 450
10.4 Lattice Structure Design 458
10.4.1 Unit Cell 458
10.4.2 Lattice Framework 459
10.4.3 Uniform Lattice 460
10.4.4 Conformal Lattices 462
10.4.5 Irregular/Randomized Lattices 462
10.4.6 Design Workflows for Lattice Structures 463
10.5 Design for Support Structures 473
10.5.1 Principles that Should Guide Support Structure Design 474
10.5.2 Build Orientation Optimization 474
10.5.3 Support Structure Optimization 476
10.6 Design Case Studies 483
10.6.1 Redesign of an Aerospace Bracket to be Made by LPBF 484
10.6.2 Design and Development of a Structural Member in a Suspension Assembly Using EB Powder Bed Fusion 487
10.6.3 Binder Jetting of the Framework of a Partial Metal Denture 488
10.6.4 Redesign of a Crank and Connecting Rod 490
10.6.5 Redesign of a Mechanical Assembly 492
10.6.6 Solid-Lattice Hip Prosthesis Design 498
10.7 Summary 501
References 501
11 Monitoring and Quality Assurance for Metal Additive Manufacturing 507
11.1 Why are Closed-Loop and Quality Assurance Platforms Essential? 507
11.2 In-Situ Sensing Devices and Setups 509
11.2.1 Types of Sensors Used in Metal AM 509
11.2.2 Mounting Strategies for In-line Monitoring Sensors in Metal AM Setups 521
11.3 Commercially Available Sensors 522
11.3.1 LPBF Commercial Sensors 522
11.3.2 LDED Commercial Sensors 525
11.4 Signal/Data Conditioning, Methodologies, and Classic Controllers for Monitoring, Control, and Quality Assurance in Metal AM Processes 526
11.4.1 Signal/Data Conditioning and Controllers for Melt Pool Geometrical Analysis 526
11.4.2 Signal/Data Conditioning and Methodologies for Temperature Monitoring and Analysis 531
11.4.3 Signal/Data Conditioning and Methodologies for the Detection of Porosity 532
11.4.4 Signal/Data Conditioning and Methodologies for Detection of Crack and Delamination 537
11.4.5 Signal/Data Conditioning and Methodologies for Detection of Plasma Plume and Spatters 538
11.5 Machine Learning for Data Analytics and Quality Assurance in Metal AM 539
11.5.1 Supervised Learning 539
11.5.2 Unsupervised Learning 549
11.6 Case Study 553
11.6.1 Design of Experiments 554
11.6.2 In-Situ Sensors and Quality Assurance Algorithm 555
11.6.3 Correlation Between CT Scan and Analyzed Data 560
11.7 Summary 563
References 565
12 Safety 577
12.1 Introduction 577
12.2 Overview of Hazards 578
12.3 AM Process Hazards 578
12.4 Laser Safety in Additive Manufacturing 579
12.4.1 Laser Categorization 579
12.4.2 Laser Hazards 581
12.4.3 Eye Protection 584
12.4.4 Laser Protective Eyewear Requirements 584
12.5 Electron Beam Safety 585
12.6 Powder Hazards 585
12.6.1 Combustibility 586
12.7 Human Health Hazards 587
12.8 Comprehensive Steps to AM Safety Management 587
12.8.1 Engineering Controls 587
12.8.2 Personal Protective Equipment 588
12.8.3 AM Guidelines and Standards 588
12.9 Summary 589
References 590
Index 591
Additive Manufacturing (AM)—also commonly referred to as 3D printing—builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise.
Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource:
Provides a thorough analysis of AM processes and their theoretical foundations Explains the classification, advantages, and applications of AM processes Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software Discusses the opportunities, challenges, and current and emerging trends within the field Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes Includes illustrative cases studies and numerous figures and tables Featuring material drawn from the lead author’s research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.