Almangour Additive Manufacturing of Emerging Materials

1. Auflage 2019
ISBN: 978-3-319-91713-9
Verlag: Springer Nature Switzerland
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 353 Seiten

This book provides a solid background for understanding the immediate past, the ongoing present, and the emerging trends of additive manufacturing, with an emphasis on innovations and advances in its use for a wide spectrum of manufacturing applications. It contains contributions from leading authors in the field, who view the research and development progress of additive manufacturing techniques from the unique angle of developing high-performance composites and other complex material parts. It is a valuable reference book for scientists, engineers, and entrepreneurs who are seeking technologically novel and economically viable innovations for high-performance materials and critical applications. It can also benefit graduate students and post-graduate fellows majoring in mechanical, manufacturing, and material sciences, as well as biomedical engineering.

AlMangour has worked as a Postdoctoral Fellow at Harvard University, School of Engineering and Applied Science during 2017. Bandar AlMangour received his Ph.D. and Master of Science in Materials Science and Engineering from University of California, Los Angeles (UCLA) in 2014 and 2017 respectively, a Master of Engineering in Materials Engineering from McGill University in 2012, and a Bachelor of Science in Mechanical Engineering from King Fahd University of Petroleum and Minerals (KFUPM) in 2005. He served as a Research Engineer at the Saudi Basic Industries Corporation (SABIC) from Jun. 2008-Dec. 2009 and as a Production Supervisor in the Rolling Mills division from Apr. 2005-May 2008 at the Saudi Iron & Steel Company (HADEED), a SABIC affiliate in Jubail, Saudi Arabia. AlMangour is a member of several professional associations and still served as a reviewer in several internationally recognized journals. AlMangour has authored a book published by LAP LAMBERT Academic Publishing (2014) and a chapter for a book published by Nova Science Publishers (2015), as well as a chapter for a book published by Springer (2017). His principle research interests include the laser-based additive manufacturing of metal alloys and metal matrix composites, scalable micro- and nano-manufacturing, materials processing, physical metallurgy, bulk-form nanostructured alloys and composites, and surface engineering. AlMangour has authored more than 20 peer-reviewed papers in internationally recognized journals and presented research at several international conferences. He was awarded the SABIC Graduate Fellowships (Doctor of Philosophy, 2012-2017; Master of Engineering, 2010-2012), the Undergraduate Memorial Honor Medal (2005), Certificates of Distinction (KFUPM, 2004 and 2005), the Department of Materials Science and Engineering 'Outstanding Ph.D. Student Award' (2017), FEI Tony Award for best SEM image (2017).

Autoren/Hrsg.

Almangour, Bandar

Inhaltsverzeichnis

1;Contents;5
2;Additive Manufacturing of In Situ Metal Matrix Composites;7
2.1;1 Introduction;7
2.2;2 Metal Matrix Composites;9
2.2.1;2.1 In-Situ Reactions Between Elemental Blend Powders;11
2.2.1.1;2.1.1 Aluminum Matrix Composites: Al-Fe2O3;11
2.2.1.2;2.1.2 AlSi10Mg-SiC;13
2.2.1.3;2.1.3 Nickel Matrix Composites: Ni-Ti-C;15
2.2.1.4;2.1.4 Titanium Matrix Composites: Ti-B and Ti64-BN;20
2.2.2;2.2 In Situ Reaction Between Elemental Blend Powders and Reactive Gases;22
2.2.2.1;2.2.1 Ti-Mo-N;22
2.2.2.2;2.2.2 Ti64/TNZT-N;28
2.3;3 Summary;29
2.4;References;31
3;Optimization of Electrical Discharge Machining of Titanium Alloy (Ti6Al4V) by Grey Relational Analysis Based Firefly Algorithm;35
3.1;1 Introduction;35
3.2;2 Literature Review;37
3.3;3 Methodology;39
3.3.1;3.1 Grey Relational Analysis (GRA);39
3.3.2;3.2 Firefly Algorithm (FA);40
3.4;4 Materials and Methods;41
3.4.1;4.1 Material Removal Rate (MRR);45
3.4.2;4.2 Tool Wear Rate (TWR);46
3.4.3;4.3 Average Surface Roughness (Ra);46
3.5;5 Result and Discussion;48
3.5.1;5.1 Effect of Parameters on MRR;48
3.5.2;5.2 Effect of Parameters on TWR;50
3.5.3;5.3 Effect of Parameters on Average Surface Roughness;50
3.6;6 Optimization by Grey Relational Analysis Based Firefly Algorithm;53
3.7;7 Surface Crack Density of Machined Surface;56
3.8;8 Conclusion;57
3.9;References;58
4;Laser-Based Additive Manufacturing of Lightweight Metal Matrix Composites;60
4.1;1 Introduction;60
4.2;2 Additive Manufacturing Processes;61
4.3;3 Additive Manufacturing Versus Conventional Manufacturing;64
4.4;4 Additive Manufacturing Processes for Fabricating MMCs;67
4.4.1;4.1 Powder Bed Fusion (PBF) Processes;68
4.4.2;4.2 Direct Energy Deposition (DED) Processes;69
4.5;5 Challenges of MMCs Fabrication Using Additive Manufacturing Processes;71
4.6;6 Various Types of MMCs;72
4.6.1;6.1 Ex-Situ Reinforced MMCs;72
4.6.2;6.2 Hybrid Ex-Situ/In-Situ Reinforced MMCs;74
4.6.3;6.3 In-Situ Reinforced MMCs;75
4.6.4;6.4 TMCs with Metallic Reinforcements;78
4.6.5;6.5 Additively Manufactured Lightweight Metal Matrix Nano-Composites (MMnCs);79
4.7;7 Temperature-Driven Forces and Flows and Viscosity in Laser-Induced Melt Pools;81
4.7.1;7.1 Surface Tension and Marangoni Flow;81
4.7.2;7.2 Recoil Pressure;83
4.7.3;7.3 Rayleigh-Benard Convection;84
4.7.4;7.4 Dynamic Viscosity of Solid-Liquid Mixed Melt Pools;84
4.8;8 Parameters Affecting Microstructural Features of Reinforcements in Hybrid Ex-Situ/In-Situ Reinforced and In-Situ Reinforced ...;85
4.8.1;8.1 Laser Energy Density;85
4.8.1.1;8.1.1 Amount of In-Situ Reaction;86
4.8.1.2;8.1.2 Size of In-Situ Reaction Products;87
4.8.1.3;8.1.3 Morphology of In-Situ Synthesized Reinforcements;88
4.8.2;8.2 Characteristics of Powder Mixture;90
4.8.2.1;8.2.1 Size of Reinforcing Particles;90
4.8.2.2;8.2.2 Volume Fraction of Reinforcing Particles;90
4.9;9 Distribution Pattern of Reinforcements;93
4.9.1;9.1 Non-homogenous Distribution;93
4.9.1.1;9.1.1 Bimodal Distribution;93
4.9.1.2;9.1.2 Agglomeration or Clustering of Reinforcements;93
4.9.2;9.2 Homogenous Distribution of Reinforcements;95
4.9.3;9.3 Microstructures with Ring-Like Distribution Pattern of Reinforcements;96
4.10;10 Effect of Reinforcement Features on Mechanical Properties of Additively Manufactured Lightweight MMCs;99
4.10.1;10.1 Volume Fraction;99
4.10.2;10.2 Size;101
4.10.3;10.3 Distribution Pattern;101
4.11;11 Applications of Additively Manufactured Lightweight MMCs;102
4.12;References;104
5;Process-Structure-Property Relationships in Additively Manufactured Metal Matrix Composites;115
5.1;1 Introduction;115
5.2;2 Why AM Instead of Conventional Manufacturing for MMC Fabrication?;118
5.3;3 Additively Manufactured MMCs (Challenges, Opportunities and Existing Literature);119
5.3.1;3.1 Aluminum-Matrix Composites (AMCs);119
5.3.2;3.2 Titanium-Matrix Composites (TMCs);120
5.3.3;3.3 Nickel-Based Matrix Composites;122
5.3.4;3.4 Copper-Matrix Composites;123
5.3.5;3.5 Iron-Based Matrix Composites;124
5.4;4 Pre-processing of Mixed Powder System;126
5.5;5 Microstructural Evolution in Additively Manufactured MMCs;130
5.5.1;5.1 Characteristics of Reinforcements Distributed in the Matrix;131
5.5.1.1;5.1.1 Size and Morphology of Reinforcements;131
5.5.1.1.1;Ex-Situ Reinforced MMCs;131
5.5.1.1.2;In-Situ Reinforced MMCs;132
5.5.1.2;5.1.2 Distribution Pattern of Reinforcements;133
5.5.1.2.1;Effect of Scanning Speed;133
5.5.1.2.2;Effect of Energy Density;135
5.5.1.2.3;Effects of Size and Volume Fraction of Reinforcements;135
5.5.2;5.2 Reinforcement/Matrix Reactions;136
5.5.2.1;5.2.1 Reaction Mechanisms;136
5.5.2.2;5.2.2 Reinforcements/Matrix Interfacial Reaction;137
5.5.2.3;5.2.3 Formation of In-Situ Reaction Products;141
5.5.3;5.3 Microstructural Evolutions in the Matrix Induced by the Presence of Reinforcements;143
5.5.3.1;5.3.1 Microstructural Refinement of the Matrix;143
5.5.3.2;5.3.2 Texture of the Matrix;145
5.5.3.3;5.3.3 Microstructural Evolution and Phase Transformation;148
5.5.3.4;5.3.4 Formation of Supersaturated Matrix;151
5.5.3.5;5.3.5 Formation of Dislocations in the Matrix;152
5.6;6 Part Quality and Surface Integrity of AM Processed MMCs;153
5.6.1;6.1 Applied Energy Density;154
5.6.2;6.2 Characteristics of Mixed Powder System;156
5.7;7 Mechanical Properties of AM Processed MMCs;159
5.7.1;7.1 Strengthening Mechanisms;159
5.7.1.1;7.1.1 Direct Strengthening;160
5.7.1.1.1;Reinforcement Volume Fraction;161
5.7.1.1.2;Reinforcement Type;162
5.7.1.1.3;Reinforcement Size;162
5.7.1.2;7.1.2 Indirect Strengthening;163
5.7.1.2.1;Grain Refinement of the Matrix;164
5.7.1.2.2;Increased Density of Dislocations in the Matrix;165
5.7.1.2.3;The Matrix Strengthening Caused by Microstructural Modifications;166
5.7.1.2.4;Solid Solution Strengthening of the Matrix;167
5.7.2;7.2 Weakening Mechanisms;168
5.7.2.1;7.2.1 Decreased Densification Level;168
5.7.2.2;7.2.2 Microstructure Coarsening;168
5.7.2.3;7.2.3 Microstructural Inhomogeneity;169
5.8;8 Wear Behavior;169
5.8.1;8.1 Effect of Size and Volume Fraction of Reinforcements;169
5.8.2;8.2 Effect of Applied Energy Density;171
5.9;References;172
6;Additive Manufacturing of Titanium Alloys for Biomedical Applications;182
6.1;1 Introduction;182
6.2;2 Additive Manufacturing for Biomedical Application;183
6.2.1;2.1 Selective Laser Melting (SLM);184
6.2.2;2.2 Electron Beam Melting (EBM);186
6.3;3 Development of AM Biomedical Titanium Alloy;187
6.3.1;3.1 Selective Laser Melting (SLM) of Titanium Alloys;188
6.3.2;3.2 Electron Beam Melting (EBM) of Titanium Alloys;193
6.4;4 Conclusion;195
6.5;References;196
7;Corrosion Behaviors of Additive Manufactured Titanium Alloys;200
7.1;1 Introduction;200
7.2;2 SLM-Produced Ti-6Al-4V;201
7.3;3 EBM-Produced Ti-6Al-4V;211
7.4;4 SLM-Produced Ti-TiB;217
7.5;5 Other Alloys Produced by AM Technique;219
7.5.1;5.1 Co-Cr Based Alloys;219
7.5.2;5.2 SLM-Produced 316L Stainless Steel;221
7.6;6 Concluding Remarks;224
7.7;References;224
8;Effect of Process Parameters of Fused Deposition Modeling and Vapour Smoothing on Surface Properties of ABS Replicas for Biome...;230
8.1;1 Surface Finishing Techniques for FDM Parts;230
8.1.1;1.1 Pre-processing Techniques of Surface Finishing;230
8.1.2;1.2 Post-processing Techniques of Surface Finishing;232
8.2;2 Optimization Study of Process Parameters of FDM and Vs Processes;233
8.3;3 Mathematical Modeling of Surface Properties Using Buckingham Pi Theorem;243
8.3.1;3.1 Mathematical Model of Surface Roughness;243
8.3.2;3.2 Mathematical Model of Surface Hardness;244
8.3.3;3.3 Mathematical Model of Dimensional Accuracy;245
8.4;4 Multi-response Optimization;246
8.5;5 Differential Scanning Calorimetry;247
8.6;6 Summary;249
8.7;References;250
9;Development of Rapid Tooling Using Fused Deposition Modeling;253
9.1;1 Introduction;253
9.2;2 Development of Low Cost Composite Material Feedstock Filament;253
9.2.1;2.1 Fabrication of Filament on Single Screw Extruder;255
9.2.1.1;2.1.1 Rheological Behavior;255
9.2.2;2.2 Fabrication of Filament on Single Screw Extruder;257
9.2.2.1;2.2.1 Inspection and Testing;258
9.2.2.2;2.2.2 Mechanical Testing;259
9.2.2.3;2.2.3 Fabrication of Parts On FDM;260
9.2.2.4;2.2.4 Dynamic Mechanical Analysis;261
9.3;3 Results and Discussion;262
9.3.1;3.1 Rheological Properties;262
9.3.2;3.2 Mechanical Properties;263
9.3.3;3.3 Dynamic Mechanical Analysis;263
9.3.3.1;3.3.1 Viscoelastic Behavior of Composite Materials;263
9.3.3.1.1;Storage Modulus (E?);263
9.3.3.1.2;Loss Modulus (E??);265
9.3.3.1.3;Loss Factor or tan ? (E??/E?);266
9.3.3.2;3.3.2 Viscoelastic Behavior of ABS Material;267
9.4;4 Design of Experiments;268
9.4.1;4.1 Taguchi´s Approach;269
9.4.2;4.2 Data Analysis Using ANOVA;269
9.4.3;4.3 Analysis of Variance for SN ratios;270
9.4.4;4.4 Significance of Process Parameters;271
9.4.5;4.5 Optimum Parameters;271
9.4.6;4.6 Empirical Relationship;272
9.5;5 Process Capability Study;273
9.6;6 Conclusions;275
9.7;References;278
10;Development of ABS-Graphene Blended Feedstock Filament for FDM Process;280
10.1;1 Evolution of Conducting Polymers;280
10.2;2 Acrylo Nitrile Butadiene Styrene and Graphene;280
10.3;3 Extraction of Gr;281
10.4;4 Materials;282
10.5;5 Twin Screw Extrusion;282
10.6;6 Testing Techniques for ABS-Gr Blended Feedstock Filament;283
10.6.1;6.1 Lee´s Method for Thermal Conductivity;283
10.6.2;6.2 Measurement of Electrical Conductivity;284
10.6.3;6.3 Measurement of Porosity and Hardness;285
10.7;7 Optimisation Study of Process Parameter of FDM;285
10.8;8 Analysis of Electrical Conductivity Test;287
10.9;9 Analysis of Thermal Conductivity Test;289
10.10;10 Analysis of Porosity;291
10.11;11 Analysis of Shore Hardness;292
10.12;12 Optical Micrograph Observations for Porosity;294
10.13;13 Differential Scanning Calorimeter;295
10.14;14 Summary;297
10.15;References;297
11;Investigate the Effects of the Laser Cladding Parameters on the Microstructure, Phases Formation, Mechanical and Corrosion Pro...;299
11.1;1 Introduction;299
11.1.1;1.1 Evolution of MG;300
11.1.2;1.2 Mechanical Properties of MG;301
11.1.3;1.3 Biocompatibility of MG Systems;303
11.2;2 Techniques to Fabricate MG;305
11.2.1;2.1 Melt Spinning;306
11.2.2;2.2 Casting;306
11.2.3;2.3 Additive Manufacturing;307
11.2.3.1;2.3.1 Laser Cladding Technique for MG Coatings;308
11.2.3.2;2.3.2 Experimental Procedures;310
11.2.3.2.1;Sample Preparation;310
11.2.3.2.2;Characterization and Testing;311
11.2.3.3;2.3.3 Results;312
11.2.3.3.1;XRD Analysis;312
11.2.3.3.2;Microstructure Examination;315
11.2.3.3.3;Hardness Measurement;316
11.2.3.3.4;Electrochemical Corrosion Test;318
11.2.3.4;2.3.4 Conclusion;319
11.3;References;321
12;Fabrication of PLA-HAp-CS Based Biocompatible and Biodegradable Feedstock Filament Using Twin Screw Extrusion;324
12.1;1 Introduction;324
12.2;2 Melt Flow Index;326
12.2.1;2.1 Procedure to Determine Melt Flow Index;327
12.3;3 Extrusion;327
12.3.1;3.1 Twin Screw Extrusion;328
12.4;4 Fused Deposition Modeling (FDM);328
12.4.1;4.1 The Technology;328
12.4.2;4.2 Process;329
12.5;5 Differential Scanning Calorimetry (DSC);329
12.5.1;5.1 Techniqe;329
12.6;6 Materials and It´s Prepration;331
12.6.1;6.1 Materials;331
12.6.1.1;6.1.1 Preparation of Materials (PLA, HAp and CS);331
12.7;7 Preparation of Feed Stock Filament On TSE for FDM;331
12.7.1;7.1 Rehological Behavior;331
12.7.2;7.2 Tensile Behavior;332
12.7.3;7.3 Thermal Behavior;333
12.7.4;7.4 Scanning Electron Microscopic Behavior;334
12.7.5;7.5 Design of Experiment (DOE);335
12.7.6;7.6 Fabrication of Feedstock Filament Based on DOE;337
12.8;8 Summary;341
12.9;References;342
13;Index;345