Advances in Additive Manufacturing: Materials, Processes and Applications (Lecture Notes in Mechanical Engineering)

✍ Scribed by Tarek Mabrouki (editor), Habib Sahlaoui (editor), Haifa Sallem (editor), Farhat Ghanem (editor), Nourredine Benyahya (editor)

• Publisher: Springer
• Year: 2023
• Tongue: English
• Leaves: 257
• Edition: 1st ed. 2024
• Category: Library

✦ Synopsis

This book reports on research and developments in the field of 3D printing, with a special emphasis on methods to analyse the products of additive manufacturing, and optimize different steps of the manufacturing process. Gathering selected contributions to the 2nd Advances in Additive Manufacturing Conference (AIAM' 2023), held on Mai 18-20, 2023, in Hammamet, Tunisia, this book covers a variety of topics, including: analysis of microstructure and material behavior, numerical simulation and model techniques for optimization of manufacturing processes, machine learning for quality control and automated monitoring, among others. Offering a good balance of fundamental research and industrially relevant findings, this book provides researchers and professionals with a timely snapshot of and extensive information on current developments in the field and a source of inspiration for future research and collaboration.

✦ Table of Contents

Preface
Contents
Control of the Microstructure and Mechanical Properties of a Super Duplex SAF 2507 Steel Produced by Additive Manufacturing
1 Introduction
2 Material and Methods
2.1 Powder
2.2 LPBF Process
2.3 Heat Treatments
2.4 Characterization Methods
3 SAF 2507 Printability by LPBF Process
3.1 LPBF Material Density
3.2 As-Built Microstructure
4 Duplex Microstructure Generation
5 Mechanical Properties
6 Conclusion
References
Microstructure and Mechanical Properties of Hybrid LPBF-DED Inconel 625
1 Introduction
2 Materials and Method
2.1 Fabrication of Samples
2.2 Mechanical Tests
2.3 Microstructural Characterization
3 Results
3.1 Hybrid LPBF-DED Inconel 625: Microstructure
3.2 Micro-hardness
3.3 Tensile Behavior
3.4 Tensile Behavior
4 Discussion
4.1 Static Properties and Microstructure
4.2 Fatigue Properties: Defects
5 Conclusion
References
Manufacturability of CoCrFeNiMnzAlxCuy High Entropy Alloy by Laser Powder Bed Fusion
1 Introduction
2 Materials and Methods
2.1 Powders
2.2 Sample Building
2.3 Heat Treatment
2.4 Sample Analysis
3 Results
3.1 Chemical Composition
3.2 Samples Structure in the As-Printed State
3.3 Mechanical Properties in the As-Printed State
3.4 Effect of Thermal Treatment
4 Discussion
4.1 Impact of Al and Cu Concentration on the Mechanical Properties
4.2 LPBF Induced Phase Repartition
5 Discussion
References
Mechanical Properties of Additively Manufactured 17-4PH SS: Heat Treatment
1 Introduction
2 Experiments
2.1 SLM process
2.2 Heat Treatments
2.3 Mechanical Characterization
3 Results and Discussion
3.1 Microhardness and Impact-Strength Energy Measurements
3.2 Wear Performance
4 Conclusion
References
Nitinol Stents Printed by Selective Laser Melting
1 Introduction
2 Methods
3 Results and Discussion
4 Conclusion
References
Preliminary Study of Geometric Defects and Topography of Bio-Carriers Fabricated by the FDM Printing Process
1 Introduction
2 Materials and Methods
2.1 Experimental Methods and Materials
2.2 Design Of Experience (DOE).
3 Results and Discussion
3.1 Geometric Defect
3.2 Topography Defect
4 Conclusion and Perspectives
References
Determination of Mechanical Parameters of 3D-Printed Parts: Experimental and Numerical Analyses
1 Introduction
2 Experimental Results
3 Determination of the Anisotropy Coefficients
4 Simulation of a Flat-Ring Part Under Compression
5 Conclusion
References
3D Printed Educational Robotic Arm
1 Introduction
2 Prototype’s Design
2.1 Base Parts
2.2 Parallelogram Linkage Parts
2.3 The Gripper Parts
3 3D Printing of the Prototype
4 Conclusion
References
Topological Optimization of Ti-6Al-4V Knee Prostheses Through Lattice Structures for Enhanced Mechanical Performance
1 Introduction
2 Topology Optimization for Additive Manufacturing
3 Case Study of Topology-Optimized Design
3.1 The General Workflow
3.2 The Chosen Software for Optimisation
3.3 Identification of the Implant: Knee Prosthesis
3.4 Material Identification
3.5 Topological Optimization of Femoral Component by Lattice Structures
3.6 Mesh of the Part
3.7 Load and Boundary Conditions
4 Results and Discussion
5 Conclusion and Perspectives
References
Manufacturing of Cranial Implant Using SPIF and 3D Printing
1 Introduction
2 Methodology
2.1 Scan, CAD, CAM and 3d Processing:
2.2 Incremental Sheet Forming (SPIF)
2.3 3D Printing (FDM)
2.4 3D Scan of the Finished SPIF and Printed Part.
3 Results
4 Conclusion
References
New Horizons in Engineering Education: From Additive Manufacturing to Immersive Learning
1 Introduction
2 Additive Manufacturing at Lab 4.0
3 Toward Immersive Simulation-Based Learning
4 Impact on Engineering Education
5 Conclusion
References
Exploring Human-Cyber-Physical Systems in Additive Manufacturing: Insights into Human-Machine Collaboration
1 Introduction
2 Human-Machine Collaboration in Additive Manufacturing
3 Concept of Human-Machine Collaborative Additive Manufacturing (HMCAM)
4 Conclusion
References
Simplification of an Additive Manufacturing Machine Implementation Using Its CAD Model and Mixed-Reality
1 Introduction
2 Literature Review
3 Experimental Setup
4 Results and Interpretation
5 Conclusion
References
A CAD-Based Method for the Measurement of AM Parts Accuracy Considering the Build Orientation
1 Introduction
2 State of the Art
3 Determination of the Build Orientation Effect on the Dimensional Accuracy
3.1 3D Printing of the Part P1
3.2 3D Scan and Reconstruction of the Part P1 Features
4 Dimensional Accuracies of Cylindrical and Rectangular Features According to Different Build Orientations
5 Conclusion
References
Thermal Study for Optimization of the Thermomechanical Welding Butt Fusion Process of the PEHD Tubes (PE100)
1 Introduction
2 Description of the Experimental
3 Results and Interpretation
3.1 Study of the Temperature During the Equalization and Heating Phases
3.2 Study of the Temperature During the Welding and Cooling Phases
4 Conclusion
References
Additive Manufacturing and Investment Casting Comparison of Superalloys: Aerospace industry
1 Introduction
2 Investment Casting
3 Additive Manufacturing
3.1 AM - Processes
3.2 AM - High Temperature Applications Alloys
4 Additive Manufacturing vs Investment Casting
5 Conclusion
References
The Impact of the Adaptive Slicing Integration on the AM Cost
1 Introduction
2 State of the Art
3 Case Study
3.1 The Results
3.2 The Discussion
4 Conclusion
References
In-Situ Monitoring of Selective Laser Melted Ti–6Al–4V Parts Using Eddy Current Testing and Machine Learning
1 Introduction
2 Experimental Methods
2.1 SLM Dataset Collection: In-Situ Eddy Current Testing (ECT)
2.2 Sample Manufacturing
2.3 Porosity Analysis and Labeling
2.4 Correlation
3 Data Description
3.1 ECT Signal Processing Method
3.2 Dataset Construction and Splitting
4 Algorithms
4.1 Baseline: SVM with Statistical Description Windows
4.2 Neural Network: CNN – LSTM
4.3 Neural Network: CNN2D
5 Results and Evaluation
6 Conclusion
References
Non-conformities and Scrap Costs Reduction in a 3D Printing Workshop
1 Introduction
2 Characteristics of 3D Printing Machines
3 Methodology
3.1 Define the Problem
3.2 Root Cause Analysis
3.3 Definition of Solutions
3.4 Implementation of Improvement Actions
3.5 Review of Results and Discussion
4 Conclusion
References
Contribution to the Formulation of a Material Based on Marble Waste for Its Use in 3D Printing in Civil Engineering
1 Introduction
2 Methodology
2.1 Valorization Alternatives of Marble Powder for 3D Printing
2.2 Gypsum Properties
2.3 Limes Properties
2.4 Chemical Reaction Between Marble Powder and Gypsum
2.5 Chemical Reaction Between Marble Powder and Lime
3 Material Characterization Tests for 3D Printing
3.1 Marble Powder Characterization Tests for 3D Printing
3.2 Gypsum Characterization Tests for 3D Printing
3.3 Lime Characterization Tests for 3D Printing
4 Materials and Methods
4.1 Robot Manufacturing Process for 3D Printing in Civil Engineering
4.2 Experimental Protocol
4.3 Printing Settings
4.4 Formulation of a Material for Use in 3D Printing in Civil Engineering
4.5 Mixing Element Testing after 3D Printing
5 Conclusion
References
Easy Conversion of PET Bottles to Eco-Filament for 3D Printing and Process Characterization
1 Introduction
2 Materials and Method
2.1 Elaboration
2.2 Characterization
3 Results and Discussion
4 Conclusion
References
Modeling and Optimization of Joint Condition Based Quality/Maintenance Strategy for an Additive Manufacturing Equipment
1 Introduction
2 Problem Statement
2.1 The Industrial Example Case
2.2 Integrated Strategy
2.3 Mathematical Model
3 Numerical Study
4 Conclusion
References
Experimental and Numerical Study of the Wire Arc Additive Manufacturing (WAAM) Process
1 Introduction
2 Experimental Study
2.1 Equipment
2.2 Materials
2.3 Methods
3 Numerical Modeling
3.1 Geometrical Specifications of the FEM Model
3.2 Material Properties and Weld Heat Source Model
3.3 Results of Simulations
4 Conclusion
References
Parameters Effect Study on Bead Geometry Deposited by CMT Technology Based Wire Additive Manufacturing (WAAM) Process
1 Introduction
2 Materials and Methods
3 Results and Discussions
3.1 ANOVA Analysis
3.2 Graphical Analysis
4 Conclusion
References
Use of the RDPP-SF Method for Robust Design of Dynamic AM-Fused Deposition Modeling Process
1 Introduction
2 The Dynamic RDPP-SF Method (DRDPP-SF)
3 The Dynamic RDPP-SF Method: A Case Study
4 Discussion and Findings
5 Conclusion
References
Effect of Printing Process Parameters on the Tensile Behavior of FDM-Built Parts
1 Introduction
2 Experimental Protocol
2.1 FDM Process and Materials
2.2 Experimental Design
2.3 Samples Manufacturing
2.4 Tensile Tests
3 Results and Discussion
4 Conclusion
References
Experimental Investigation of SLM Parameters Effects on Roughness of 316L Parts
1 Introduction
2 Principle of the SLM Process
3 Experimental Study
3.1 Design of Experiments
3.2 Part Printing
3.3 Roughness Measurement
4 Experimental Results
4.1 Top Surface Roughness
4.2 Build Surface Roughness
5 Conclusion
References
Experimental Study of Morphological Defects Generated by SLM on 17-4PH Stainless Steel
1 Introduction
2 Experimental Procedures
3 Results and Discussion
3.1 Surface Topography and Roughness
3.2 Morphological Analysis
4 Conclusion
References
Author Index