Post-Processing Techniques for Metal-Based Additive Manufacturing: Towards Precision Fabrication

✍ Scribed by Hao Wang, Yan Jin Lee, Yuchao Bai, Jiong Zhang

• Publisher: CRC Press
• Year: 2023
• Tongue: English
• Leaves: 289
• Category: Library

✦ Synopsis

This book shares insights on post-processing techniques adopted to achieve precision-grade surfaces of additive manufactured metals including material characterization techniques and the identified material properties.

Post-processes are discussed from support structure removal and heat treatment to the material removal processes including hybrid manufacturing. Also discussed are case studies on unique applications of additive manufactured metals as an exemplary of the considerations taken during post-processing design and selection.

• Addresses the critical aspect of post-processing for metal additive manufacturing

• Provides systematic introduction of pertinent materials

• Demonstrates post-process technique selection with the enhanced understanding of material characterization methods and evaluation

• Includes in-depth validation of ultra-precision machining technology

• Reviews precision fabrication of industrial-grade titanium alloys, steels, and aluminium alloys, with additive manufacturing technology

The book is aimed at researchers, professionals, and graduate students in advanced manufacturing, additive manufacturing, machining, and materials processing.

✦ Table of Contents

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
About the Authors
1 Introduction
1.1 Precision Manufacturing
1.2 Market for Precision Manufacturing
1.3 Machine Tools and Processes
1.3.1 Mechanical Machining
1.3.2 Electric Discharge Machining
1.3.3 Laser Machining
1.3.4 Status of Precision Surface Manufacturing
1.4 Additive Manufacturing Technology
1.4.1 Powder Bed Fusion (PBF) Processes
1.4.2 Directed Energy Deposition (DED)
References
2 Unique Properties of AM Metals
2.1 Material Characterization and Testing Techniques
2.1.1 Chemical Composition Analysis
2.1.1.1 Spectroscopic Analysis
2.1.1.2 Mass Spectrometry Analysis
2.1.1.3 Energy Spectrum Analysis
2.1.2 Microstructure and Phase Composition
2.1.2.1 Microstructure Analysis
2.1.2.2 Phase Analysis
2.1.3 Physical Properties
2.1.3.1 Thermal Properties
2.1.3.2 Electrical Properties
2.1.3.3 Magnetic Properties
2.1.4 Mechanical Properties
2.1.4.1 Hardness
2.1.4.2 Tensile Strength
2.1.4.3 Compression Strength
2.1.4.4 Torsional Strength
2.1.4.5 Bending
2.1.4.6 Toughness
2.1.4.7 Fatigue Strength
2.1.4.8 Friction and Wear
2.1.4.9 Creep
2.2 Characterization and Testing of AM Metals
2.2.1 Surface Morphology
2.2.2 Internal Defects
2.2.3 Chemical Composition and Element Distribution
2.2.4 Microstructure Characterization
2.2.5 Phase Composition and Transformation
2.2.6 Mechanical Properties
2.3 Concluding Remarks
References
3 Manufacturing Workflow
3.1 Manufacturing Process Chain
3.1.1 3D Model Creation
3.1.2 Raw Material Preparation
3.1.3 AM Parameter Selection
3.2 Support Structure Removal
3.2.1 Role of the Support Structure
3.2.2 Methods of Removing Support Structures
3.2.3 Balance of Support Structures
3.3 Microstructure Modification
3.3.1 Conventional Heat Treatment
3.3.2 Hot Isostatic Pressing
3.4 Concluding Remarks
References
4 Machinability of AM Metals
4.1 Aluminum-Based Alloys
4.2 Iron-Based Alloys
4.3 Titanium Alloys
4.4 Superalloys
4.5 High-Entropy Alloys
4.6 Other Metals
4.7 Concluding Remarks
References
5 Abrasive-Based Finishing Processes
5.1 Definition AND CLASSIFICATION
5.2 Bonded Abrasive Finishing Processes
5.2.1 Grinding
5.2.2 Mass Finishing
5.2.3 Magnetically Driven Internal Finishing
5.3 Unbonded Abrasive Finishing Processes
5.3.1 Sandblasting
5.3.2 Abrasive Flow Machining
5.3.3 Magnetic Abrasive Finishing
5.3.4 Cavitation Abrasive Finishing
5.4 Concluding Remarks
References
6 Thermal-Based Finishing Processes
6.1 Definition and Working Principle
6.1.1 Classification of Laser Polishing
6.1.2 Process Parameters in Laser Polishing
6.1.2.1 Workpiece Properties
6.1.2.2 Laser Subsystem Parameters
6.1.2.3 Mechanical Subsystem Parameters
6.1.3 Surface Defects in Laser Polishing
6.1.3.1 Laser Macro-Polishing
6.1.3.2 Laser Micro-Polishing
6.2 Laser Polishing of AM Metallic Parts
6.2.1 Challenges
6.2.2 Steel (Stainless Steel and Tool Steel)
6.2.3 Titanium and Its Alloys
6.2.4 Other Alloys (Inconel, CoCr, Al)
6.3 Concluding Remarks
References
7 Chemical-Based Finishing Processes
7.1 Definition and Classification
7.1.1 Chemical Etching (CE)
7.1.2 Electrochemical Polishing (ECP)
7.1.3 Hybrid Electrochemical Polishing
7.2 Chemical Etching of AM Parts
7.3 Electrochemical Polishing of AM Parts
7.3.1 External Surfaces
7.3.2 Internal Surfaces
7.4 Hybrid Polishing
7.5 Concluding Remarks
References
8 Theoretical Modeling Considerations for Post-Processing
8.1 Modeling Methodology
8.2 Finite Element Method Modeling
8.2.1 Thermal Modeling
8.2.2 Simulating the AM Process
8.2.3 Distortion After Additive Manufacturing
8.2.4 Development of Residual Stresses From Additive Manufacturing
8.2.5 AM Microstructure Modeling
8.2.6 Mechanical Modeling
8.2.7 Material Model for Large Deformation of Metals
8.2.8 Post-Process Residual Stresses
8.2.9 Post-Processing of Support Structures
8.3 Molecular Dynamics Simulations
8.3.1 Melting and Solidification
8.3.2 Defect Modeling
8.4 Concluding Remarks
References
9 Hybrid Additive Manufacturing
9.1 Successful Integrations
9.1.1 Hybrid Additive/Subtractive Manufacturing
9.1.2 Multi-Energy Field Coupled Hybrid Additive Manufacturing
9.1.3 Hybrid Additive/Semi-Forming Manufacturing
9.2 Multi-Material, Structural, and Functional Manufacturing
9.2.1 Multi-Material Manufacturing
9.2.2 Multi-Structural Manufacturing
9.2.3 Multi-Functional Manufacturing
9.3 Concluding Remarks
References
10 Case Studies
10.1 Lightweight Optical Surface Fabrication
10.1.1 Application
10.1.2 Material Selection
10.1.3 Process Flow
10.1.4 Shape Generation By Diamond Turning
10.1.5 Microstructure Modifications
10.1.6 Alternative Shape Generation Method 1: Ultrasonic Elliptical Vibration-Assisted Machining
10.1.7 Alternative Shape Generation Method 2: Replacing Optical Surface With Nickel-Phosphorous Coating
10.1.8 Finishing Processes
10.1.9 Summarized Workflow
10.2 Intravascular Stent Production
10.2.1 Application
10.2.2 Process Chain
10.2.3 Design and Fabrication
10.2.4 Mechanical-Based Finishing
10.2.5 Performance of Micro-Blasting
10.2.6 Performance of Electrochemical Polishing
10.2.7 Summarized Workflow
References
11 Future of Post-Processing
11.1 Review On Post-Processing Technologies
11.2 Surface Processing Innovations
11.2.1 Surface Effects
11.2.2 Field-Assisted Machining
11.2.3 Internal Finishing
11.3 Hybrid Additive Manufacturing
11.3.1 Artificial Intelligence
11.3.2 Field-Assisted Integrations
References
Index