Solid-State Metal Additive Manufacturing: Physics, Processes, Mechanical Properties, and Applications

✍ Scribed by Hang Z. Yu (editor), Nihan Tuncer (editor), Zhili Feng (editor)

• Publisher: Wiley-VCH
• Year: 2024
• Tongue: English
• Leaves: 395
• Edition: 1
• Category: Library

✦ Synopsis

Solid-State Metal Additive Manufacturing

Timely summary of state-of-the-art solid-state metal 3D printing technologies, focusing on fundamental processing science and industrial applications

Solid-State Metal Additive Manufacturing: Physics, Processes, Mechanical Properties, and Applications provides detailed and in-depth discussion on different solid-state metal additive manufacturing processes and applications, presenting associated methods, mechanisms and models, and unique benefits, as well as a detailed comparison to traditional fusion-based metal additive manufacturing.

The text begins with a high-level overview of solid-state metal additive manufacturing with an emphasis on its position within the metal additive manufacturing spectrum and its potential for meeting specific demands in the aerospace, automotive, and defense industries. Next, each of the four categories of solid-state additive technologies―cold spray additive manufacturing, additive friction stir deposition, ultrasonic additive manufacturing, and sintering-based processes―is discussed in depth, reviewing advances in processing science, metallurgical science, and innovative applications. Finally, the future directions of these solid-state processes, especially the material innovation and artificial intelligence aspects, are discussed.

Sample topics covered in Solid-State Metal Additive Manufacturing include:

• Physical processes and bonding mechanisms in impact-induced bonding and microstructures and microstructural evolution in cold sprayed materials
• Process fundamentals, dynamic microstructure evolution, and potential industrial applications of additive friction stir deposition
• Microstructural and mechanical characterization and industrial applications of ultrasonic additive manufacturing
• Principles of solid-state sintering, binder jetting-based metal printing, and sintering-based metal additive manufacturing methods for magnetic materials
• Critical issues inherent to melting and solidification, such as porosity, high residual stress, cast microstructure, anisotropic mechanical properties, and hot cracking

Solid-State Metal Additive Manufacturing is an essential reference on the subject for academic researchers in materials science, mechanical, and biomedicine, as well as professional engineers in various manufacturing industries, especially those involved in building new additive technologies.

✦ Table of Contents

fmatter
Title Page
Copyright
Contents
Preface
ch1
Chapter 1 Introduction and Overview
1.1 Overview and History of Metal Additive Manufacturing
1.2 Liquid‐State Bonding Versus Solid‐State Bonding
1.2.1 Liquid‐State Bonding
1.2.2 Solid‐State Bonding
1.3 Nonbeam‐Based, Solid‐State Metal Additive Manufacturing
1.3.1 Deformation‐Based Metal Additive Manufacturing
1.3.2 Sintering‐Based Metal Additive Manufacturing
1.4 Additive Manufacturing Categorization Based on the Relationship Between Shape Forming and Consolidation
1.5 Organization of the Book
References
ch2
Chapter 2 Impact‐Induced Bonding: Physical Processes and Bonding Mechanisms
2.1 Introduction
2.2 Fundamentals of Impact Bonding
2.2.1 Plate Impacts and Explosive Welding
2.2.1.1 The Shock Equations of State
2.2.1.2 Limiting Conditions for Explosive Welding
2.2.2 Laser Impact Bonding
2.3 Bonding Mechanisms in Cold Spray
2.3.1 Proposed Mechanisms
2.3.1.1 The Role of Jetting and Impact Pressure in Particle Bonding
2.3.1.2 The Limiting Case of Impact Melting
2.3.1.3 Adiabatic Shear Instability
2.3.1.4 Dissimilar Materials Impact
2.3.2 Influence of Particle Characteristics
2.3.2.1 Particle Temperature
2.3.2.2 Particle Size
2.3.2.3 Surface Oxide and Hydroxide Effects
References
ch3
3.1 Introduction
3.2 Defect Structures
3.2.1 Vacancies
3.2.2 Dislocation Structure
3.2.3 Grain Structure
3.2.4 Precipitate Structure
3.2.5 Porosity
3.3 Microstructural Evolution of Thermally Treated Cold‐Sprayed Materials
3.3.1 Recovery, Recrystallization, and Grain Growth
3.3.2 Precipitation
3.3.3 Heat Treatment of Feedstock Powders and its Impact on Microstructure
3.4 Conclusions
Acknowledgements
References
ch4
4.1 Introduction
4.2 Mechanical Properties
4.2.1 Adhesive Strength
4.2.1.1 Adhesive Strength Test Methods
4.2.1.2 The Effect of Process Parameters on Adhesive Strength
4.2.1.3 The effect of Pre‐/Post‐treatments on Adhesive Strength
4.2.2 Cohesive Strength
4.2.2.1 Cohesive Strength Test methods
4.2.2.2 Cohesive Strength Under Static Loading
4.2.2.3 Cohesive Strength Under Fatigue Loading
4.2.2.4 Anisotropy in Cohesive Strength
4.2.3 Summary and Future Perspectives
References
ch5
5.1 Introduction
5.1.1 The Cold Spray Process
5.1.2 Cold Spray Additive Manufacturing (CSAM)
5.2 Materials
5.2.1 Cu and Cu Alloys
5.2.1.1 2Cu–Ga and Cu–In–Ga
5.2.1.2 Cu–Sn
5.2.1.3 Cu–W
5.2.2 Al and Al Alloys
5.2.3 Ni and Ni Alloys
5.2.4 Stainless Steels
5.2.5 Body Center Cubic (BCC) Metals
5.2.5.1 Tantalum
5.2.5.2 Niobium
5.2.6 Hexagonal Close‐Packed (HCP) Metals
5.2.6.1 Titanium
5.2.6.2 Magnesium
5.2.7 Metal Mixes and Metal Matrix Composite (MMC)
5.2.7.1 Metal Mixes
5.2.7.2 Metal Matrix Composite
5.2.8 Multicomponent and High Entropy Alloys
5.2.8.1 MCrAlY Multicomponent Alloy
5.2.8.2 High Entropy Alloy (HEA)
5.2.9 Multimaterials
5.3 Perspective and Challenges
References
ch6
Chapter 6 Process Fundamentals of Additive Friction Stir Deposition
6.1 Additive Friction Stir Deposition – Macroscopic Process Overview
6.2 Thermo‐Mechanical Processing Evolution
6.3 Heat Generation and Heat Transfer
6.3.1 Heat Generation and Heat Transfer Mechanisms
6.3.2 Peak Temperature and Material Dependence
6.4 Material Flow and Deformation
References
ch7
7.1 Introduction to Microstructure Evolution in Additive Friction Stir Deposition
7.2 Dynamic Microstructure Evolution in Single‐Phase Materials
7.2.1 Stacking Fault Energy and Dislocation Mobility
7.2.2 Dynamic Recovery
7.2.3 Continuous Dynamic Recrystallization
7.2.4 Discontinuous Dynamic Recrystallization
7.2.5 Static and Post‐Dynamic Recrystallization
7.2.6 Heterogeneous Deposits and Metadynamic Recrystallization
7.3 Dynamic Microstructure Evolution in Multiple‐Phase Materials
7.3.1 Thermal Evolution During Additive Friction Stir Deposition
7.3.2 Evolution of Secondary Phases at Low Temperature
7.3.3 Evolution of Secondary Phases at High Temperature
7.3.4 Evolution of Secondary Phases After Deformation
7.3.5 Mapping Secondary Phase Evolution to Processing Space
7.4 Effects of Material Transport on Microstructure Evolution
7.4.1 Mechanisms of Material Transport
7.4.2 Material Transport for the Homogenization of Mixtures
7.4.3 Densification of Material Through Material Transport
7.4.4 Material Transport and Spatial Variance in Thermomechanical Conditions
7.5 The Study of Microstructure Evolution in Additive Friction Stir Deposition
7.5.1 Contemporary Approaches
7.5.2 Novel Approaches
Acknowledgement
References
ch8
8.1 Introduction
8.2 Magnesium‐Based Alloys
8.2.1 WE43
8.2.2 AZ31
8.3 Aluminum‐Based Alloys
8.3.1 5xxx
8.3.2 2xxx
8.3.3 6xxx
8.3.4 7xxx
8.3.5 Cast Al Alloys
8.4 Other Alloys Systems
8.4.1 Nickel‐Based Alloys
8.4.2 Copper‐Based Alloys
8.4.3 Titanium‐Based Alloys
8.4.4 Steel Alloys
8.4.5 High‐Entropy Alloys
8.4.6 Metal Matrix Composites
8.5 Repair
8.6 Summary and Future Perspectives
8.6.1 Anisotropy
8.6.2 Graphite Lubricant
8.6.3 Multimaterial or Designed Feedstock
8.6.4 Effect of Process Parameters on Mechanical Properties
8.6.5 Active Cooling/Heating
8.6.6 Heat Treatment
8.6.7 High‐Temperature Materials – Tool Wear
8.6.8 Unique Possibilities
8.6.9 Modeling
References
ch9
9.1 Large‐Scale Metal Additive Manufacturing
9.2 Selective Area Cladding
9.3 Recycling and Upcycling
9.4 Structural Repair
9.5 Underwater Deposition
Acknowledgment
References
ch10
Chapter 10 Process Fundamentals of Ultrasonic Additive Manufacturing
10.1 Process Overview
10.1.1 Process Parameters
10.2 Temperature Rise and Thermal Modeling
10.2.1 Heat Generation During Welding
10.2.2 Sonotrode Contact Stress
10.2.3 Coefficient of Friction
10.2.4 Temperature Profile
10.3 Feedstock Bonding Mechanisms
10.3.1 Oxide Breakdown
10.3.2 Asperity Deformation
10.3.3 Diffusional Bonding Processes
10.3.4 Liquid‐Phase Bonding
10.4 Dissimilar Metal Consolidation
10.4.1 Mechanical and Thermal Modeling
10.4.2 Dissimilar Metal Junction Growth
10.4.3 Interdiffusion
10.5 Acoustic Softening and Strain Normality
10.5.1 Cyclic Strain Ratcheting
10.6 Summary
Acknowledgments
References
ch11
11.1 Introduction
11.2 Microstructure Analysis of UAM Builds
11.2.1 Similar Material Joining with UAM
11.2.2 Dissimilar Material Joining with UAM
11.2.2.1 Al‐Ceramic Weld
11.2.2.2 Ni‐Steel Weld
11.3 Hardness Analysis of UAM Builds
11.4 Mechanical Characterization of UAM Builds
11.4.1 Design of a Custom Shear Testing Method
11.4.2 Validation of the Shear Test
11.4.3 Finite element Modeling of the Shear Test
11.4.4 Application of the Shear Test to UAM Samples
11.5 Conclusions
References
ch12
12.1 Early Years
12.2 Increased Power → Increased Capability
12.3 Modern Applications
12.3.1 Electrification
12.3.2 Thermal Management
12.3.3 Embedded Electronics
12.3.3.1 SmartPlate
12.3.3.2 SensePipe
12.4 Future Applications
References
ch13
Chapter 13 Principles of Solid‐State Sintering
13.1 Introduction
13.2 Basic Terminology
13.2.1 Sintering
13.2.2 Relative Density/Green Density
13.2.3 Coordination Number
13.2.4 Surface Tension/Surface Energy
13.2.5 Wetting Angle/Dihedral Angle
13.2.6 Neck Growth/Shrinkage/Densification
13.3 Sintering Stress
13.3.1 Two Particle Model
13.3.1.1 Case I: Without Shrinkage
13.3.1.2 Case II: With Shrinkage
13.3.2 Driving Force
13.3.3 Interfacial Activity/Thermodynamics
13.4 Mass Transport Mechanisms
13.4.1 Grain Boundary Diffusion
13.4.2 Lattice/Volume Diffusion
13.4.3 Viscous Flow
13.4.4 Surface Diffusion
13.4.5 Evaporation/Condensation
13.4.6 Gas Diffusion
13.5 Sintering Stages
13.6 Sintering Simulation
13.7 Concluding Remarks, Challenges, and Future Works
References
ch14
14.1 Introduction
14.2 Hierarchy of MEAM Parts and Feedstock Behavior
14.3 Feedstock Attributes
14.4 Extrusion Control
14.5 Toolpathing: Strength and Quality
14.6 Conclusions
Acknowledgments
References
ch15
15.1 Introduction to Binder Jetting
15.2 Printing Phase
15.2.1 Particulate Feedstock
15.2.1.1 Feedstock Materials
15.2.1.2 Feedstock Morphology and Size Distribution
15.2.2 Binder Selection
15.2.3 Powder Spreading and Binder Deposition System Configurations
15.3 Thermal Treatments
15.3.1 Curing
15.3.2 Debinding
15.3.3 Sintering
15.3.4 Additional Treatments
15.4 Future Developments
15.5 Conclusion
References
ch16
16.1 Introduction
16.2 Background
16.3 Additive Manufacturing Methods
16.4 Applications
16.5 Summary
Acknowledgments
References
ch17
17.1 Enhancing the Understanding of Process Fundamentals
17.2 Expanding the Printable Material Library
17.3 Embracing Artificial Intelligence for Quality Control and Process Prediction
References
index