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Metal Powder—Based Additive Manufacturing Highly comprehensive resource covering all key aspects of the current developments of metal powder—based additive manufacturing
Metal Powder—Based Additive Manufacturing provides valuable knowledge and critical insights regarding the recent advances in various metal powder—based additive manufacturing techniques. This book also reviews typical powder preparation processes and highlights the significance of metal powder—based additive manufacturing for various industrial applications.
The key features covered in this book:
A rigorous overview of the underlying theories and practical applications of metal powder—based additive manufacturing techniques, including laser powder bed fusion, electron beam melting, laser-based directed energy deposition, and metal binder jetting.
An expansive introduction of each technique and its significance pertaining to the printing processes, metallurgical defects, powder materials, equipment, and the microstructures and mechanical properties of the printed parts.
A deep exploration of the preparation processes of metal powders for additive manufacturing and the effects of different processes on the powder properties.
Comprehensive case studies of parts printed by metal powder—based additive manufacturing for various industrial applications.
By providing extensive coverage of relevant concepts in the field of metal powder—based additive manufacturing, this book highlights its essential role in Industry 4.0 and serves as a valuable resource for scientists, engineers, and students in materials science, powder metallurgy, physics, and chemistry. The rich research experience of the authors in additive manufacturing ensures that the readers are provided with both an in-depth understanding and informative technical guidance of metal powder—based additive manufacturing.
Contents
Biography ix
Preface xi
1 Introduction 1
1.1 History and Fundamentals of AM 1
1.2 AM Techniques 2
1.3 Metal Powder-Based AM 8
1.4 Post-Processing 8
1.4.1 Surface Quality Improvement 9
1.4.2 Residual Stress Relief and Defect Reduction 11
1.4.3 Aesthetic Improvement 11
1.5 Powder Properties and Characterization Methods 12
1.5.1 Particle Morphology 12
1.5.2 Particle Size Distribution 14
1.5.3 Density 15
1.5.4 Flowability 16
1.5.5 Chemical Composition 18
1.5.5.1 Surface Analysis Methods 18
1.5.5.2 Bulk Analysis Methods 18
1.5.6 Microstructure 19
1.6 Challenges and Future Trends of Metal Powder-Based AM 21
1.7 Summary 23
References 23
2 Metal Powder Preparation Processes 27
2.1 Atomization 27
2.1.1 Gas Atomization 28
2.1.2 Water Atomization 35
2.1.3 Plasma Atomization 38
2.1.4 Plasma Rotating Electrode Process 41
2.2 Mechanical Mixing 44
2.3 Reduction Process 50
2.3.1 Hydride-Dehydride Process 50
2.3.2 Oxide Reduction 53
2.3.3 Chloride Reduction 56
2.3.4 Carbonyl Reactions 57
2.4 Powder Modification 58
2.4.1 Plasma Spheroidization 58
2.4.2 Granulation-Sintering-Deoxygenation 61
2.4.3 Fluidized-bed Granulation 64
2.5 Summary 65
References 67
3 Laser Powder Bed Fusion 75
3.1 History 75
3.2 Fundamentals 76
3.3 Printing Process 81
3.3.1 Melt Pool 82
3.3.2 Balling 86
3.3.3 Spattering 88
3.4 Metallurgical Defects 91
3.4.1 Porosity 91
3.4.2 Cracks and Warpage 96
3.5 Powder Materials 102
3.6 Equipment 106
3.7 Typical Materials Used in LPBF 109
3.7.1 Titanium and Its Alloys 109
3.7.2 Aluminum Alloys 121
3.7.3 Nickel Alloys 126
3.7.4 Iron Alloys 129
3.7.5 Others 132
3.7.5.1 Cobalt Alloys 132
3.7.5.2 Copper Alloys 132
3.7.5.3 Magnesium Alloys 133
3.7.5.4 High-Entropy Alloys 135
3.8 Mechanical Metamaterials for LPBF 135
3.8.1 Fundamentals of Mechanical Metamaterials 136
3.8.2 Mechanical Metamaterials with High Young's Modulus 137
3.8.3 Mechanical Metamaterials with High Shear and Bulk Moduli 143
3.8.4 Mechanical Metamaterials with Zero or Negative Poisson's Ratio 146
3.9 Summary 148
References 150
4 Electron Beam Melting 161
4.1 History 161
4.2 Fundamentals 162
4.3 Preheating and Melting Processes 165
4.4 Metallurgical Defects 168
4.5 Powder Materials 171
4.6 Equipment 172
4.7 Microstructures and Mechanical Properties 173
4.7.1 Titanium and Its Alloys 174
4.7.2 Nickel Alloys 179
4.7.3 Cobalt Alloys 180
4.7.4 Iron Alloys 183
4.7.5 Others 184
4.7.5.1 Copper and Its Alloys 184
4.7.5.2 High-Entropy Alloys 185
4.8 Summary 185
References 186
5 Laser-Based Directed Energy Deposition 191
5.1 History 191
5.2 Fundamentals 192
5.3 Deposition Process 195
5.4 Metallurgical Defects 199
5.5 Powder Materials 202
5.6 Equipment 203
5.7 Microstructure and Mechanical Properties 209
5.7.1 Titanium and Its Alloys 209
5.7.2 Nickel Alloys 214
5.7.3 Iron Alloys 218
5.7.4 Others 221
5.7.4.1 Aluminum Alloys 221
5.7.4.2 Copper and Its Alloys 223
5.7.4.3 High-Entropy Alloys 229
5.8 Summary 230
References 231
6 Metal Binder Jetting 237
6.1 History 237
6.2 Fundamentals 237
6.3 Printing Process 239
6.4 Raw Materials 245
6.5 Equipment 247
6.6 Microstructure and Mechanical Properties 249
6.6.1 Iron Alloys 250
6.6.2 Nickel Alloys 252
6.6.3 Titanium and Its Alloys 254
6.6.4 Copper and Its Alloys 255
6.6.5 Refractory Metals 256
6.6.6 Others 257
6.7 Summary 259
References 259
7 Applications 263
7.1 Aerospace 263
7.2 Biomedical 270
7.3 Automotive 275
7.4 Molding and Tooling 277
7.5 Energy 281
7.6 Jewelry 285
7.7 Marine, Oil, and Gas 287
7.8 Challenges and Risks 289
References 290
Index 295
