Ehsan Toyserkani - Metal Additive Manufacturing

5 Chapter 5Figure 5.1 Schematic of LPBF, showing physical phenomena surrounding the mel...Figure 5.2 Heat source models schematics: (a) cylindrical shape; (b) semi‐sp...Figure 5.3 Powder–laser interaction mechanisms.Figure 5.4 Thermophysical properties of bulk and powder material: (a) therma...Figure 5.5 Schematic of (a) keyhole mode and (b) conduction mode. Top figure...Figure 5.6 Temperature gradient mechanism inducing residual stress.Figure 5.7 The laser scanning path used for the case study.Figure 5.8 Geometry and mesh used in the finite element simulation of the ca...Figure 5.9 Ripples of a single track: (a) experimental results and (b) numer...Figure 5.10 Experimental surface of the multiple‐track scanning: (a) microsc...Figure 5.11 Melt pool cross section of a single track from (a) experiment (b...Figure 5.12 Multi‐track melt pool cross sections: (a) experiment and (b) sim...Figure 5.13 Schematic of the theoretical model of the LPF process.Figure 5.14 Electron acceleration between anode and cathode and electric pot...Figure 5.15 Binary head‐on collision of particles in a hexagonal grid model ...Figure 5.16 Three‐dimensional projection of a face‐centered hypercubic latti...Figure 5.17 Phases assigned to different cells in the LB method. The specifi...Figure 5.18 Exponential (60 kV) and constant (120 kV) absorption profiles....Figure 5.19 Melt pool evolution during EB‐PBF processing using the LB method...Figure 5.20 (a) Rain model schematic. (b) Generated powder bed. (c) Relative...Figure 5.21 Gaussian EB model using the constant absorption profile.Figure 5.22 (a) Micro‐scale simulation temperature distribution for a scan l...Figure 5.23 Strain evolution of a part during the build process.Figure 5.24 Comparison between the FEM model and produced parts. It uses the...

6 Chapter 6Figure 6.1 Schematic of (a) continuous inkjet printing showing the working m...Figure 6.2 The droplet formation and flight in inkjet printing. The tail of ...Figure 6.3 (a) The thinning of the jet on the onset of droplet formation in ...Figure 6.4 The pinch‐off of liquid column as time passes for a liquid with r...Figure 6.5 Schematic of surface wettability for a droplet of water as a func...Figure 6.6 Droplet impact regimes on dry surfaces.Figure 6.7 Droplet cross section changes as a function of time from impact t...Figure 6.8 Infiltration of the droplet into (a) dry and (b) ‐ (c) pre‐wetted...Figure 6.9 The wetted region imaged using micro‐CT for one droplet dispensed...Figure 6.10 The creation of crater geometry: (a) droplet approaching the sur...Figure 6.11 Schematic of liquid bridge between two identical spherical parti...Figure 6.12 The penetration of a droplet with the impact velocity of 5 m/s i...Figure 6.13 Droplet formation modeling using level‐set method showing the ef...Figure 6.14 (a) Sample D2Q9 LBM.(b) Lattice vectors in a D2Q9 cell.Figure 6.15 Streaming step in LBM.Figure 6.16 Collision step in LBM.Figure 6.17 (a) 2D view of droplet spreading on a smooth surface from initia...

7 Chapter 7Figure 7.1 Components of a typical printhead in a ME system.Figure 7.2 HF composite filament at different ME process stages: Metal–polym...Figure 7.3 The schematic view of liquefier and nozzle in ME.Figure 7.4 Schematic of heat transfer region in ME.Figure 7.5 Three pressure drop zones in the nozzle.Figure 7.6 (a) The gap (B) between the filament and liquefier walls filled w...Figure 7.7 (a) Nozzle configuration in a conventional ME (FDM) model and (b)...Figure 7.8 Die swell effect results in an increase in the diameter of the be...Figure 7.9 Schematics of the liquefier entrance.Figure 7.10 (a) Geometry and temperature zones of Serdeczny's model and (b) ...Figure 7.11 (a) Temperature distribution at the liquefier at different times...

8 Chapter 8Figure 8.1 The relationship between four major components of materials scien...Figure 8.2 Conventional manufacturing processes: e.g., casting.Figure 8.3 AM powder production steps [1].Figure 8.4 Schematic of cooling curves during solidification, (a) definition...Figure 8.5 Fe–C phase diagram.Figure 8.6 Continuous cooling transformation diagram for steel.Figure 8.7 Time–temperature profile of a single‐layer AM‐manufactured Ti‐6Al...Figure 8.8 Critical continuous cooling transformation diagram for welded or ...Figure 8.9 Time–temperature diagram presenting the nucleation onset of two d...Figure 8.10 A comparative presentation of the theoretical equilibrium (solid...Figure 8.11 Solidification during inadequate diffusion in liquid and no diff...Figure 8.12 Solute distribution without diffusion in the solid and dissimila...Figure 8.13 Schematic presentation of constitutional supercooling: (a) parti...Figure 8.14 Schematic presentation on the relation between the Gibbs free en...Figure 8.15 (a) The figure depicting the nucleation of a sphere‐shaped parti...Figure 8.16 (a) Solid nucleus connected with substrate metal and liquid. (b)...Figure 8.17 Schematic presentation of the Walton and Chalmers model showing ...Figure 8.18 The graphics showing the growth characteristics and constitution...Figure 8.19 Epitaxial growth of the solidified metal adjacent the fusion lin...Figure 8.20 The schematic diagrams illustrate the modes of solidification pa...Figure 8.21 Occurrence of various solidification structures related to const...Figure 8.22 Change of the temperature in time, throughout the solidification...Figure 8.23 Schematic of the dendrite formation/growth.Figure 8.24 Influence of temperature gradient G and growth rate R on size an...Figure 8.25 Formation mechanism of grains in AM: (a) single track, (b) multi...Figure 8.26 Schematic of (a) Keyhole porosity.(b) Process and gas‐induce...Figure 8.27 Process window for LPBF manufactured Ti‐6Al‐4V alloy.Figure 8.28 Schematic of balling incident appeared by coarsened sphere‐shape...Figure 8.29 Representation of balling phenomenon characterized by small shap...Figure 8.30 The mechanism of liquation cracking in the melt pool area.Figure 8.31 Schematic presentation of the microstructural development and ph...Figure 8.32 Transformation–time–temperature plot for IN718 alloy [79].Figure 8.33 Microstructure of Stellite 12 manufactured through laser‐based A...Figure 8.34 Effect of (a) α ‐stabilizing, (b) β ‐isomorphous, and (c...Figure 8.35 The graphical presentation of ternary titanium alloys having bot...Figure 8.36 The graphical illustration of thermal profiles.Figure 8.37 Continuous cooling transformation curve for Ti‐6Al‐4v alloy [99]...Figure 8.38 Micro‐hardness values with respect to the secondary arms spacing...Figure 8.39 The micro‐hardness values with respect to the secondary arms spa...Figure 8.40 Microstructure of Ti‐6Al‐4V manufactured by LPBF, (a) after stre...Figure 8.41 Micro‐hardness plot with respect to the alpha lath width for Ti6...Figure 8.42 The property window presents yield strength vs. elongation for v...Figure 8.43 The property window presents yield strength vs. elongation for T...Figure 8.44 The fatigue behavior of (a) 316L and (b) LPBF‐manufactured 17‐4 ...Figure 8.45 The schematic shows the breaking up of Laves phase and split‐up ...Figure 8.46 The fatigue plot shows strain amplitude vs. reversals to failure...

9 Chapter 9Figure 9.1 The production route of metal matrix composites in AM.Figure 9.2 Schematic illustration of the collision between grinding ball and...Figure 9.3 Geometrical presentation of the particle motion trajectory in an ...Figure 9.4 Formation mechanism of TiC reinforced 316L matrix composite, (a) ...Figure 9.5 Microstructure showing the morphology of matrix, interface, and W...Figure 9.6 The schematic diagram shows that the formation mechanism of ferro...Figure 9.7 Schematic presentation for the formation of TiB phase from in‐sit...Figure 9.8 Schematic depiction of the formation mechanism of quasi‐continuou...Figure 9.9 Schematic presentation of the microstructural development in pure...Figure 9.10 Schematic microstructure of the as‐printed Ti‐6Al‐4V/MG composit...Figure 9.11 SEM micrograph showing Ti‐6Al‐4V‐ 3% B 4C composite.Figure 9.12 The schematic diagram illustrates the mechanism of Inconel–TiB 2...Figure 9.13 Demonstration of various failure approaches during compressive l...Figure 9.14 (a) The influence of Marangoni flow, (b) TiC particles under int...