Ehsan Toyserkani - Metal Additive Manufacturing

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Ehsan Toyserkani, Dyuti Sarker, Osezua Obehi Ibhadode, Farzad Liravi, Paola Russo, Katayoon Taherkhani

University of Waterloo

Waterloo, Ontario

Canada

This edition first published 2022

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The right of Ehsan Toyserkani, Dyuti Sarker, Osezua Obehi Ibhadode, Farzad Liravi, Paola Russo, and Katayoon Taherkhani to be identified as the authors of this work has been asserted in accordance with law.

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Library of Congress Cataloging‐in‐Publication Data

Names: Toyserkani, Ehsan, author. | Sarker, Dyuti, 1983- author. | Ibhadode, Osezua Obehi, 1989‐ author. | Liravi, Farzad, 1990- author. | Russo, Paola, 1986‐ author. | Taherkhani, Katayoon, 1989- author. | John Wiley & Sons, publisher.

Title: Metal additive manufacturing / Ehsan Toyserkani, Dyuti Sarker, Osezua Obehi Ibhadode, Farzad Liravi, Paola Russo, Katayoon Taherkhani.

Description: Hoboken, NJ : Wiley, 2021.

Identifiers: LCCN 2021028894 (print) | LCCN 2021028895 (ebook) | ISBN 9781119210788 (cloth) | ISBN 9781119210849 (adobe pdf) | ISBN 9781119210832 (epub)

Subjects: LCSH: Additive manufacturing. | Metal powder products–Design and construction. | Powder metallurgy.

Classification: LCC TS183.25 .T69 2021 (print) | LCC TS183.25 (ebook) | DDC 621.9/88–dc23

LC record available at https://lccn.loc.gov/2021028894LC ebook record available at https://lccn.loc.gov/2021028895

Cover Design: Wiley

Cover Image: Courtesy of Ehsan Toyserkani (top); © MarinaGrigorivna/Shutterstock

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In memory of

Professor Pearl Sullivan (1961–2020)

Former Dean of Faculty of Engineering, University of Waterloo, Canada

A true leader, an exemplary advocate for engineering education, and a great friend

Additive manufacturing (AM) promises to change the entire manufacturing enterprise over the next two decades. No longer limited to prototyping and low‐volume manufacturing, AM is being adopted for economies of scale without compromising economies of scope . The need for the digitization of manufacturing, on‐demand personalized manufacturing, distributed production, and rapid production in the event of crises have all elevated the position of AM in the medical and engineering sectors. AM is now a major research target for industrialized countries as they seek to regain leadership in advanced manufacturing through innovation. The global economy is on the verge of the next industrial revolution and sector after sector is pulling away from traditional, conventional production methods to engage in and utilize AM. However, this promise does come with many challenges, particularly for metal AM. Research and development activities are progressing at full steam to address multiple technical challenges, such as speed and productivity, quality assurance, standards, and end‐to‐end workflow.

A major skill sets gap currently hinders efforts to tackle these challenges. For companies seeking to embrace AM, this gap translates into a limited availability of expertise to draw an entry strategy to the AM industry. The wider adoption of AM will require overcoming the limited foundational understanding of AM that currently exists within the workforce. A thorough understanding of AM capabilities is necessary for technical experts to accurately communicate the pros and cons of AM to decision‐makers, while preventing misconceptions and misinformation about AM capabilities. Currently, the knowledge gap is significantly impacting progress in the sector, as companies have difficulties in recruiting AM experts to help them develop effective designs for AM as well as meaningful business cases for metal AM.

This book is designed to help academia and industry move toward filling this gap. Enhancing AM skills will require the development of foundational knowledge of AM starting at the undergraduate level. To our knowledge, there is currently no textbook available that links the basics of fundamental undergraduate Engineering courses with metal AM processes. There is a clear need to customize undergraduate concepts in technical courses related to design, heat transfer, fluid mechanics, solid mechanics, and control, with respect to AM applications. Additionally, business‐ and management‐oriented courses should include AM to facilitate the consideration of AM in conjunction with life cycle assessment and business model developments among students.