Advanced Topics in Metal Additive Manufacturing

Catalog description

This course delves into three distinct categories of metal additive manufacturing processes, each governed by unique principles: solidification-based techniques, sintering-dependent methods, and solid-state bonding processes. Students will explore the intricacies of powder bed fusion and direct energy deposition, where solidification mechanisms play a pivotal role in controlling microstructure formation. The course will provide a comprehensive understanding of how factors such as heat transfer, cooling rates, and alloy composition influence solidification behavior in these processes. Additionally, students will examine indirect metal printing methods, including extrusion, stereolithography, and binder jetting, which rely on sintering to fuse metal powders together. Detailed discussions will cover the sintering process, its underlying mechanisms, and its impact on the final properties of printed parts. Furthermore, the course will delve into metal additive manufacturing processes based on solid-state bonding, such as cold spray and sheet lamination. Students will explore the principles of solid-state bonding, including diffusion bonding and mechanical interlocking, and understand how these processes are applied to join metal powders/sheets without melting. Throughout the course, major alloys commonly used in metal additive manufacturing, such as Ni-based alloys, titanium alloys, steels, and aluminum alloys, will be discussed. Common defects encountered in metal printing technologies, post-processing steps for defect removal, and in situ monitoring techniques for defect mitigation will also be covered, ensuring students gain a comprehensive understanding of quality assurance in metal AM.