Week 2: Metal Additive Manufacturing Quiz
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Questions and Answers

What is one method used to remove excess powder from parts after LPBF?

  • Electro-polishing
  • Laser cutting
  • Cooling
  • Ultrasonic cleaning (correct)

    • Thermal processing is not necessary for relieving stress in LPBF parts.

    False

    What is one limitation of LPBF related to geometric freedom?

    Requirement for supports due to thermal warpage

    After LPBF, surface finishing operations include machining, shot-peening, and __________.

    <p>electro-polishing</p> Signup and view all the answers

    Match the following LPBF operations with their purposes:

    <p>Thermal processing = Improve mechanical properties Support removal = Detach parts from platform Surface finishing = Enhance surface quality Powder removal = Prepare part for further processes</p> Signup and view all the answers

    Which of the following characteristics are typically associated with metals?

    <p>Ductile and shiny</p> Signup and view all the answers

    All metals are solid at room temperature, with the exception of mercury.

    <p>True</p> Signup and view all the answers

    Name two processes that involve material removal in conventional metal processing.

    <p>Milling and Grinding</p> Signup and view all the answers

    Metals generally have a higher __________ than most non-metals.

    <p>density</p> Signup and view all the answers

    Match the following types of conventional metal processing with their categories:

    <p>Casting = Material forming with no removal Milling = Material removal Welding = Joining methods Extrusion = Material forming with no removal</p> Signup and view all the answers

    What advantage does Metal Additive Manufacturing have?

    <p>Reduces material waste</p> Signup and view all the answers

    Ductility refers to a material's ability to be drawn into wires.

    <p>True</p> Signup and view all the answers

    Which additive manufacturing technique is most commonly used for producing metal parts?

    <p>Laser Powder Bed Fusion</p> Signup and view all the answers

    Laser Powder Bed Fusion uses mechanical energy to create parts.

    <p>False</p> Signup and view all the answers

    What type of metal was used by Bugatti to redesign and print lightweight brake callipers?

    <p>titanium</p> Signup and view all the answers

    The GE fuel injector produced using additive manufacturing is used for the __________ engine.

    <p>LEAP</p> Signup and view all the answers

    Match the following applications with their corresponding details:

    <p>Bugatti = Lightweight brake callipers GE = Fuel injector for LEAP engine Rolls Royce = Trent engine stator vanes Aerospace = Titanium fan blades</p> Signup and view all the answers

    Which is NOT a benefit of additive manufacturing mentioned?

    <p>Higher production cost</p> Signup and view all the answers

    Unused powder in the Laser Powder Bed Fusion process is discarded and not reused.

    <p>False</p> Signup and view all the answers

    What is a primary advantage of using laser or electron beams in additive manufacturing?

    <p>To produce high density fully functional parts</p> Signup and view all the answers

    Metal additive manufacturing techniques like LPBF utilize __________ layers of metallic powder.

    <p>thin</p> Signup and view all the answers

    What property of LPBF parts can match or exceed that of cast parts?

    <p>High Density</p> Signup and view all the answers

    Complete melting of the material in LPBF leads to potential issues with fracture toughness and fatigue properties.

    <p>False</p> Signup and view all the answers

    What is the effect of less than full density in LPBF parts?

    <p>It compromises fracture toughness and fatigue properties.</p> Signup and view all the answers

    The process of rapid melting and cooling in LPBF results in a _____ microstructure.

    <p>fine</p> Signup and view all the answers

    Match the following LPBF attributes with their respective descriptions:

    <p>High Density = Achieves complete melting in a single step Fine Microstructure = Results from rapid melting and cooling Custom Microstructures = Controlled by varying processing parameters Material Segregation = Smaller scale than in casting processes</p> Signup and view all the answers

    Which of the following factors can impact the mechanical properties of LPBF parts?

    <p>All of the above</p> Signup and view all the answers

    LPBF can produce parts with varying chemical compositions that are inconsistent compared to casting.

    <p>False</p> Signup and view all the answers

    What is a critical compliance area for LPBF parts used in aerospace and medical applications?

    <p>Toughness and fatigue properties.</p> Signup and view all the answers

    The standard particle size distribution for LPBF powders typically includes a layer thickness of _____ micrometers.

    <p>25</p> Signup and view all the answers

    What disadvantage can occur due to premature failure in LPBF parts?

    <p>Crack initiation sites</p> Signup and view all the answers

    What is a primary advantage of titanium alloys in aerospace applications?

    <p>High tensile strength and low weight</p> Signup and view all the answers

    Nickel alloys are suitable for engine components due to their low mechanical strength.

    <p>False</p> Signup and view all the answers

    What percentage of material can be saved compared to conventional manufacturing methods?

    <p>50%</p> Signup and view all the answers

    The Bloodhound Project aims to achieve speeds of __________.

    <p>1000mph</p> Signup and view all the answers

    Match the following applications to their characteristics:

    <p>Medical implants = Custom fit and biocompatibility Automotive = High volume production of roof brackets Jewellery/Fashion = Complex/intricate geometries Dental = Dental copings and frameworks</p> Signup and view all the answers

    Which of the following metals are commonly used in medical implants due to their biocompatibility?

    <p>Titanium and TiCp</p> Signup and view all the answers

    Metal additive manufacturing can only be used for automotive applications.

    <p>False</p> Signup and view all the answers

    What is one of the key benefits of using metal additive manufacturing in jewellery production?

    <p>Geometric freedom</p> Signup and view all the answers

    The use of topology optimization in manufacturing can lead to a __________ weight saving without losing mechanical properties.

    <p>65%</p> Signup and view all the answers

    What factor(s) can influence the final properties of a part produced by additive manufacturing?

    <p>Process parameters and environmental conditions</p> Signup and view all the answers

    What is a characteristic of the microstructure produced by Laser Powder Bed Fusion (LPBF)?

    <p>Uniform microstructure</p> Signup and view all the answers

    LPBF parts can achieve complete melting in a single step.

    <p>True</p> Signup and view all the answers

    Name one critical compliance area for LPBF parts used in the aerospace industry.

    <p>Toughness or fatigue properties</p> Signup and view all the answers

    The rapid melting and cooling in LPBF leads to a _____ microstructure.

    <p>fine</p> Signup and view all the answers

    Match the features with their respective attributes in LPBF:

    <p>High Density = Match or exceed properties of cast Fine Microstructure = Uniform microstructure Custom Microstructures = Controlled by varying processing parameters Material Segregation = Smaller scale compared to casting processes</p> Signup and view all the answers

    What is one of the primary benefits of innovation in manufacturing?

    <p>It leads to products that are cheaper and of better quality.</p> Signup and view all the answers

    Metal additive manufacturing has not seen significant growth in applications over the years.

    <p>False</p> Signup and view all the answers

    What type of metal is notably used in high-performance cycling applications?

    <p>Aluminum or carbon fiber composites</p> Signup and view all the answers

    The major countries leading in the growth of the metals market include the US, UK, __________, France, and China.

    <p>Germany</p> Signup and view all the answers

    Match the following applications with their sectors:

    <p>High performance cycling = Sports Aerospace fuel injector = Aerospace Dental = Healthcare Jewellery = Fashion</p> Signup and view all the answers

    Which of the following is NOT commonly associated with Metal Additive Manufacturing?

    <p>It solely uses a single type of metal.</p> Signup and view all the answers

    The use of laser or electron beams in additive manufacturing only results in thicker layers of material.

    <p>False</p> Signup and view all the answers

    All metals have low density compared to non-metals.

    <p>False</p> Signup and view all the answers

    What is one property of metals that relates to their ability to be shaped?

    <p>Malleability</p> Signup and view all the answers

    Metals generally have good __________ of electricity and heat.

    <p>conductivity</p> Signup and view all the answers

    Match the following metal processing methods to their categories:

    <p>Milling = Subtractive/cutting Extrusion = Forming Welding = Joining Casting = Forming (no material removal)</p> Signup and view all the answers

    In conventional metal processing, which method involves material removal?

    <p>Grinding</p> Signup and view all the answers

    All metals are malleable and ductile.

    <p>False</p> Signup and view all the answers

    Investment casting is a method of __________ processing.

    <p>casting</p> Signup and view all the answers

    Name one additive manufacturing technique used for metals.

    <p>Laser Powder Bed Fusion</p> Signup and view all the answers

    Which of the following is a benefit of using Laser Powder Bed Fusion (LPBF) in metal additive manufacturing?

    <p>High density fully functional parts</p> Signup and view all the answers

    Metal Additive Manufacturing techniques cannot produce parts with excellent mechanical properties.

    <p>False</p> Signup and view all the answers

    What type of energy is typically used in Laser Powder Bed Fusion?

    <p>laser or electron beam</p> Signup and view all the answers

    The prototype components for the Rolls Royce Trent Engine Stator were created using ________ melting.

    <p>electron beam</p> Signup and view all the answers

    Match the following metal applications with their corresponding details:

    <p>Bugatti = Lightweight brake callipers from titanium GE = Single piece fuel injector for LEAP engine Rolls Royce = Largest 3D printed flying engine component Aerospace = Manufacturing titanium fan blades</p> Signup and view all the answers

    What is the primary advantage of using metal additive manufacturing for automotive components?

    <p>Ability to create complex geometries</p> Signup and view all the answers

    LPBF processes are known for exhaustive testing to ensure high performance components.

    <p>True</p> Signup and view all the answers

    Which metal was specifically mentioned as being used by Bugatti for brake callipers?

    <p>titanium</p> Signup and view all the answers

    Unused powder in LPBF can be ________.

    <p>recycled</p> Signup and view all the answers

    What aspect of additive manufacturing contributes to cost savings in production?

    <p>Customisation capabilities</p> Signup and view all the answers

    What percentage of material can be saved with metal additive manufacturing compared to conventional methods?

    <p>50%</p> Signup and view all the answers

    Titanium alloys are desirable for aerospace applications due to their low weight and high tensile strength.

    <p>True</p> Signup and view all the answers

    Name one application of metal additive manufacturing in the automotive industry.

    <p>Production of BMW roof brackets</p> Signup and view all the answers

    Cobalt Chrome and Titanium alloys are commonly used in dental labs to produce __________.

    <p>dental copings, bridges, crowns and partial denture frameworks</p> Signup and view all the answers

    Match the following metals or alloys with their applications:

    <p>Titanium = Medical implants Nickel alloys = Engine components Cobalt Chrome = Dental frameworks Titanium alloys = Aerospace applications</p> Signup and view all the answers

    Which of the following statements about Nickel alloys is correct?

    <p>They have good corrosive resistance.</p> Signup and view all the answers

    Additive manufacturing cannot be used for producing complex geometries in jewellery and fashion.

    <p>False</p> Signup and view all the answers

    What specific material property makes Titanium alloys suitable for medical implants?

    <p>Biocompatibility</p> Signup and view all the answers

    The Bloodhound Project aims to achieve a speed of __________ mph.

    <p>1000</p> Signup and view all the answers

    What is a significant advantage of using additive manufacturing in automotive applications?

    <p>High volume production of complex parts</p> Signup and view all the answers

    Study Notes

    Additive Manufacturing - Principles and Applications

    • This course, MEC454, covers the principles and applications of additive manufacturing, specifically focusing on metal additive manufacturing.
    • The course is structured in five parts:
      • Introduction to Metal AM and Industry Growth
      • Laser Powder Bed Fusion (LPBF) & Applications
      • Part Properties (PBF) and Post-Processing
      • Materials & Process Comparisons
      • Other Metal Processes
    • The date of the first lecture was October 7th, 2024, and it was part of week 2 of the course.

    Metal Additive Manufacturing

    • Additive Manufacturing (AM) is a process that builds parts layer by layer.
    • The evolution of the bicycle is used to illustrate the concept of design, materials and manufacturing innovation through history.
    • Innovation in manufacturing leads to improved products, better materials and reduces costs.
    • Metal AM has applications in aerospace (fuel injectors), high-performance cycling, dental, automotive, and jewellery.

    Metal AM Cost Examples

    • Stator Ring: Cobalt chrome material, 160mm diameter x 60mm height, 40µm layer thickness, 40 hours build time, 50 hours finishing (including polishing), approximately £4500.
    • Fuel Injector: Inconel 718 material, 60mm diameter x 160mm height, 40µm layer thickness, 50 hours build time (2 parts in one piece), 3 hours finishing, ~£3500 per item.
    • Swirler: Cobalt chrome material, 27mm diameter x 30mm height, 20µm layer thickness, 90 hours build time (45 parts), approximately £300 per unit (45 parts total).

    Laser Powder Bed Fusion (LPBF)

    • LPBF is a common additive manufacturing process for metal parts.
    • It uses thermal energy (usually a laser or an electron beam) to melt and fuse metal powder layers on a substrate.
    • This process is often used for creating high-density, fully functional parts with excellent mechanical properties, and offers a good variety of materials and part properties.
    • LPBF parts may need post-processing to remove excess powder, stress relief or improve mechanical properties by using thermal cycles, or machining supports.

    Sheet Lamination

    • Sheet lamination involves bonding thin sheets of metal foil using ultrasonic vibration.
    • The process uses an ultrasonic sonotrode for bonding and maintains a good microstructure.
    • High quality surface finish but has limited geometric complexity, significant material wastage and the need for post-processing.

    Binder Jetting

    • A binder is printed onto a pre-deposited powder bed.
    • Parts are de-binded, then sintered at high temperature and infiltrated with copper or bronze.
    • Best suited to industries requiring molds for casting.
    • Advantages are no need for support structure and very large build volumes, but this process has poor accuracy, requires multiple sintering/infiltration cycles and limited materials.

    Extrusion-Based

    • Uses polymer or metal feedstock, similar to FDM.
    • This process needs post-processing (debending and sintering) and has high material shrinkage.

    Other Processes

    • Aerosol Jet, MetalJet, Powder spray, micro-stereo-lithography + plating and 3D Systems Sintersation.
    • Look for more information about these independently.

    PBF Systems

    • Lasers: Use absorbed laser energy for melting. Typically fibre lasers.
    • Electron Beams: Use electron kinetic energy transfer for melting.

    PBF Commercial Systems

    • The prices for different types of PBF vary significantly.

    PBF vs Conventional

    • CNC machining removes material quicker but may require more setup time, CNC has more material wastage, and PBF is better for intricate geometries, and superior surface finish and accuracy.
    • PBF has better accuracy and resolution, but generates more residual stress, and costs are independent of geometric complexity.
    • PBF may require supporting structures, but it is faster for parts without geometric complexity compared to casting.
    • Casting is better for bulk/large components, while PBF is better for customisation.

    PBF Summary

    • PBF shares several similarities with polymer-based systems, but differs in terms of higher melt temperatures, increased energy density, the need for substrate plates, and supports, and expensive systems.

    Summary on Overall Metal AM at Sheffield

    • A wide range of both polymer and metal AM facilities are available.

    Closing Remarks

    • Advances in metal additive manufacturing technology are driving significant investment in various industries (e.g., aerospace, medical).
    • Key professionals believe that a large percentage of jet engines will be produced using metal additive manufacturing methods in the near future.
    • Investigate and analyse the reasons why particular metals are used for particular applications, such as titanium in gas turbine engines.

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    Related Documents

    Additive Manufacturing – Principles and Applications MEC454 PDF

    Description

    Test your knowledge on Metal Additive Manufacturing, specifically focusing on Laser Powder Bed Fusion (LPBF) processes and characteristics. This quiz covers various aspects, including limitations, operations, and comparisons with conventional metal processing. Perfect for students and professionals in materials science and engineering.

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