Podcast
Questions and Answers
What is one method used to remove excess powder from parts after LPBF?
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.
Thermal processing is not necessary for relieving stress in LPBF parts.
False (B)
What is one limitation of LPBF related to geometric freedom?
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 __________.
After LPBF, surface finishing operations include machining, shot-peening, and __________.
Match the following LPBF operations with their purposes:
Match the following LPBF operations with their purposes:
Which of the following characteristics are typically associated with metals?
Which of the following characteristics are typically associated with metals?
All metals are solid at room temperature, with the exception of mercury.
All metals are solid at room temperature, with the exception of mercury.
Name two processes that involve material removal in conventional metal processing.
Name two processes that involve material removal in conventional metal processing.
Metals generally have a higher __________ than most non-metals.
Metals generally have a higher __________ than most non-metals.
Match the following types of conventional metal processing with their categories:
Match the following types of conventional metal processing with their categories:
What advantage does Metal Additive Manufacturing have?
What advantage does Metal Additive Manufacturing have?
Ductility refers to a material's ability to be drawn into wires.
Ductility refers to a material's ability to be drawn into wires.
Which additive manufacturing technique is most commonly used for producing metal parts?
Which additive manufacturing technique is most commonly used for producing metal parts?
Laser Powder Bed Fusion uses mechanical energy to create parts.
Laser Powder Bed Fusion uses mechanical energy to create parts.
What type of metal was used by Bugatti to redesign and print lightweight brake callipers?
What type of metal was used by Bugatti to redesign and print lightweight brake callipers?
The GE fuel injector produced using additive manufacturing is used for the __________ engine.
The GE fuel injector produced using additive manufacturing is used for the __________ engine.
Match the following applications with their corresponding details:
Match the following applications with their corresponding details:
Which is NOT a benefit of additive manufacturing mentioned?
Which is NOT a benefit of additive manufacturing mentioned?
Unused powder in the Laser Powder Bed Fusion process is discarded and not reused.
Unused powder in the Laser Powder Bed Fusion process is discarded and not reused.
What is a primary advantage of using laser or electron beams in additive manufacturing?
What is a primary advantage of using laser or electron beams in additive manufacturing?
Metal additive manufacturing techniques like LPBF utilize __________ layers of metallic powder.
Metal additive manufacturing techniques like LPBF utilize __________ layers of metallic powder.
What property of LPBF parts can match or exceed that of cast parts?
What property of LPBF parts can match or exceed that of cast parts?
Complete melting of the material in LPBF leads to potential issues with fracture toughness and fatigue properties.
Complete melting of the material in LPBF leads to potential issues with fracture toughness and fatigue properties.
What is the effect of less than full density in LPBF parts?
What is the effect of less than full density in LPBF parts?
The process of rapid melting and cooling in LPBF results in a _____ microstructure.
The process of rapid melting and cooling in LPBF results in a _____ microstructure.
Match the following LPBF attributes with their respective descriptions:
Match the following LPBF attributes with their respective descriptions:
Which of the following factors can impact the mechanical properties of LPBF parts?
Which of the following factors can impact the mechanical properties of LPBF parts?
LPBF can produce parts with varying chemical compositions that are inconsistent compared to casting.
LPBF can produce parts with varying chemical compositions that are inconsistent compared to casting.
What is a critical compliance area for LPBF parts used in aerospace and medical applications?
What is a critical compliance area for LPBF parts used in aerospace and medical applications?
The standard particle size distribution for LPBF powders typically includes a layer thickness of _____ micrometers.
The standard particle size distribution for LPBF powders typically includes a layer thickness of _____ micrometers.
What disadvantage can occur due to premature failure in LPBF parts?
What disadvantage can occur due to premature failure in LPBF parts?
What is a primary advantage of titanium alloys in aerospace applications?
What is a primary advantage of titanium alloys in aerospace applications?
Nickel alloys are suitable for engine components due to their low mechanical strength.
Nickel alloys are suitable for engine components due to their low mechanical strength.
What percentage of material can be saved compared to conventional manufacturing methods?
What percentage of material can be saved compared to conventional manufacturing methods?
The Bloodhound Project aims to achieve speeds of __________.
The Bloodhound Project aims to achieve speeds of __________.
Match the following applications to their characteristics:
Match the following applications to their characteristics:
Which of the following metals are commonly used in medical implants due to their biocompatibility?
Which of the following metals are commonly used in medical implants due to their biocompatibility?
Metal additive manufacturing can only be used for automotive applications.
Metal additive manufacturing can only be used for automotive applications.
What is one of the key benefits of using metal additive manufacturing in jewellery production?
What is one of the key benefits of using metal additive manufacturing in jewellery production?
The use of topology optimization in manufacturing can lead to a __________ weight saving without losing mechanical properties.
The use of topology optimization in manufacturing can lead to a __________ weight saving without losing mechanical properties.
What factor(s) can influence the final properties of a part produced by additive manufacturing?
What factor(s) can influence the final properties of a part produced by additive manufacturing?
What is a characteristic of the microstructure produced by Laser Powder Bed Fusion (LPBF)?
What is a characteristic of the microstructure produced by Laser Powder Bed Fusion (LPBF)?
LPBF parts can achieve complete melting in a single step.
LPBF parts can achieve complete melting in a single step.
Name one critical compliance area for LPBF parts used in the aerospace industry.
Name one critical compliance area for LPBF parts used in the aerospace industry.
The rapid melting and cooling in LPBF leads to a _____ microstructure.
The rapid melting and cooling in LPBF leads to a _____ microstructure.
Match the features with their respective attributes in LPBF:
Match the features with their respective attributes in LPBF:
What is one of the primary benefits of innovation in manufacturing?
What is one of the primary benefits of innovation in manufacturing?
Metal additive manufacturing has not seen significant growth in applications over the years.
Metal additive manufacturing has not seen significant growth in applications over the years.
What type of metal is notably used in high-performance cycling applications?
What type of metal is notably used in high-performance cycling applications?
The major countries leading in the growth of the metals market include the US, UK, __________, France, and China.
The major countries leading in the growth of the metals market include the US, UK, __________, France, and China.
Match the following applications with their sectors:
Match the following applications with their sectors:
Which of the following is NOT commonly associated with Metal Additive Manufacturing?
Which of the following is NOT commonly associated with Metal Additive Manufacturing?
The use of laser or electron beams in additive manufacturing only results in thicker layers of material.
The use of laser or electron beams in additive manufacturing only results in thicker layers of material.
All metals have low density compared to non-metals.
All metals have low density compared to non-metals.
What is one property of metals that relates to their ability to be shaped?
What is one property of metals that relates to their ability to be shaped?
Metals generally have good __________ of electricity and heat.
Metals generally have good __________ of electricity and heat.
Match the following metal processing methods to their categories:
Match the following metal processing methods to their categories:
In conventional metal processing, which method involves material removal?
In conventional metal processing, which method involves material removal?
All metals are malleable and ductile.
All metals are malleable and ductile.
Investment casting is a method of __________ processing.
Investment casting is a method of __________ processing.
Name one additive manufacturing technique used for metals.
Name one additive manufacturing technique used for metals.
Which of the following is a benefit of using Laser Powder Bed Fusion (LPBF) in metal additive manufacturing?
Which of the following is a benefit of using Laser Powder Bed Fusion (LPBF) in metal additive manufacturing?
Metal Additive Manufacturing techniques cannot produce parts with excellent mechanical properties.
Metal Additive Manufacturing techniques cannot produce parts with excellent mechanical properties.
What type of energy is typically used in Laser Powder Bed Fusion?
What type of energy is typically used in Laser Powder Bed Fusion?
The prototype components for the Rolls Royce Trent Engine Stator were created using ________ melting.
The prototype components for the Rolls Royce Trent Engine Stator were created using ________ melting.
Match the following metal applications with their corresponding details:
Match the following metal applications with their corresponding details:
What is the primary advantage of using metal additive manufacturing for automotive components?
What is the primary advantage of using metal additive manufacturing for automotive components?
LPBF processes are known for exhaustive testing to ensure high performance components.
LPBF processes are known for exhaustive testing to ensure high performance components.
Which metal was specifically mentioned as being used by Bugatti for brake callipers?
Which metal was specifically mentioned as being used by Bugatti for brake callipers?
Unused powder in LPBF can be ________.
Unused powder in LPBF can be ________.
What aspect of additive manufacturing contributes to cost savings in production?
What aspect of additive manufacturing contributes to cost savings in production?
What percentage of material can be saved with metal additive manufacturing compared to conventional methods?
What percentage of material can be saved with metal additive manufacturing compared to conventional methods?
Titanium alloys are desirable for aerospace applications due to their low weight and high tensile strength.
Titanium alloys are desirable for aerospace applications due to their low weight and high tensile strength.
Name one application of metal additive manufacturing in the automotive industry.
Name one application of metal additive manufacturing in the automotive industry.
Cobalt Chrome and Titanium alloys are commonly used in dental labs to produce __________.
Cobalt Chrome and Titanium alloys are commonly used in dental labs to produce __________.
Match the following metals or alloys with their applications:
Match the following metals or alloys with their applications:
Which of the following statements about Nickel alloys is correct?
Which of the following statements about Nickel alloys is correct?
Additive manufacturing cannot be used for producing complex geometries in jewellery and fashion.
Additive manufacturing cannot be used for producing complex geometries in jewellery and fashion.
What specific material property makes Titanium alloys suitable for medical implants?
What specific material property makes Titanium alloys suitable for medical implants?
The Bloodhound Project aims to achieve a speed of __________ mph.
The Bloodhound Project aims to achieve a speed of __________ mph.
What is a significant advantage of using additive manufacturing in automotive applications?
What is a significant advantage of using additive manufacturing in automotive applications?
Flashcards
Closely packed atomic structure in metals
Closely packed atomic structure in metals
The way atoms are arranged in metals, with a tightly packed structure and outer shell electrons easily lost.
Metals are generally solid
Metals are generally solid
Metals are typically solid at room temperature, with the exception of mercury, which is a liquid.
Metals are denser than non-metals
Metals are denser than non-metals
Metals are denser than most non-metals. This means they have more mass packed into a given volume.
Metals are hard
Metals are hard
Signup and view all the flashcards
Metals are malleable and ductile
Metals are malleable and ductile
Signup and view all the flashcards
Metals are shiny and good conductors
Metals are shiny and good conductors
Signup and view all the flashcards
Conventional Metal Processing
Conventional Metal Processing
Signup and view all the flashcards
Laser Powder Bed Fusion (LPBF)
Laser Powder Bed Fusion (LPBF)
Signup and view all the flashcards
What is Laser Powder Bed Fusion (LPBF) used for?
What is Laser Powder Bed Fusion (LPBF) used for?
Signup and view all the flashcards
Geometric Freedom in Metal AM
Geometric Freedom in Metal AM
Signup and view all the flashcards
Quicker to Market in Metal AM
Quicker to Market in Metal AM
Signup and view all the flashcards
Cost Savings in Metal AM
Cost Savings in Metal AM
Signup and view all the flashcards
Improved Design / Performance in Metal AM
Improved Design / Performance in Metal AM
Signup and view all the flashcards
Example of Metal AM Application - Lightweight Brake Calliper
Example of Metal AM Application - Lightweight Brake Calliper
Signup and view all the flashcards
Example of Metal AM Application - GE Fuel Injector
Example of Metal AM Application - GE Fuel Injector
Signup and view all the flashcards
Example Application of Metal AM on Engine Component
Example Application of Metal AM on Engine Component
Signup and view all the flashcards
Laser Powder Bed Fusion
Laser Powder Bed Fusion
Signup and view all the flashcards
Tensile Strength
Tensile Strength
Signup and view all the flashcards
Toughness
Toughness
Signup and view all the flashcards
Creep Resistance
Creep Resistance
Signup and view all the flashcards
Corrosion Resistance
Corrosion Resistance
Signup and view all the flashcards
Topology Optimization
Topology Optimization
Signup and view all the flashcards
Biocompatibility
Biocompatibility
Signup and view all the flashcards
Modulus of Elasticity
Modulus of Elasticity
Signup and view all the flashcards
Weight Saving
Weight Saving
Signup and view all the flashcards
Engine Cover Door Hinge
Engine Cover Door Hinge
Signup and view all the flashcards
Scanning Speed
Scanning Speed
Signup and view all the flashcards
Hatch Distance
Hatch Distance
Signup and view all the flashcards
LPBF Environment
LPBF Environment
Signup and view all the flashcards
Powder Morphology
Powder Morphology
Signup and view all the flashcards
Layer Thickness
Layer Thickness
Signup and view all the flashcards
Substrate Type
Substrate Type
Signup and view all the flashcards
Pre-heat
Pre-heat
Signup and view all the flashcards
High Density
High Density
Signup and view all the flashcards
Fine Microstructure
Fine Microstructure
Signup and view all the flashcards
Custom Microstructure
Custom Microstructure
Signup and view all the flashcards
What is Laser Powder Bed Fusion (LPBF)?
What is Laser Powder Bed Fusion (LPBF)?
Signup and view all the flashcards
What is Warpage in LPBF?
What is Warpage in LPBF?
Signup and view all the flashcards
What are Supports/Anchors in LPBF?
What are Supports/Anchors in LPBF?
Signup and view all the flashcards
Why are Support Removal Costs a Factor in LPBF?
Why are Support Removal Costs a Factor in LPBF?
Signup and view all the flashcards
Why are Post-processing Operations Needed in LPBF?
Why are Post-processing Operations Needed in LPBF?
Signup and view all the flashcards
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.
Studying That Suits You
Use AI to generate personalized quizzes and flashcards to suit your learning preferences.
Related Documents
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.
