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Thermo-mechanical Modeling of Additive Manufacturing provides the background, methodology and description of modeling techniques to enable the reader to perform their own accurate and reliable simulations of any additive process. Part I provides an in depth introduction to the fundamentals of additive manufacturing modeling, a description of adaptive mesh strategies, a thorough description of thermal losses and a discussion of residual stress and distortion. Part II applies the engineering fundamentals to direct energy deposition processes including laser cladding, LENS builds, large electron beam parts and an exploration of residual stress and deformation mitigation strategies. Part III concerns the thermo-mechanical modeling of powder bed processes with a description of the heat input model, classical thermo-mechanical modeling, and part scale modeling. The book serves as an essential reference for engineers and technicians in both industry and academia, performing both research and full-scale production. Additive manufacturing processes are revolutionizing production throughout industry. These technologies enable the cost-effective manufacture of small lot parts, rapid repair of damaged components and construction of previously impossible-to-produce geometries. However, the large thermal gradients inherent in these processes incur large residual stresses and mechanical distortion, which can push the finished component out of engineering tolerance. Costly trial-and-error methods are commonly used for failure mitigation. Finite element modeling provides a compelling alternative, allowing for the prediction of residual stresses and distortion, and thus a tool to investigate methods of failure mitigation prior to building. - Provides understanding of important components in the finite element modeling of additive manufacturing processes necessary to obtain accurate results - Offers a deeper understanding of how the thermal gradients inherent in additive manufacturing induce distortion and residual stresses, and how to mitigate these undesirable phenomena - Includes a set of strategies for the modeler to improve computational efficiency when simulating various additive manufacturing processes - Serves as an essential reference for engineers and technicians in both industry and academia
Computational welding mechanics (CWM) provides an important technique for modelling welding processes. Welding simulations are a key tool in improving the design and control of welding processes and the performance of welded components or structures. CWM can be used to model phenomena such as heat generation, thermal stresses and large plastic deformations of components or structures. It also has a wider application in modelling thermomechanical and microstructural phenomena in metals. This important book reviews the principles, methods and applications of CWM.The book begins by discussing the physics of welding before going on to review modelling methods and options as well as validation techniques. It also reviews applications in areas such as fatigue, buckling and deformation, improved service life of components and process optimisation. Some of the numerical methods described in the book are illustrated using software available from the author which allows readers to explore CWM in more depth.Computational welding mechanics is a standard work for welding engineers and all those researching welding processes and wider thermomechanical and microstructural phenomena in metals. - Highlights the principles, methods and applications of CWM - Discusses the physics of welding - Assesses modelling methods and validation techniques
Marine Composites: Design and Performance presents up-to-date information and recent research findings on the application and use of advanced fibre-reinforced composites in the marine environment. Following the success of their previously published title: Marine Applications of Advanced Fibre-reinforced Composites which was published in 2015; this exemplary new book provides comprehensive information on materials selection, characterization, and performance. There are also dedicated sections on sandwich structures, manufacture, advanced concepts, naval architecture and design considerations, and various applications. The book will be an essential reference resource for designers, materials engineers, manufactures, marine scientists, mechanical engineers, civil engineers, coastal engineers, boat manufacturers, offshore platform and marine renewable design engineers. - Presents a unique, high-level reference on composite materials and their application and use in marine structures - Provides comprehensive coverage on all aspects of marine composites, including the latest advances in damage modelling and assessment of performance - Contains contributions from leading experts in the field, from both industry and academia - Covers a broad range of naval, offshore and marine structures
This is the second volume of an advanced textbook on microstructure and properties of materials. (The first volume is on aluminum alloys, nickel-based superalloys, metal matrix composites, polymer matrix composites, ceramics matrix composites, inorganic glasses, superconducting materials and magnetic materials). It covers titanium alloys, titanium aluminides, iron aluminides, iron and steels, iron-based bulk amorphous alloys and nanocrystalline materials.There are many elementary materials science textbooks, but one can find very few advanced texts suitable for graduate school courses. The contributors to this volume are experts in the subject, and hence, together with the first volume, it is a good text for graduate microstructure courses. It is a rich source of design ideas and applications, and will provide a good understanding of how microstructure affects the properties of materials.Chapter 1, on titanium alloys, covers production, thermomechanical processing, microstructure, mechanical properties and applications. Chapter 2, on titanium aluminides, discusses phase stability, bulk and defect properties, deformation mechanisms of single phase materials and polysynthetically twinned crystals, and interfacial structures and energies between phases of different compositions. Chapter 3, on iron aluminides, reviews the physical and mechanical metallurgy of Fe3Al and FeAl, the two important structural intermetallics. Chapter 4, on iron and steels, presents methodology, microstructure at various levels, strength, ductility and strengthening, toughness and toughening, environmental cracking and design against fracture for many different kinds of steels. Chapter 5, on bulk amorphous alloys, covers the critical cooling rate and the effect of composition on glass formation and the accompanying mechanical and magnetic properties of the glasses. Chapter 6, on nanocrystalline materials, describes the preparation from vapor, liquid and solid states, microstructure including grain boundaries and their junctions, stability with respect to grain growth, particulate consolidation while maintaining the nanoscale microstructure, physical, chemical, mechanical, electric, magnetic and optical properties and applications in cutting tools, superplasticity, coatings, transformers, magnetic recordings, catalysis and hydrogen storage.
Welding is a cost-effective and flexible method of fabricating large structures, but drawbacks such as residual stress, distortion and buckling must be overcome in order to optimize structural performance. Minimization of welding distortion and buckling provides a systematic overview of the methods of minimizing distortion and buckling in welded structures.Following an introductory chapter, part one focuses on understanding welding stress and distortion, with chapters on such topics as computational welding mechanics, modelling the effect of phase transformations on welding stress and distortion and using computationally efficient reduced-solution methods to understand welding distortion. Part two covers different methods of minimizing welding distortion. Chapters discuss methods such as differential heating for minimizing distortion in welded stiffeners, dynamic thermal tensioning, reverse-side heating and ways of minimizing buckling such as weld cooling and hybrid laser arc welding.With its distinguished editor and international team of contributors, Minimization of welding distortion and buckling is an essential reference for all welders and engineers involved in fabrication of metal end-products, as well as those in industry and academia with a research interest in the area. - Provides a systematic overview of the methods of minimizing distortion and buckling in welded structures - Focuses on understanding welding stress and distortion featuring computational welding mechanics and modelling the effect of phase transformations - Explores different methods of minimizing welding distortion discussing differential heating and dynamic thermal tensioning
Proceedings of the NATO Advanced Study Institute, Lisbon, Portugal, July 4-15, 1988
The field of additive manufacturing has seen explosive growth in recent years due largely in part to renewed interest from the manufacturing sector. Conceptually, additive manufacturing, or industrial 3D printing, is a way to build parts without using any part-specific tooling or dies from the computer-aided design (CAD) file of the part. Today, mo
Laser Materials Processing aims to introduce lasers and laser systems to the newcomers to laser terminology and to provide enough background material on lasers to reduce one's hesitation to employ these devices. The book covers the use of lasers in materials processing, including its application in cutting and welding, as well as the principles behind them; laser heat treatment; rapid solidification laser processing at high power density; shaping of materials using lasers; and laser processing of semiconductors. The selection also covers considerations in laser manufacturing and a survey in laser applications. The text is recommended for both experienced laser users, engineers, or scientists yet unfamiliar with the subject. The book is also recommended for those who wish to know about the importance of lasers in the field of materials processing, as the bulk of the book is devoted to the discussions of some of the most important materials processing activities in use or under development.
METAL ADDITIVE MANUFACTURING A comprehensive review of additive manufacturing processes for metallic structures Additive Manufacturing (AM)—also commonly referred to as 3D printing—builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise. Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource: Provides a thorough analysis of AM processes and their theoretical foundations Explains the classification, advantages, and applications of AM processes Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software Discusses the opportunities, challenges, and current and emerging trends within the field Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes Includes illustrative cases studies and numerous figures and tables Featuring material drawn from the lead author’s research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.