Quality Analysis of Additively Manufactured Metals Simulation Approaches, Processes, and Microstructure Properties

Quality Analysis of Additively Manufactured Metals: Simulation Approaches, Processes, and Microstructure Properties provides readers with a firm understanding of the failure and fatigue processes of additively manufactured metals. With a focus on computational methods, the book analyzes the process-microstructure-property relationship of these metals and how it affects their quality while also providing numerical, analytical, and experimental data for material design and investigation optimization. It outlines basic additive manufacturing processes for metals, strategies for modeling the microstructural features of metals and how these features differ based on the manufacturing process, and more.

Improvement of additively manufactured metals through predictive simulation methods and microdamage and micro-failure in quasi-static and cyclic loading scenarios are covered, as are topology optimization methods and residual stress analysis techniques. The book concludes with a section featuring case studies looking at additively manufactured metals in automotive, biomedical and aerospace settings.

Part One: Fundamentals 1. Standards for metal additive manufacturing: Quality and quality control procedures 2. Processing-microstructure-property relationship for AM metals and the effect of thermal properties 3. Process-dependent material characteristics of DMLSmanufactured specimens 4. Structural defects and mechanical properties of additively manufactured parts 5. Microstructural features in metallic parts made by AM 6. Additive manufacturing processes for metals

Part Two: Process, microstructure, property for AM metals: Experimental investigations 7. Postprocess treatments for surface quality improvement, mitigation of defects, and microstructural control 8. Linking materials systems approach to alloy design and part qualification for laser powder bed fusion additive manufacturing 9. Microstructure and mechanical property correlation for additively manufactured aluminum-silicon alloys

Part Three: Improvement/optimization of am part quality by predictive simulation methods 10. A multiscale simulation approach to parametric investigation of process parameters in the characteristics and mechanical properties of AlSi10Mg parts manufactured by LPBF 11. Residual stress analysis and geometrical tolerances in powder bed fusion and direct energy deposition processes 12. Wire arc additive manufacturing of light metals: From experimental investigation to numerical process simulation and microstructural modeling 13. Predictive simulation of microstructural pattern in additively manufactured metallic materials 14. Rapid alloying in additive manufacturing using integrated computational materials engineering

Part Four: Future perspectives and applications of AM industrial products 15. Prospects of additively manufactured nickel aluminum bronzes for marine applications 16. Quality of AM implants in biomedical application 17. Quality of AM parts in automotive application: Design-processproperty relation for automotive parts 18. Metal-3D-printed permeable leading edges for airfoil noise reduction 19. Highly efficient and resource-saving function-integrated additively manufactured components for the mobility of tomorrow

Javad Kadkhodapour is currently Guest Professor at the University of Stuttgart, Germany, focusing on quality control of additively manufactured materials. He has previously worked as a research associate and project manager for research projects in several prestigious European and Iranian universities, gaining expert knowledge in the areas of multi-scale analysis for multiphase metallic and multi-material polymeric structures in different manufacturing processes, including additive manufacturing. His industry experience includes working on additive manufacturing of metals and polymers at Shining 3D Company in Hangzhou, China, as well as research and development roles with multiple companies in the automotive and biomedical sectors in Germany.
Siegfried Schmauder is Professor of Mechanical Engineering at University of Stuttgart, Germany. His research focuses on microstructure mechanics, multiscale modeling, additive manufacturing, material and component testing, material development and optimization, as well as component reliability and design. He applies experimental and numerical investigation techniques to steels, light alloys, fiber composite materials on a metal and polymer basis, metal/ceramic composite materials, hard metals and coatings. The investigative focus is on microstructure modeling and nanosimulation with a view to examining the correlation between material structure and material properties as well as shedding light on the phenomena that occur at grid level that are important in terms of elastic and place material and damage response.
Felix Sajadi is currently a PhD student at the University of Stuttgart, in Germany.