Additive Manufacturing of Emerging Materials (eBook)

AlMangour has worked as a Postdoctoral Fellow at Harvard University, School of Engineering and Applied Science during 2017. Bandar AlMangour received his Ph.D. and Master of Science in Materials Science and Engineering from University of California, Los Angeles (UCLA) in 2014 and 2017 respectively, a Master of Engineering in Materials Engineering from McGill University in 2012, and a Bachelor of Science in Mechanical Engineering from King Fahd University of Petroleum and Minerals (KFUPM) in 2005. He served as a Research Engineer at the Saudi Basic Industries Corporation (SABIC) from Jun. 2008–Dec. 2009 and as a Production Supervisor in the Rolling Mills division from Apr. 2005–May 2008 at the Saudi Iron & Steel Company (HADEED), a SABIC affiliate in Jubail, Saudi Arabia. AlMangour is a member of several professional associations and still served as a reviewer in several internationally recognized journals. AlMangour has authored a book published by LAP LAMBERT Academic Publishing (2014) and a chapter for a book published by Nova Science Publishers (2015), as well as a chapter for a book published by Springer (2017). His principle research interests include the laser-based additive manufacturing of metal alloys and metal matrix composites, scalable micro- and nano-manufacturing, materials processing, physical metallurgy, bulk-form nanostructured alloys and composites, and surface engineering. AlMangour has authored more than 20 peer-reviewed papers in internationally recognized journals and presented research at several international conferences. He was awarded the SABIC Graduate Fellowships (Doctor of Philosophy, 2012–2017; Master of Engineering, 2010–2012), the Undergraduate Memorial Honor Medal (2005), Certificates of Distinction (KFUPM, 2004 and 2005), the Department of Materials Science and Engineering “Outstanding Ph.D. Student Award” (2017), FEI Tony Award for best SEM image (2017).

Contents 5
Additive Manufacturing of In Situ Metal Matrix Composites 7
1 Introduction 7
2 Metal Matrix Composites 9
2.1 In-Situ Reactions Between Elemental Blend Powders 11
2.1.1 Aluminum Matrix Composites: Al-Fe2O3 11
2.1.2 AlSi10Mg-SiC 13
2.1.3 Nickel Matrix Composites: Ni-Ti-C 15
2.1.4 Titanium Matrix Composites: Ti-B and Ti64-BN 20
2.2 In Situ Reaction Between Elemental Blend Powders and Reactive Gases 22
2.2.1 Ti-Mo-N 22
2.2.2 Ti64/TNZT-N 28
3 Summary 29
References 31
Optimization of Electrical Discharge Machining of Titanium Alloy (Ti6Al4V) by Grey Relational Analysis Based Firefly Algorithm 35
1 Introduction 35
2 Literature Review 37
3 Methodology 39
3.1 Grey Relational Analysis (GRA) 39
3.2 Firefly Algorithm (FA) 40
4 Materials and Methods 41
4.1 Material Removal Rate (MRR) 45
4.2 Tool Wear Rate (TWR) 46
4.3 Average Surface Roughness (Ra) 46
5 Result and Discussion 48
5.1 Effect of Parameters on MRR 48
5.2 Effect of Parameters on TWR 50
5.3 Effect of Parameters on Average Surface Roughness 50
6 Optimization by Grey Relational Analysis Based Firefly Algorithm 53
7 Surface Crack Density of Machined Surface 56
8 Conclusion 57
References 58
Laser-Based Additive Manufacturing of Lightweight Metal Matrix Composites 60
1 Introduction 60
2 Additive Manufacturing Processes 61
3 Additive Manufacturing Versus Conventional Manufacturing 64
4 Additive Manufacturing Processes for Fabricating MMCs 67
4.1 Powder Bed Fusion (PBF) Processes 68
4.2 Direct Energy Deposition (DED) Processes 69
5 Challenges of MMCs Fabrication Using Additive Manufacturing Processes 71
6 Various Types of MMCs 72
6.1 Ex-Situ Reinforced MMCs 72
6.2 Hybrid Ex-Situ/In-Situ Reinforced MMCs 74
6.3 In-Situ Reinforced MMCs 75
6.4 TMCs with Metallic Reinforcements 78
6.5 Additively Manufactured Lightweight Metal Matrix Nano-Composites (MMnCs) 79
7 Temperature-Driven Forces and Flows and Viscosity in Laser-Induced Melt Pools 81
7.1 Surface Tension and Marangoni Flow 81
7.2 Recoil Pressure 83
7.3 Rayleigh-Benard Convection 84
7.4 Dynamic Viscosity of Solid-Liquid Mixed Melt Pools 84
8 Parameters Affecting Microstructural Features of Reinforcements in Hybrid Ex-Situ/In-Situ Reinforced and In-Situ Reinforced ... 85
8.1 Laser Energy Density 85
8.1.1 Amount of In-Situ Reaction 86
8.1.2 Size of In-Situ Reaction Products 87
8.1.3 Morphology of In-Situ Synthesized Reinforcements 88
8.2 Characteristics of Powder Mixture 90
8.2.1 Size of Reinforcing Particles 90
8.2.2 Volume Fraction of Reinforcing Particles 90
9 Distribution Pattern of Reinforcements 93
9.1 Non-homogenous Distribution 93
9.1.1 Bimodal Distribution 93
9.1.2 Agglomeration or Clustering of Reinforcements 93
9.2 Homogenous Distribution of Reinforcements 95
9.3 Microstructures with Ring-Like Distribution Pattern of Reinforcements 96
10 Effect of Reinforcement Features on Mechanical Properties of Additively Manufactured Lightweight MMCs 99
10.1 Volume Fraction 99
10.2 Size 101
10.3 Distribution Pattern 101
11 Applications of Additively Manufactured Lightweight MMCs 102
References 104
Process-Structure-Property Relationships in Additively Manufactured Metal Matrix Composites 115
1 Introduction 115
2 Why AM Instead of Conventional Manufacturing for MMC Fabrication? 118
3 Additively Manufactured MMCs (Challenges, Opportunities and Existing Literature) 119
3.1 Aluminum-Matrix Composites (AMCs) 119
3.2 Titanium-Matrix Composites (TMCs) 120
3.3 Nickel-Based Matrix Composites 122
3.4 Copper-Matrix Composites 123
3.5 Iron-Based Matrix Composites 124
4 Pre-processing of Mixed Powder System 126
5 Microstructural Evolution in Additively Manufactured MMCs 130
5.1 Characteristics of Reinforcements Distributed in the Matrix 131
5.1.1 Size and Morphology of Reinforcements 131
Ex-Situ Reinforced MMCs 131
In-Situ Reinforced MMCs 132
5.1.2 Distribution Pattern of Reinforcements 133
Effect of Scanning Speed 133
Effect of Energy Density 135
Effects of Size and Volume Fraction of Reinforcements 135
5.2 Reinforcement/Matrix Reactions 136
5.2.1 Reaction Mechanisms 136
5.2.2 Reinforcements/Matrix Interfacial Reaction 137
5.2.3 Formation of In-Situ Reaction Products 141
5.3 Microstructural Evolutions in the Matrix Induced by the Presence of Reinforcements 143
5.3.1 Microstructural Refinement of the Matrix 143
5.3.2 Texture of the Matrix 145
5.3.3 Microstructural Evolution and Phase Transformation 148
5.3.4 Formation of Supersaturated Matrix 151
5.3.5 Formation of Dislocations in the Matrix 152
6 Part Quality and Surface Integrity of AM Processed MMCs 153
6.1 Applied Energy Density 154
6.2 Characteristics of Mixed Powder System 156
7 Mechanical Properties of AM Processed MMCs 159
7.1 Strengthening Mechanisms 159
7.1.1 Direct Strengthening 160
Reinforcement Volume Fraction 161
Reinforcement Type 162
Reinforcement Size 162
7.1.2 Indirect Strengthening 163
Grain Refinement of the Matrix 164
Increased Density of Dislocations in the Matrix 165
The Matrix Strengthening Caused by Microstructural Modifications 166
Solid Solution Strengthening of the Matrix 167
7.2 Weakening Mechanisms 168
7.2.1 Decreased Densification Level 168
7.2.2 Microstructure Coarsening 168
7.2.3 Microstructural Inhomogeneity 169
8 Wear Behavior 169
8.1 Effect of Size and Volume Fraction of Reinforcements 169
8.2 Effect of Applied Energy Density 171
References 172
Additive Manufacturing of Titanium Alloys for Biomedical Applications 182
1 Introduction 182
2 Additive Manufacturing for Biomedical Application 183
2.1 Selective Laser Melting (SLM) 184
2.2 Electron Beam Melting (EBM) 186
3 Development of AM Biomedical Titanium Alloy 187
3.1 Selective Laser Melting (SLM) of Titanium Alloys 188
3.2 Electron Beam Melting (EBM) of Titanium Alloys 193
4 Conclusion 195
References 196
Corrosion Behaviors of Additive Manufactured Titanium Alloys 200
1 Introduction 200
2 SLM-Produced Ti-6Al-4V 201
3 EBM-Produced Ti-6Al-4V 211
4 SLM-Produced Ti-TiB 217
5 Other Alloys Produced by AM Technique 219
5.1 Co-Cr Based Alloys 219
5.2 SLM-Produced 316L Stainless Steel 221
6 Concluding Remarks 224
References 224
Effect of Process Parameters of Fused Deposition Modeling and Vapour Smoothing on Surface Properties of ABS Replicas for Biome... 230
1 Surface Finishing Techniques for FDM Parts 230
1.1 Pre-processing Techniques of Surface Finishing 230
1.2 Post-processing Techniques of Surface Finishing 232
2 Optimization Study of Process Parameters of FDM and Vs Processes 233
3 Mathematical Modeling of Surface Properties Using Buckingham Pi Theorem 243
3.1 Mathematical Model of Surface Roughness 243
3.2 Mathematical Model of Surface Hardness 244
3.3 Mathematical Model of Dimensional Accuracy 245
4 Multi-response Optimization 246
5 Differential Scanning Calorimetry 247
6 Summary 249
References 250
Development of Rapid Tooling Using Fused Deposition Modeling 253
1 Introduction 253
2 Development of Low Cost Composite Material Feedstock Filament 253
2.1 Fabrication of Filament on Single Screw Extruder 255
2.1.1 Rheological Behavior 255
2.2 Fabrication of Filament on Single Screw Extruder 257
2.2.1 Inspection and Testing 258
2.2.2 Mechanical Testing 259
2.2.3 Fabrication of Parts On FDM 260
2.2.4 Dynamic Mechanical Analysis 261
3 Results and Discussion 262
3.1 Rheological Properties 262
3.2 Mechanical Properties 263
3.3 Dynamic Mechanical Analysis 263
3.3.1 Viscoelastic Behavior of Composite Materials 263
Storage Modulus (E?) 263
Loss Modulus (E??) 265
Loss Factor or tan ? (E??/E?) 266
3.3.2 Viscoelastic Behavior of ABS Material 267
4 Design of Experiments 268
4.1 Taguchi´s Approach 269
4.2 Data Analysis Using ANOVA 269
4.3 Analysis of Variance for SN ratios 270
4.4 Significance of Process Parameters 271
4.5 Optimum Parameters 271
4.6 Empirical Relationship 272
5 Process Capability Study 273
6 Conclusions 275
References 278
Development of ABS-Graphene Blended Feedstock Filament for FDM Process 280
1 Evolution of Conducting Polymers 280
2 Acrylo Nitrile Butadiene Styrene and Graphene 280
3 Extraction of Gr 281
4 Materials 282
5 Twin Screw Extrusion 282
6 Testing Techniques for ABS-Gr Blended Feedstock Filament 283
6.1 Lee´s Method for Thermal Conductivity 283
6.2 Measurement of Electrical Conductivity 284
6.3 Measurement of Porosity and Hardness 285
7 Optimisation Study of Process Parameter of FDM 285
8 Analysis of Electrical Conductivity Test 287
9 Analysis of Thermal Conductivity Test 289
10 Analysis of Porosity 291
11 Analysis of Shore Hardness 292
12 Optical Micrograph Observations for Porosity 294
13 Differential Scanning Calorimeter 295
14 Summary 297
References 297
Investigate the Effects of the Laser Cladding Parameters on the Microstructure, Phases Formation, Mechanical and Corrosion Pro... 299
1 Introduction 299
1.1 Evolution of MG 300
1.2 Mechanical Properties of MG 301
1.3 Biocompatibility of MG Systems 303
2 Techniques to Fabricate MG 305
2.1 Melt Spinning 306
2.2 Casting 306
2.3 Additive Manufacturing 307
2.3.1 Laser Cladding Technique for MG Coatings 308
2.3.2 Experimental Procedures 310
Sample Preparation 310
Characterization and Testing 311
2.3.3 Results 312
XRD Analysis 312
Microstructure Examination 315
Hardness Measurement 316
Electrochemical Corrosion Test 318
2.3.4 Conclusion 319
References 321
Fabrication of PLA-HAp-CS Based Biocompatible and Biodegradable Feedstock Filament Using Twin Screw Extrusion 324
1 Introduction 324
2 Melt Flow Index 326
2.1 Procedure to Determine Melt Flow Index 327
3 Extrusion 327
3.1 Twin Screw Extrusion 328
4 Fused Deposition Modeling (FDM) 328
4.1 The Technology 328
4.2 Process 329
5 Differential Scanning Calorimetry (DSC) 329
5.1 Techniqe 329
6 Materials and It´s Prepration 331
6.1 Materials 331
6.1.1 Preparation of Materials (PLA, HAp and CS) 331
7 Preparation of Feed Stock Filament On TSE for FDM 331
7.1 Rehological Behavior 331
7.2 Tensile Behavior 332
7.3 Thermal Behavior 333
7.4 Scanning Electron Microscopic Behavior 334
7.5 Design of Experiment (DOE) 335
7.6 Fabrication of Feedstock Filament Based on DOE 337
8 Summary 341
References 342
Index 345