Advanced Additive Manufacturing in Aerospace, Mechanical, and Biomedical Engineering
AME 4970/5970
Yingtao Liu
Additive manufacturing, often referred as 3D printing, is revolutionizing the way we build structures and products, since it allows the design flexibility that is well beyond what can be achieved using standard manufacturing techniques. In the last two decades, the advance of additive manufacturing technologies has led to new approaches to build 3D objects by adding layer-upon-layer of materials, including plastics, metals, concrete, and even biological cells. Early use of additive manufacturing in the form of rapid prototyping focused on preproduction visualization models. More recently, novel 3D printing technologies are being used to fabricate end-use products in aircraft, dental restorations, medical implants, and automobiles. Due to the strong industrial needs, it is critical to train both undergraduate and graduate engineering students with the latest 3D printing technologies.
This Presidential Dream Course will expose students to the state-of-the-art of additive manufacturing technologies. Special efforts are focused on assisting students to understand the recent technologies developed in additive manufacturing for aerospace, mechanical, and biomedical engineering applications, emphasizing three specific topics: (i) the design orientated additive manufacturing; (ii) 3D printing of soft polymers for biomedical applications; (iii) rapid 3D printing of high temperature super alloys as critical aerospace components.
Public Lecture Series
Information for this Lecture Series will be posted here as it comes in.
A Simple Cost Model to Drive Design for Additive Manufacturing
Tuesday, Septebmer 14, 2021
Zoom
Timothy W. Simpson, Ph.D.
Paul Morrow Professor of Engineering Design & Manufacturing
The Pennsylvania State University
Designing for additive manufacturing (AM) is as much about maximizing the value afforded by AM’s layer-wise fabrication as it is about minimizing the costs associated with an AM process. While our understanding of Design for AM (DfAM) has matured rapidly over the past decade as tools and methods have evolved, we still struggle to translate this into direct economic benefit, which is key to industrializing AM. In this talk, I introduce a simple cost model for metal AM, specifically laser powder bed fusion, that can help drive DfAM decisions and enable DfAM trade studies. Despite its simplicity, the simple model provides a guide to identify profitable pathways to AM. If none of those pathways are immediately profitable, then the cost model provides insight into when the part will become viable as other economic factors (e.g., material costs, machine cost) or technical factors (e.g., laser powder, number of lasers) fluctuate in the market. An example from an industry training exercise will be discussed to demonstrate application of the costing guide to achieve a viable AM part when using DfAM. The example also illustrates how DfAM is the “value multiplier” for AM, helping to achieve a profitable AM part faster and with more control than waiting for powder costs to come down or and machine prices to fall. Generalizability of the costing guide to other AM processes will also be discussed.
Additive Manufacturing of Metal Parts for Extreme Environments
Thursday, September 23, 2021
9 am
Zoom
Dr. Scott Thompson
Steve Hsu Keystone Associate Professor
Alan Levin Department of Mechancial & Nuclear Engineering
Additive manufacturing (AM) has demonstrated to be a unique means for rapidly and remotely building customized, complex metallic parts for a variety of engineering applications within the energy, aerospace, biomedical and automotive industries. For the energy sector, there is an emerging interest in using AM to fabricate customized components for enhancing the efficiency and overall manufacturability of modular (very small) nuclear power plants. This talk will focus on describing the opportunities and challenges associated with metals AM for critical, 'extreme' applications such as nuclear power cycles. The process- structure-property-performance relationships inherent to laser-powder bed fusion (L-PBF) AM methods, nickel-based superalloys, and microstructure, residual stress and porosity will be discussed. Results demonstrating the effects of nuclear and ion radiation on L-PBF metal hardness and microstructure will be shown.
Scott M. Thompson is a Steve Hs Keystone Associate Professor in the Alan Levin Department of Mechanical & Nuclear Engineering in the Carl R. Ice College of Engineering at Kansas State University (KSU). He received both his B.S. and Ph.D. in Mechanical Engineering from the University of Missouri (MU) in 2008 and 2012, respectively. Dr. Thompson's research focuses on modeling the metals additive manufacturing (AM) process and in characterizing such parts (microstructure, properties, residual stress) before/ after nuclear environmental exposure. He also performs research on heat exchanger design, heat pipes, heat transfer, energy harvesting, passive flow control, and more. His research efforts have led to 50+ published/peer-reviewed journal articles, 2 book chapters, and 80+ conference proceedings and presentations. He has helped secure and lead several externally- funded research projects (>$ 3 Mil) from agencies such as the DoD, DoE, DARPA, NSF, and NASA. Thompson is a senior member of the AIAA and ASME. He continues to co-organize the annual ASME IMECE Symposium on AM and iS currently the Chair of ASME's K13 Committee on Heat Transfer in Multiphase Systems.
Modeling and Control of Laser Metal Deposition Processes in Additive Manufacturing
Tuesday, September 28, 2021
9 am
Zoom
Dr. Robert Landers
Curators’ Distinguished Professor
Department of Mechanical and Aerospace Engineering
Missouri University of Science and Technology
Laser metal deposition (LMD) is a metal blown powder bed additive manufacturing (AM) process capable of fabricating large parts and parts with graded materials, adding engineering features onto parts, and cost-effective part repair. Unfortunately, as compared to the more popular metal powder bed AM processes, it is quite challenging to regulate the morphology and LMD builds. There are a variety of sources that cause variations in the process and can lead to builds of high-value parts failing. Process control is seen as a means to account for variations such as high-value parts can be certified, which is critical for the aerospace, defense, and biomedical industries. A number of research studies have investigated the use of feedback control where a process parameter is automatically adjusted to regulate a measurement signal. While some success has been demonstrated in the laboratory, most additive manufacturing machines have closed control architecture, limiting the usefulness of these approaches. Our research concentrates on layer-to-layer control where measurements gathered during printing of a layer. Immediately after the fabrication of a layer, the control analysis results are used to automatically adjust the process parameters for the subsequent layer. These algorithms can be easily implemented on industrial machines. In this talk, we will describe our work in the two-dimensional modeling of the LMD process. The models characterize the important features of the LMD process needed to understand part’s fabricated morphology and elucidate critical dynamic properties. Layer-to-layer control strategies are constructed for the LMD process to regulate the part morphology. Experiments are conducted to identify critical process model parameters, stability is analyzed, and the control strategies are applied to an LMD process.
Dr. Robert G. Landers is a Curators' Distinguished Professor of Mechanical Engineering in the Department of Mechanical and Aerospace Engineering at the Missouri University of Science and Technology (formerly University of Missouri Rolla) and served as the department's Associate Chair for Graduate Affairs for eight years. He received his Ph.D. degree in Mechanical Engineering from the University of Michigan in 1997. His research interests are in the areas of modeling, analysis, monitoring, and control of manufacturing processes (laser metal deposition, glass direct energy deposition, selective laser melting, freeze-form extrusion fabrication, wire saw machining, metal cutting, friction stir welding), and estimation and control of lithium ion batteries, hydrogen fuel cells, and digital control applications. He has over 200 refereed technical publications, including 79 journal articles, and over $6.4M in research funding. He received the Society of Manufacturing Engineers' Outstanding Young Manufacturing Engineer Award in 2004 and the ASME Journal of Manufacturing Science and Engineering Best Paper Award in 2014. He is a Fellow of ASME, a senior member of IEEE and SME, and a member of ASEE. He served as associate editor for the ASME Journal of Dynamic Systems, Measurement, and Control (2009-2012), ASME Journal of Manufacturing Science and Engineering (2010-2014), and the IEEE Transaction on Control System Technology (2006-2012), and is currently an associate editor for Mechatronics.
Principles of Additive Manufacturing and Their Impact on Possibilities of Quality Assurance
Thursday, September 30, 2021
Zoom
Dr. Peter Collins
Al and Julie Renken Professor
Department of Materials Science and Engineering
In this technical presentation, I will discuss the principles of additive manufacturing (AM), especially related to metals-based additive manufacturing. This talk will present a short history of AM, as the evolution of our understanding has paralleled the evolution of the processes themselves. The core of the talk will address our understanding of the interrelationships between the process(es) and the evolution of the materials state and its influence on properties and performance. There is still much that we don’t understand, and so some vignettes into recent discoveries will be presented, as will some technical possibilities once we fully understand and can predict the process, structure, and performance of any arbitrary material and process. The talk will conclude with some possibilities related to AM-NDE, but will present this more as an important yet still very underdeveloped technical space.
P.C. Collins is a Professor and Entrepreneurial Fellow within the Department of Materials Science and Engineering at Iowa State University and an affiliated faculty in Aerospace Engineering. He received his Ph.D. from The Ohio State University in Materials Science and Engineering. Prior to starting in his first university role, he set up a not-for-profit advanced manufacturing facility embedded in an Army Arsenal. Dr. Collins is actively involved in two NSF Industry/University Cooperative Research Centers, serving as the co-director for the Center for Advanced Non-Ferrous Structural Alloys, and as past director for the Center for Nondestructive Evaluation (CNDE). His primary research interests involve: the physical metallurgy of advanced non-ferrous materials; advanced characterization techniques including various electron microscopies and emergent spectroscopic methods; quantification of defects and crystal orientation across length scales; combinatorial materials science; advanced materials processing with special interest in additive manufacturing; and the mechanical behavior of non-ferrous materials, including establishing composition-microstructure property relationships. He has conducted basic and applied research on metal-based additive manufacturing for over 20 years, and most recently has worked to demonstrate new methods to fully characterize the materials state of additively manufactured metallic systems. He has received multiple awards for teaching and his research, and has been actively involved in a variety of professional societies, planning of conferences and symposia, various government panels and working groups, and has 50+ publications, 50+ invited talks, and multiple US patents.
