Metal Additive Manufacturing. Ehsan Toyserkani

USA

      Editorial Office 111 River Street, Hoboken, NJ 07030, USA

      For details of our global editorial offices, customer services, and more information about Wiley products, visit us at www.wiley.com.

      Wiley also publishes its books in a variety of electronic formats and by print‐on‐demand. Some content that appears in standard print versions of this book may not be available in other formats.

      Limit of Liability/Disclaimer of Warranty While the publisher and authors have used their best efforts in preparing this work, they make no representations or warranties with respect to the accuracy or completeness of the contents of this work and specifically disclaim all warranties, including without limitation any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives, written sales materials, or promotional statements for this work. The fact that an organization, website, or product is referred to in this work as a citation and/or potential source of further information does not mean that the publisher and authors endorse the information or services the organization, website, or product may provide or recommendations it may make. This work is sold with the understanding that the publisher is not engaged in rendering professional services. The advice and strategies contained herein may not be suitable for your situation. You should consult with a specialist where appropriate. Further, readers should be aware that websites listed in this work may have changed or disappeared between when this work was written and when it is read. Neither the publisher nor authors shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages.

       Library of Congress Cataloging‐in‐Publication Data

      Names: Toyserkani, Ehsan, author. | Sarker, Dyuti, 1983- author. | Ibhadode, Osezua Obehi, 1989‐ author. | Liravi, Farzad, 1990- author. | Russo, Paola, 1986‐ author. | Taherkhani, Katayoon, 1989- author. | John Wiley & Sons, publisher.

      Title: Metal additive manufacturing / Ehsan Toyserkani, Dyuti Sarker, Osezua Obehi Ibhadode, Farzad Liravi, Paola Russo, Katayoon Taherkhani.

      Description: Hoboken, NJ : Wiley, 2021.

      Identifiers: LCCN 2021028894 (print) | LCCN 2021028895 (ebook) | ISBN 9781119210788 (cloth) | ISBN 9781119210849 (adobe pdf) | ISBN 9781119210832 (epub)

      Subjects: LCSH: Additive manufacturing. | Metal powder products–Design and construction. | Powder metallurgy.

      Classification: LCC TS183.25 .T69 2021 (print) | LCC TS183.25 (ebook) | DDC 621.9/88–dc23

      LC record available at https://lccn.loc.gov/2021028894 LC ebook record available at https://lccn.loc.gov/2021028895

      Cover Design: Wiley

      Cover Image: Courtesy of Ehsan Toyserkani (top); © MarinaGrigorivna/Shutterstock

10 9 8 7 6 5 4 3 2 1

       In memory of

       Professor Pearl Sullivan (1961–2020)

       Former Dean of Faculty of Engineering, University of Waterloo, Canada

       A true leader, an exemplary advocate for engineering education, and a great friend

      Preface

      Additive manufacturing (AM) promises to change the entire manufacturing enterprise over the next two decades. No longer limited to prototyping and low‐volume manufacturing, AM is being adopted for economies of scale without compromising economies of scope. The need for the digitization of manufacturing, on‐demand personalized manufacturing, distributed production, and rapid production in the event of crises have all elevated the position of AM in the medical and engineering sectors. AM is now a major research target for industrialized countries as they seek to regain leadership in advanced manufacturing through innovation. The global economy is on the verge of the next industrial revolution and sector after sector is pulling away from traditional, conventional production methods to engage in and utilize AM. However, this promise does come with many challenges, particularly for metal AM. Research and development activities are progressing at full steam to address multiple technical challenges, such as speed and productivity, quality assurance, standards, and end‐to‐end workflow.

      A major skill sets gap currently hinders efforts to tackle these challenges. For companies seeking to embrace AM, this gap translates into a limited availability of expertise to draw an entry strategy to the AM industry. The wider adoption of AM will require overcoming the limited foundational understanding of AM that currently exists within the workforce. A thorough understanding of AM capabilities is necessary for technical experts to accurately communicate the pros and cons of AM to decision‐makers, while preventing misconceptions and misinformation about AM capabilities. Currently, the knowledge gap is significantly impacting progress in the sector, as companies have difficulties in recruiting AM experts to help them develop effective designs for AM as well as meaningful business cases for metal AM.

This book is designed to help academia and industry move toward filling this gap. Enhancing AM skills will require the development of foundational knowledge of AM starting at the undergraduate level. To our knowledge, there is currently no textbook available that links the basics of fundamental undergraduate Engineering courses with metal AM processes. There is a clear need to customize undergraduate concepts in technical courses related to design, heat transfer, fluid mechanics, solid mechanics, and control, with respect to AM applications. Additionally, business‐ and management‐oriented courses should include AM to facilitate the consideration of AM in conjunction with life cycle assessment and business model developments among students.

      The development of this book was motivated by our desire to provide foundational material for a core undergraduate course in Mechanical and Manufacturing Engineering, and we envision its use in graduate courses as well. Universities globally are revising their curriculum to incorporate AM‐related courses. This textbook may provide an introductory platform to be adopted in such courses to promote an appreciation for and grasp of AM among both undergraduate and graduate students. This book may also fill a gap for engineers working outside academia who want to appreciate AM processes by identifying links between traditional core physics and engineering concepts courses and AM. The book provides a step‐by‐step understanding of metal AM and a solid foundation of the topic for readers, who will subsequently be well equipped to explore AM research in greater depth.

      For a broad range of readers, this book sheds light on various key metal AM technologies, focusing on basic physics and modeling. This textbook is not a literature survey, nor is it intended for readers with no engineering background. In contrast, it is an introduction to basic physical concepts and phenomena of metal AM processes and their applications. Relevant foundational concepts, such as energy deposition, powder bed fusion, and binder jetting processes, are explained in‐depth and illustrated by case studies throughout the book. Additionally, two emerging processes for metal AM: material extrusion and material jetting, are described. Basic design for AM (DfAM) and quality assurance principles are also covered.

      We would like to express our sincere gratitude to several people who helped in the preparation of this book. Special thanks to Francis Dibia, Ali Keshavarzkermani, Zhidong Zhang, Yuze Huang, Mazyar Ansari, Andrew Barlow, Misha Karpinska, Donovan Kwong, and Eniife Elebute, who helped us with some materials and produced some of the figures, as attributed in the book. In addition, we acknowledge all organizations, publishers, authors, and companies that permitted use of their figures, plots, and texts; they have been cited accordingly throughout the book. Last but not least, thanks to our families, who make it all worthwhile.

      Like any first edition, this textbook may contain errors and typos. We openly