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Lecture

Advanced Manufacturing of Metals: Thermal History and Microstructure

In course

MICRO-631: Selected topics in advanced manufacturing

The course aims to provide a comprehensive overview of ongoing advanced manufacturing research topics and an opportunity for students to investigate current research trends. ...

Description

This lecture delves into the advanced manufacturing of metals, focusing on the thermal history and microstructure of laser powder bed fusion (LPBF) processes. Dr. Charlotte de Formanoir discusses the epitaxial growth, solidification microstructure at grain and sub-grain levels, and the impact of process parameters on melt pool morphology. The lecture also covers the origin of porosity, keyhole mode formation, and lack-of-fusion defects. Strategies to mitigate residual stresses, enhance surface roughness, and optimize mechanical properties through post-treatments are explored. The importance of heat treatments in achieving balanced mechanical properties and the mechanical anisotropy of LPBF metals are highlighted. The lecture concludes by emphasizing the critical role of material science in additive manufacturing of metals.

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Related concepts (32)

Porosity

Porosity or void fraction is a measure of the void (i.e. "empty") spaces in a material, and is a fraction of the volume of voids over the total volume, between 0 and 1, or as a percentage between 0% and 100%. Strictly speaking, some tests measure the "accessible void", the total amount of void space accessible from the surface (cf. closed-cell foam). There are many ways to test porosity in a substance or part, such as industrial CT scanning.

Residual stress

In materials science and solid mechanics, residual stresses are stresses that remain in a solid material after the original cause of the stresses has been removed. Residual stress may be desirable or undesirable. For example, laser peening imparts deep beneficial compressive residual stresses into metal components such as turbine engine fan blades, and it is used in toughened glass to allow for large, thin, crack- and scratch-resistant glass displays on smartphones.

Materials science

Materials science is an interdisciplinary field of researching and discovering materials. Materials engineering is an engineering field of finding uses for materials in other fields and industries. The intellectual origins of materials science stem from the Age of Enlightenment, when researchers began to use analytical thinking from chemistry, physics, and engineering to understand ancient, phenomenological observations in metallurgy and mineralogy. Materials science still incorporates elements of physics, chemistry, and engineering.

Effective porosity

Effective porosity is most commonly considered to represent the porosity of a rock or sediment available to contribute to fluid flow through the rock or sediment, or often in terms of "flow to a borehole". Porosity that is not considered "effective porosity" includes water bound to clay particles (known as bound water) and isolated "vuggy" porosity (vugs not connected to other pores). The effective porosity is of great importance in considering the suitability of rocks or sediments as oil or gas reservoirs, or as aquifers.

3D printing

3D printing or additive manufacturing is the construction of a three-dimensional object from a CAD model or a digital 3D model. It can be done in a variety of processes in which material is deposited, joined or solidified under computer control, with material being added together (such as plastics, liquids or powder grains being fused), typically layer by layer. In the 1980s, 3D printing techniques were considered suitable only for the production of functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping.

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