Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing.
Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward.
Key Features
- Presents laser powder bed fusion fundamentals, as well as their inherent challenges
- Provides an up-to-date summary of this advancing technology and its potential
- Provides a comprehensive textbook for universities, as well as a reference for industry
- Acts as quick-reference guide
1. Historical background
Joseph J. Beaman, University of Texas, Austin, Texas, USA
2. Basics of laser powder bed fusion
Igor Yadroitsev and Ina Yadroitsava, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa
3. A step-by-step guide to the L-PBF process
Igor Yadroitsev and Ina Yadroitsava, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa;
4. Physics and modeling
Andrey V. Gusarov, Moscow State University of Technology STANKIN, Moscow, Russia
5. Design principles
Martin Leary, David Downing, and Bill Lozanovski, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia; Jonathan Harris, nTopology, New York, New York, USA
6. Porosity in laser powder bed fusion
Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa
7. Surface roughness
Martin Leary, Avik Sarker, Johnathan Tran, Kate Fox, and David Downing, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia; Mahyar Khorasani, School of Engineering, Deakin University, Waurn Ponds, Victoria, Australia; Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa
8. Microstructure of L-PBF alloys
Pavel Krakhmalev, Department of Engineering and Physics, Karlstad University, Karlstad, Sweden; Nataliya Kazantseva, Institute of Metal Physics UB RAS, Ekaterinburg, Russia
9. Residual stress in laser powder bed fusion
Lameck Mugwagwa, Ina Yadroitsava and Igor Yadroitsev, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; Nkutwane Washington Makoana, Council for Scientific and Industrial Research, National Laser Centre, Pretoria, South Africa
10. Non-destructive testing of parts produced by laser powder bed fusion
Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa; Eric MacDonald, W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, Texas, USA; Jess M. Waller, NASA-Johnson Space Center White Sands Test Facility, Las Cruces, New Mexico, USA; Filippo Berto, Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology (NTNU), Trondheim, Norway
11. Process monitoring of laser powder bed fusion
Marco Grasso and Bianca Maria Colosimo, Department of Mechanical Engineering, Polytechnic University of Milan, Milan, Italy; Kevin Slattery, The Barnes Global Advisors, Pittsburgh, Pennsylvania, USA; Eric MacDonald, W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, Texas, USA
12. Post-processing
Sara Bagherifard and Mario Guagliano, Department of Mechanical Engineering, Polytechnic University of Milan, Milan, Italy
13. Structural integrity I: static mechanical properties
Pavel Krakhmalev, Department of Engineering and Physics, Karlstad University, Karlstad, Sweden; Anna Martin Vilardell and Naoki Takata, Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Nagoya, Aich, Japan
14. Structural integrity II: fatigue properties
Uwe Zerbst and Mauro Madia, Federal Institute for Materials Research and Testing (BAM), Berlin, Germany
15. Structural integrity III: energy-based fatigue prediction for complex parts
Seyed Mohammad Javad Razavi and Filippo Berto, Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology (NTNU), Trondheim, Norway; Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa
16. Lattice structures made by laser powder bed fusion
Mohammad J. Mirzaali, Jie Zhou, and Amir A. Zadpoor, Department of Biomechanical Engineering, Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Delft, the Netherlands; Abolfazl Azarniya, Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore; Saeed Sovizi, Independent Researcher, Tehran, Iran
17. Bio-inspired design
Yash Mistry, Daniel Anderson, and Dhruv Bhate, 3DX Research Group, The Polytechnic School, Arizona State University, Mesa, Arizona, USA
18. Powder characterization — methods, standards, and state of the art
Robert Groarke, School of Mechanical Engineering, Dublin City University, Dublin, Ireland; R. K. Vijayaraghavan, School of Electronic Engineering, Dublin City University, Dublin, Ireland; Daniel Powell, Centre for Defense Engineering, Cranfield University, Shrivenham, United Kingdom; Allan Rennie, Engineering Department, Lancaster University, Lancaster, United Kingdom; Dermot Brabazon, I-Form, Advanced Manufacturing Research Centre, Dublin City University, Dublin, Ireland
19. New materials development
Bonnie Attard, Abd El-Moez A. Mohamed, and Moataz M. Attallah, School of Metallurgy and Materials, University of Birmingham, Birmingham, United Kingdom
20. Recent progress on global standardization
Johannes Gumpinger, ESA/ESTEC, European Space Research and Technology Center, Noordwijk, the Netherlands; Mohsen Seifi, ASTM International, Washington, District of Columbia, USA; Nima Shamsaei, National Center for Additive Manufacturing Excellence (NCAME), Auburn University, Auburn, Alabama, USA; Christian Seidel, Munich University of Applied Sciences, Munich, Germany; Richard W. Russell, NASA Engineering and Safety Center (NESC), Langley Research Center, Hampton, Virginia, USA
21. Industrial applications
Elena Lopez, Frank Brueckner, and Samira Gruber, Fraunhofer IWS, Dresden, Germany
22. Economic feasibility and cost-benefit analysis
Martin Leary, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia
23. Current state and future trends in laser powder bed fusion technology
Andrey Molotnikov, Alex Kingsbury, and Milan Brandt, Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Victoria, Australia
24. Case study
Anton Du Plessis, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa; Igor Yadroitsev and Ina Yadroitsava, Department of Mechanical and Mechatronic Engineering, Central University of Technology, Bloemfontein, Free State, South Africa; Johan Els, Centre of Rapid Prototyping and Manufacturing, Central University of Technology, Bloemfontein, Free State, South Africa; Eric MacDonald, W. M. Keck Center for 3D Innovation, University of Texas at El Paso, El Paso, Texas, USA
Please visit the book's companion site for additional information: https://www.elsevier.com/books-and-journals/book-companion/9780128240908 (hyperlink available in the Resources box)
9780128166345; 9780128134894; 9780128121559
