First-and-Every-Part-Right Metal Additive Manufacturing

Abstract

Recognized as a milestone technology, metal additive manufacturing (MAM) has promised unparalleled part complexity and small-batch cost effectiveness for the manufacturing of functionally critical parts and components. However, the control of MAM throughput and build quality has been challenged by the deficiency in process mechanics understanding to support systematic prediction, monitoring, and optimization. Aiming at a scientific scope and engineering applicability way beyond experimentation and FEM which are typical time-demanding, physics-based analytical modeling flanked by computational mechanics of materials is developed at the Georgia Institute of Technology and presented herein to quantify the thermodynamics, heat-transfer, and materials thermos-physical behaviors in powder bed and powder feed MAM. Closed-form solutions have been established for temperature distributions. The corresponding thermal stresses, residual stresses, microstructure, build distortion, porosity, and mechanical properties are expressed as explicit and algebraic functions of process parameters and powder properties, factoring in the effects of scan strategy, and powder packing. Extensive experimental validations are also presented. The solutions deliver more penetrating physics of the MAM process, showing much higher accuracy, and costing less than 1% time of commercial FEM’s, thus promising effective prediction and optimization for first-and-every-print-correct MAM.

About the Speaker

Prof. Steven Y. LIANG obtained his PhD in Mechanical Engineering from the University of California, Berkeley in 1987. He joined the Georgia Institute of Technology in 1990 as an Assistant Professor, having previously held a similar position at Oklahoma State University. In 2005, he was appointed to the Bryan Professorship and is currently the Morris M. Bryan, Jr. Professor in Mechanical Engineering for Advanced Manufacturing Systems in the George W. Woodruff School of Mechanical Engineering at Georgia Tech.

Prof. Liang’s research interests include modeling, monitoring, and control of precision machining and additive manufacturing processes and systems. He has served as President of the North American Manufacturing Research Institution of the Society of Manufacturing Engineers (SME), Chair of the Manufacturing Engineering Division of the American Society of Mechanical Engineers (ASME), and President of Walsin-Lihwa Corporation, a multinational manufacturing enterprise of USD 6+ billion yearly revenue with 35,000 employees. He currently holds the position of Technical Editor for the International Journal of Precision Engineering and Manufacturing and Editor-in-Chief of the Journal of Manufacturing and Materials Processing.

Prof. Liang has received numerous accolades, including the Robert B. Douglas Outstanding Young Manufacturing Engineer Award from SME (1991), the Ralph R. Teetor Educational Award from the Society of Automotive Engineers (1995), the Blackall Machine Tool and Gage Award from ASME (2005), the Outstanding Service Award from ASME (2007), the Milton C. Shaw Manufacturing Research Medal from ASME (2016), the Most Influential Professor in Smart Manufacturing from SME (2020), and the Gold Medal from SME (2021). He is also a Fellow of ASME, SME, and the International Academy of Engineering and Technology.

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