Laser Based Additive Manufacturing

www.am.msstate.edu

2016 Manufacturing SummitMarch 16, 2016

Scott M. Thompson, Ph.D.thompson@me.msstate.edu

Additive Manufacturing

• Material extrusion• Material jetting• Binder jetting• Vat photopolymerisation• Sheet lamination• Powder bed fusion• Directed energy deposition

“a process of joining materials to make objects from 3D model data, usually layer upon layer…”- ASTM Standard F2792-12a

dupress.com/articles/additive-manufacturing-3d-opportunity-in-aerospace/

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Additive Manufacturing

Rapid/visual prototyping, hobbyists, science projects

1985-1990• Metals ‘printing’ emergence• Commercialization of 3D

printing technology

2000-2010 2010+• Plastics• metal sintering

• Metals printing commercialization

• Production-grade metallic parts sought

Part production, defense applications

www.am.msstate.edu

Material Extrusion

• Fused filament fabrication, Fused deposition modeling, 3D printing

• Stratasys®, MakerBot®• Thermoplastics, nylon• < 570 ºF, heated nozzle (liquid on delivery)• Home, office or industry

By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055

By John Abella - https://www.flickr.com/photos/jabella/8965235630, CC BY 2.0, https://commons.wikimedia.org/w/index.php?curid=41054993

www.am.msstate.edu

Material Jetting

• Drop-on-demand, 3D printing• Similar to inkjet, 2D printing• Liquid photopolymer that is cured• Home, office or industry

http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/materialjetting/

www.am.msstate.edu

Sheet Lamination

• Ultrasonic additive manufacturing, laminated object manufacturing

• Sheets/ribbons of material bound via ultrasonic welding

• Low-temperature• Non-structural parts

http://www.insidemetaladditivemanufacturing.com/blog/ultrasonic-additive-manufacturing

http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/sheetlamination/

www.am.msstate.edu

• Powder Bed Fusion & Directed Energy Deposition

• Powder and wire feedstock

• Laser based methods

• Powder Bed Fusion – Laser, e.g. Selective Laser Melting

• Direct Laser Deposition, e.g. Laser Engineered Net Shaping

Selective Laser MeltingDirect Laser Deposition

• Good surface finish • High precision• Very complex geometries

Thompson, S.M., Bian, L, Shamsaei, N., Yadollahi, A., 2015, “An Overview of Direct Laser Deposition for Additive Manufacturing; Part I: Transport Phenomena, Modeling and Diagnostics,” Additive Manufacturing, 8, pp. 36-62. DOI: 10.1016/j.addma.2015.07.001.

• Multi-material feeding• High build rates• Parts repair

Additive Manufacturing of Metals

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Additive Manufacturing of Metals: Large Potential

• Customize parts for specific applications• Biomedical implants, heat exchangers

• Fabricate complex geometries• Repair expensive parts• Manufacture in remote locations

• Submarines, battlefield, ships, space• Reduce weight and cost of parts

• Aerospace• Potential economic rewards:

• New skilled jobs created in U.S.• Restored U.S. strength in manufacturing• Trade deficit reduction

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Additive Manufacturing of Metals: The Bottleneck

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• Process-property relationships must be learned for each new material, machine, geometry, etc.

• Experimental trial-and-error ($$)• Parts consist of porosity• Process quality control lagging• Material properties during manufacture unknown• Minimal standards and regulation for production

and end-parts• Powder, machine variability

Challenge: Mechanical behavior of AM parts not easily predictable or trustworthy. This is hampering widespread adoption of AM parts.

Additive Manufacturing: Trending

10

blog.purisllc.com/blog

Economic Growth

Where is Mississippi in this global market?

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Biomedical Applications in Additive Manufacturing

Biomedical industry is getting interested in AM

Large market potential MSU has already researched

biomedical supply chains in MS Have initiated some preliminary

research collaboration with MSU Vet School and UMMC in Jackson, MS.

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Facilities at MSU/CAVS

Direct Laser Deposition (DLD)Donated by Army c. 2006OPTOMEC LENS 750 w/ 1 kW laser and multi-

camera thermal monitoringMulti-powder feeder for functional-grading

Laser Powder Bed FusionRenishaw AM 250 w/ 400 W laser

Materials characterization equipmentMechanical testing (fatigue, tension, etc.)Microstructural characterization

• EBSD, Microscopy, X-Ray tomography

www.am.msstate.edu

Advanced Laser-Based Additive Manufacturing… Our ApproachThe Complexity of Additive Manufacturing

“It’s is not a printer, it is a mini foundry”

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Mechanical Testing of Additive-Manufactured Parts

Sterling, A.J., Torries, B., Lugo, M., Shamsaei, N., Thompson, S.M., 2015, “Fatigue Behavior of Ti-6Al-4V Alloy Additively Manufactured by Laser Engineered Net Shaping,” 56th AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference Kissimmee, FL. || DOI: 10.2514/6.2015-1354.

An order of magnitude shorter fatigue lives for additive-manufactured samples as compared to wrought samples.

Strain Life Curve: Wrought & LENS Ti-6Al-4V

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Thermal Monitoring and Control

“By FY2018, develop process metrology, in-process sensing

methods, and real-time process control approaches to maximize

part quality and production throughput in Additive Manufacturing (AM).”

- National Institutes of Standards and Technology (NIST.gov)

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Dual Thermal Monitoring of LENS

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Porosity & X-Ray Computed Tomography

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Simulation via High Performance Computing at MSU

Effects of laser velocity for laser power of 2 W (substrate response)

powder bedsubstrate

deposited track

Masoomi, M., Elwany, A., Shamsaei, N., Bian, L., Thompson, S.M., 2015, “An Experimental-Numerical Investigation of Heat Transfer during Selective Laser Melting,” 2015 Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, Austin, TX.

Fluid dynamics, solidification, high heat flux diffusion, microstructural evolution

Time scale ~ 10-100 μs (10-100 million time steps)Space scale ~ 1 μm (resolution smaller than laser)

Additive Manufacturing Research Team

Nima ShamsaeiAssistant Professor

Mechanical EngineeringFatigue & microstructure characterization

Scott M. ThompsonAssistant Professor

Mechanical EngineeringProcess thermal modeling and monitoring

Steve R. DaniewiczProfessor, ASTM FellowMechanical Engineering

Fracture mechanics, joining methods

Linkan BianAssistant Professor

Industrial & Systems EngineeringStatistical modeling, uncertainty propagation,

supply chains

Shuai ShaoPost-Doctoral Associate

Center for Advanced Vehicular SystemsMicrostructural characterization, multi-scale

modeling

Jutima SimsiriwongPost-Doctoral Associate

Center for Advanced Vehicular SystemsFatigue & mechanical behavior

www.am.msstate.edu

Additive Manufacturing at Mississippi StateNational leadershipOrganizing joint workshop with ASTM & NIST in

2016Organizing ASME’s Symposium on Additive

ManufacturingMSU is leading certification efforts AM parts

with Federal Aviation Administration (FAA)MSU Faculty serving as Guest Editors of Special

Issue in Additive ManufacturingASTM Representative on U.S. National

Committee on Theoretical and Applied Mechanics: Supervisory Role in Additive ManufacturingCAVS is now a member of ‘America Makes’Sponsored AM research projects from NSF,

NASA, Army and industry

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Questions?

Thanks!

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