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Additive Manufacturing with Metals

Design, Processes, Materials, Quality Assurance, and Applications

  • Textbook
  • © 2023

Overview

Authors:
  1. Sanjay Joshi

    1. Pennsylvania State University, University Park, USA

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  2. Richard P. Martukanitz

    1. University of Virginia, Charlottesville, USA

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  3. Abdalla R. Nassar

    1. John Deere, Moline, USA

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  4. Pan Michaleris

    1. Pan Computing LLC, State College, USA

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  • Adopts an integrated treatment of topics underscoring relationships across disciplines
  • Emphasizes the science of AM and application of fundamental science to maximize understanding of the defining mechanisms
  • Structured to facilitate knowledge acquisition and retention

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About this book

This textbook and reference provides a comprehensive treatment of additive manufacturing (AM) for metals, including design and digital work flows, process science and reliability, metallic systems, quality assurance, and applications. The book is rooted in the fundamental science necessary to develop and understand AM technologies, as well as the application of engineering principles covering several disciplines to successfully exploit this important technology. As additive manufacturing of metals is the fastest growing subset of this transformative technology, with the potential to make the widest impact to industrial production, Metals Additive Manufacturing: Design, Processes, Materials, Quality Assurance, and Applications is ideal for students in a range of engineering disciplines and practitioners working in aerospace, automotive, medical device manufacturing industries.

Keywords

Table of contents (21 chapters)

  1. Front Matter

    Pages i-xviii
    Download chapter PDF

  2. Introduction to Metal Additive Manufacturing

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 1-11

  3. Digital Processing Workflow for AM

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 13-58

  4. Metal Additive Manufacturing Processes – Laser and Electron Beam Powder Bed Fusion

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 59-109

  5. Metal Additive Manufacturing Processes – Directed Energy Deposition Processes

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 111-150

  6. Metal Additive Manufacturing Processes – Jetting- and Extrusion-Based Processes

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 151-193

  7. Metal Additive Manufacturing Processes – Deformation-Based AM and Hybrid AM Processes

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 195-220

  8. Design for Additive Manufacturing and Cost and Economics of AM

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 221-248

  9. Energy Sources and Propagation

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 249-284

  10. Source-Material Interactions

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 285-316

  11. Feedstock Delivery and Dynamics

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 317-333

  12. Mechanical Response

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 335-337

  13. Analytical Models

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 339-358

  14. Alloy Systems for Additive Manufacturing

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 359-382

  15. Metallic Feedstock

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 383-426

  16. Solidification During Additive Manufacturing

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 427-480

  17. Solid State Transformations and Gas Reactions During the Additive Manufacturing Process

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 481-526

  18. Modeling of Microstructure for Additive Manufacturing

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 527-548

  19. Multiple Alloy Processing

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 549-565

  20. Post Processing

    • Sanjay Joshi, Richard P. Martukanitz, Abdalla R. Nassar, Pan Michaleris
    Pages 567-589
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Authors and Affiliations

  • Pennsylvania State University, University Park, USA

    Sanjay Joshi

  • University of Virginia, Charlottesville, USA

    Richard P. Martukanitz

  • John Deere, Moline, USA

    Abdalla R. Nassar

  • Pan Computing LLC, State College, USA

    Pan Michaleris

About the authors

Dr. Sanjay Joshi is Professor of Industrial and Manufacturing Engineering at Penn State University. His research and teaching interests are in the areas of Computer Aided Design and Manufacturing (CAD/CAM) with specific focus on Additive Manufacturing, Computer Aided Process Planning, and Manufacturing Systems Design and Analysis. He has been involved in actively teaching AM at the graduate and undergraduate level for over 20 years. He has been on the faculty for 36 years, and has received several national and international research awards. 

Dr. Richard Martukanitz is Professor of Material Science and Engineering at the University of Virginia and former Fellow of Virginia’s Commonwealth Center for Advanced Manufacturing (CCAM). Prior to joining the University of Virginia, Dr. Martukanitz served as Director of the Pennsylvania State University’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) and Head of the Laser Processing Division at Penn State’s Applied Research Laboratory.  He has over 40-years of experience in develo** and applying laser-based additive manufacturing techniques for metallic systems.  

Dr. Abdalla R Nassar is the Enterprise Additive Manufacturing (AM) Lead for John Deere, where leads AM strategy development, R&D, and servers and the subject matter expert for the global organization. Prior to this role, he served as an Associate Research Professor and Head of the Process Physics, Analytics, and Engineering Department within the Materials Science Division of the Applied Research Laboratory (ARL) at the Pennsylvania State University.  At Penn State, he developed and taught courses on Engineering and Scientific Principles of Additive Manufacturing and Laser-Materials Interactions at the graduate level. 

Dr. Pan Michaleris is the founder and CEO of PanOptimization LLC. In 2012, he founded Pan Computing LLC which was acquired by Autodesk in 2016. The additive manufacturing process simulation software CUBES developed by Pan Computing was commercialized as Netfabb Simulation. Dr. Michaleris became Sr. Software Architect at Autodesk and supervised the development of additive manufacturing simulation software until 2021. He has over 30 years of experience in high performance computing and thermo-mechanical process modeling such as additive manufacturing, welding and thermal forming. He has a Ph.D. in Theoretical and Applied Mechanics from the University of Illinois at Champaign-Urbana, and has worked as a senior research engineer at Edison Welding Institute (EWI) from 1994 to 1997, and as professor at the Department of Mechanical and Nuclear Engineering of The Pennsylvania State University from 1997 to 2016.

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