Analysis of the Knowledge Gain and Cognitive Load Experienced Due to the Computer-Aided Instruction of Additive Manufacturing Processes

2021 ◽  
Author(s):  
Jayant Mathur ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Cognitive Load ◽  
Knowledge Gain ◽  
Powder Bed Fusion ◽  
Computer Aided Instruction ◽  
Powder Bed ◽  
Material Extrusion ◽  
Significant Difference ◽  
Computer Aided ◽  
Am Processes

Abstract Although there is a substantial growth in the Additive Manufacturing (AM) market commensurate with the demand for products produced by AM methods, there is a shortage of skilled designers in the workforce that can apply AM effectively to meet this demand. This is due to the innate complications with cost and infrastructure for high-barrier-to-entry AM processes such as powder bed fusion when attempting to educate designers about these processes through in-person learning. To meet the demands for a skilled AM workforce while also accounting for the limited access to the range of AM processes, it is important to explore other mediums of AM education such as computer-aided instruction (CAI) which can increase access to hands-on learning experiences. Therefore, the purpose of this paper is to analyze the use of CAI in AM process education and focus on its effects on knowledge gain and cognitive load. Our findings show that when designers are educated about material extrusion and powder bed fusion through CAI, the knowledge gain for powder bed fusion is significantly different than knowledge gain for material extrusion, with no significant difference in cognitive load between these two AM processes. These findings imply that there is potential in virtual mediums to improve a designer’s process-centric knowledge for the full range of AM processes including those that are usually inaccessible. We take these findings to begin developing recommendations and guidelines for the use of virtual mediums in AM education and future research that investigates implications for virtual AM education.

Toward Metamodels for Composable and Reusable Additive Manufacturing Process Models

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Paul Witherell ◽  
Shaw Feng ◽  
Timothy W. Simpson ◽  
David B. Saint John ◽  
Pan Michaleris ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metal Powder ◽  
Manufacturing Process ◽  
Process Model ◽  
Model Development ◽  
Process Models ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Future Work ◽  
Am Processes

In this paper, we advocate for a more harmonized approach to model development for additive manufacturing (AM) processes, through classification and metamodeling that will support AM process model composability, reusability, and integration. We review several types of AM process models and use the direct metal powder bed fusion AM process to provide illustrative examples of the proposed classification and metamodel approach. We describe how a coordinated approach can be used to extend modeling capabilities by promoting model composability. As part of future work, a framework is envisioned to realize a more coherent strategy for model development and deployment.

scholarly journals An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3895 ◽  
Author(s):  
Abbas Razavykia ◽  
Eugenio Brusa ◽  
Cristiana Delprete ◽  
Reza Yavari
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Powder Bed Fusion ◽  
Laser Melting ◽  
Powder Bed ◽  
Part Quality ◽  
Melt Pool ◽  
Wide Range ◽  
Am Processes

Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

Powder-Scale Meshfree Simulations of Powder Bed Fusion Based Additive Manufacturing Processes

2019 ◽  
Author(s):  
Zongyue Fan ◽  
Hao Wang ◽  
Bo Li
Keyword(s):  
Additive Manufacturing ◽  
Optimal Transportation ◽  
The Novel ◽  
Powder Bed Fusion ◽  
Computational Framework ◽  
Powder Bed ◽  
Materials Behaviors ◽  
Melt Pool ◽  
Powder Particles ◽  
Am Processes

Abstract We present a powder-scale meshfree direct numerical simulation (DNS) capability for the powder bed fusion (PBF) based additive manufacturing (AM) processes using the novel Hot Optimal Transportation Meshfree (HOTM) method. The HOTM method is an incremental Lagrangian meshfree computational framework for materials behaviors under extreme thermomechanical loading conditions, which combines the Optimal Transportation Meshfree (OTM) method and the variational thermomechanical constitutive updates. The realistic multi-layer powder bed geometry is modeled explicitly in the HOTM simulations based on experimental data. A phase-aware constitutive model is developed to predict the phase change and multiphase mixing during the PBF AM processes automatically. The governing equations including the linear momentum and energy conservation equations are solved for the multiphase flow simultaneously to predict the deformation, temperature and local state of the powder particles. The powder-scale DNS is employed to study the influence of various laser powers on the melt pool thermodynamics.

Fundamental Requirements for Data Representations in Laser-Based Powder Bed Fusion

2015 ◽  
Author(s):  
Shaw C. Feng ◽  
Paul W. Witherell ◽  
Gaurav Ameta ◽  
Duck Bong Kim
Keyword(s):  
Additive Manufacturing ◽  
Heterogeneous Systems ◽  
Powder Bed Fusion ◽  
Process Data ◽  
Data Interoperability ◽  
Powder Bed ◽  
Related Data ◽  
Data Representations ◽  
Am Processes

Additive Manufacturing (AM) processes intertwine aspects of many different engineering-related disciplines, such as material metrology, design, in-situ and off-line measurements, and controls. Due to the increasing complexity of AM systems and processes, data cannot be shared among heterogeneous systems because of a lack of a common vocabulary and data interoperability methods. This paper aims to address insufficiencies in laser-based Powder Bed Fusion (PBF), a specific AM process, data representations to improve data management and reuse in PBF. Our approach is to formally decompose the processes and align PBF process-specifics with information elements as fundamental requirements for representing process-related data. The paper defines the organization and flow of process information. After modeling selected PBF processes and sub-processes as activities, we discuss requirements for the development of more advanced process data models that provide common terminology and process knowledge for managing data from various stages in AM.

Exploring Additive Manufacturing Processes for Direct 3D Printing of Copper Induction Coils

2017 ◽  
Author(s):  
John D. Martin
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Electron Beam Melting ◽  
Energy Deposition ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Laser Melting ◽  
Powder Bed ◽  
Computer Aided ◽  
Directed Energy

A number of additive manufacturing processes were analyzed and compared in regards to the direct 3D printing of copper induction coils. The purpose of this study was to narrow in on 3D printing technologies that would best be suited for the manufacture of copper inductions coils. The main focus of the study was to look at how all the available additive processes could specifically be successful at creating parts made of copper pure enough to effectively conduct electricity and also geometries complex enough to meet the demands of various induction coil designs. The results of this study led to three main categories of additive manufacturing that were deemed good choices for producing copper induction coils, these included: powder bed fusion, sheet lamination, and directed energy deposition. Specific processes identified within these categories were powder bed fusion using electron beam melting and laser melting; ultrasonic additive manufacturing; and directed energy deposition utilizing laser melting and electron beam melting using both wire and powder material delivery systems. Also discussed was additional benefits that using 3D printing technology could provide beyond the physical manufacturing portion by opening doors for coupling with computer aided drafting (CAD) and computer aided engineering (CAE) software in order to create a seamless design-to-production process.

Insights on Laser Additive Manufacturing of Invar 36

2020 ◽  
pp. 71-93
Author(s):  
Mostafa Yakout ◽  
M. A. Elbestawi
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Additive Manufacturing ◽  
Coefficient Of Thermal Expansion ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
Iron Nickel ◽  
Am Processes

Recently, additive manufacturing (AM) became a promising technology to manufacture complex structures with acceptable mechanical properties. The laser powder-bed fusion (L-PBF) process is one of the most common AM processes that has been used for producing a wide variety of metals and composites. Invar 36 is an austenite iron-nickel alloy that has a very low coefficient of thermal expansion; therefore, it is a good candidate for the L-PBF process. This chapter covers the state-of-the-art for producing Invar 36 using the L-PBF process. The chapter aims at describing research insights of using metal AM techniques in producing Invar 36 components. Like most of nickel-based alloys, Invar 36 is weldable but hard-to-machine. However, there are some challenges while processing these alloys by laser. This chapter also covers the challenges of using the L-PBF process for producing nickel-based alloys. In addition, it reports the L-PBF conditions that could be used to produce fully dense Invar 36 components with mechanical properties comparable to the wrought Invar 36.

Failures Related to Metal Additive Manufacturing

2021 ◽  
pp. 250-265
Author(s):  
Daniel P. Dennies ◽  
S. Lampman
Keyword(s):  
Quality Control ◽  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Key Factors ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Design Considerations ◽  
Directed Energy ◽  
Am Processes ◽  
Metal Additive

Abstract This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production considerations, and quality assurance. The emphasis is on the design and metallurgical aspects for the two main types of metal AM processes: powder-bed fusion (PBF) and directed-energy deposition (DED). The article also describes the processes involved in binder jet sintering, provides information on the design and fabrication sources of failure, addresses the key factors in production and quality control, and explains failure analysis of AM parts.

scholarly journals Intra- and Inter-Repeatability of Profile Deviations of an AlSi10Mg Tooling Component Manufactured by Laser Powder Bed Fusion

2018 ◽  
Vol 2 (3) ◽  
pp. 56 ◽  
Author(s):  
Floriane Zongo ◽  
Antoine Tahan ◽  
Ali Aidibe ◽  
Vladimir Brailovski
Keyword(s):  
Statistical Analysis ◽  
Additive Manufacturing ◽  
Stress Relief ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Metrological Investigation ◽  
Powder Bed ◽  
Manufacturing Procedure ◽  
Industrial Use ◽  
Am Processes

Laser powder bed fusion (LPBF) is one of the most potent additive manufacturing (AM) processes. Metallic LPBF is gaining popularity, but one of the obstacles facing its larger industrial use is the limited knowledge of its dimensional and geometrical performances. This paper presents a metrological investigation of the geometrical and dimensional deviations of a selected LPBF-manufactured component, according to the ASME Y14.5-2009 standard. This approach allows for an estimation of both the process capability, as per ISO 22514-4 standard, and the correlations between the part location in the manufacturing chamber and the profile deviations. Forty-nine parts, which are representative of a typical aerospace tooling component (30 mm in diameter and 27.2 mm in height) were manufactured from AlSi10Mg powder using an EOSINT M280 printer and subjected to a stress relief annealing at 300 °C for two hours. This manufacturing procedure was repeated three times. A complete statistical analysis was carried out and the results of the investigation show that LPBF performances for all geometrical variations of 147 identical parts fall within a range of 230 µm at a 99.73% level.

scholarly journals Additive Manufacturing Processes in Medical Applications

Materials ◽  
2021 ◽  
Vol 14 (1) ◽  
pp. 191
Author(s):  
Mika Salmi
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Manufacturing Processes ◽  
Medical Applications ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Material Extrusion ◽  
Fusion Material ◽  
Directed Energy ◽  
Binder Jetting

Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

scholarly journals 3D Modeling of the Solidification Structure Evolution of Superalloys in Powder Bed Fusion Additive Manufacturing Processes

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1995
Author(s):  
Laurentiu Nastac
Keyword(s):  
Additive Manufacturing ◽  
Process Model ◽  
Single Layer ◽  
Multiscale Model ◽  
Solidification Structure ◽  
Grain Structure ◽  
Structure Evolution ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Am Processes

Recently, a few computational methodologies and algorithms have been developed to simulate the microstructure evolution in powder bed fusion (PBF) additive manufacturing (AM) processes. However, none of these have attempted to simulate the grain structure evolution in multitrack, multilayer AM components in a fully 3D transient mode and for the entire AM geometry. In this work, a multiscale model, which consists of coupling a transient, discrete-source 3D AM process model with a 3D stochastic solidification structure model, was applied to quickly, efficiently, and accurately predict the grain structure evolution of IN625 alloys during Laser Powder Bed Fusion (LPBF). The capabilities of this model include studying the effects of process parameters and part geometry on solidification conditions and their impact on the grain structure formation within multicomponent alloy parts processed via AM. Validation was accomplished based on single-layer LPBF IN625 benchmark experiments, previously performed and analyzed at the National Institute of Standards and Technology (NIST), USA. This modeling approach can also be used to quantitatively predict the solidification structure of Ti-6Al-4V alloys in electron beam AM processes.

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