Additive manufacturing brings together various techniques to build complex three-dimensional objects layer by layer with a fully optimized architecture. Additive manufacturing leads to reduced material and energy consumption compared to conventional manufacturing processes by material subtraction. It is also the process of choice for repairing expensive parts.
We study the manufacture and repair of metal parts using additional fabrication, including: the design of of the work piece adapted to additional fabrication, the deposition strategies, the optimization of process parameters, post-heat treatments, as well as the characterization of in use properties. Practical examples will concern mainly the Wire Arc Additive manufacturing.
| On completion of the unit, the student will be capable of: | Classification level | Priority |
|---|---|---|
| Understanding the challenge to produce desired microstructures in a work piece | 2. Understand | Essential |
| Know the advanges and disadvantages of the most common techniques in metal additive manucturing | 1. Knowledge | Important |
| Be able to choose the most adequate additionnal fabrication technique for a given application | 3. Apply | Essential |
| Understand the relation between process parameters and microstructure | 2. Understand | Essential |
| Percentage ratio of individual assessment | Percentage ratio of group assessment | ||||
|---|---|---|---|---|---|
| Written exam: | 0 | % | Project submission: | 0 | % |
| Individual oral exam: | 0 | % | Group presentation: | 0 | % |
| Individual presentation: | 0 | % | Group practical exercise: | 0 | % |
| Individual practical exercise: | 0 | % | Group report: | 0 | % |
| Individual report: | 1 | % | |||
| Other(s): % | |||||
| Type of teaching activity | Content, sequencing and organisation |
|---|---|
| Lecture and labwork |
The lectures correspond to 3 main parts: 1. METAL ADDITIVE MANUFACTURING This chapter is dedicated to the presentation of a comprehensive overview of the most common techniques used today. Particular attention is given to the energy consumption of the different processes, the possible build volumes and the main defects. The different subsection are: 1.1 Energy used in metal production 1.2 Notion of by to fly 1.3 Different processes of additive manufacturing metal parts
1.4 Comparision addditive manufacturing to substractive fabrication
1.5 Summary and review questions
2. WELDING This section is ment to apply basic knowledge the students acquired previously in solidification to a particular process with. The small path between theroretically feasable structures and technically difficult to realize is shown. The different subsections are:
2.1 Different types of welding 2.2 Mooving heat source solution 2.3 Solidification microstructures 2.4 Weldability of an alloy
2.5 Summary and review questions.
3. WIRE ARC ADDITIVE MANUFACTURING This section is devoted to a technique available at the Ecole des Mines. The different modelling techniques of microstructures are addressed. The different subsections are: 3.1 Different types of wire arc additive manufacturing facilities
3.2 Solidification microstructures different simulation techniques 3.3 Typical defects and mechanical behavior 3.4 From the numerical model to the final work piece 3.5 Summary and review questions. The lectures finish with a practical application concerning the scanning of a work piece. The exam consist in a written report on the SWOT analysis of wire arc additive manufacturing. The summaries of the preceeding sections and the review questions prepare this report. |