1

ME/AMD 597: Data Science for Advanced

Manufacturing

Week 1, Lecture 2

Amrita Basak
Email: [email protected]
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Agenda
• Additive manufacturing (AM): short Introduction
• Process-structure-property relationships

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Slide acknowledgement

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Additive Manufacturing/3D Printing

Additive Manufacturing by ASTM: “Process of joining
materials to make objects from 3D model data, usually
layer upon layer, as opposed to subtractive manufacturing
methodologies, such as traditional machining”

Rapid Prototyping: This term was used in the beginning of

the professional use of the technology because the main
application was the manufacturing of prototypes, mock
ups and sample parts.

Todays most common terminologies are:

ADDITIVE MANUFACTURING (AM) or 3D PRINTING

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Additive Manufacturing/3D Printing

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Additive Manufacturing/3D Printing

Hybrid (Additive and Subtractive manufacturing)

Directed energy deposition with traditional machining

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The powder bed fusion AM value chain consists of five steps – AM system providers are active in most areas of the
value chain

Application
Material System Software Production
design
Mainly: Creation of > Usually stand- > Differentiation > Support for end > Different produc-
metal powder alone powder bed between process customers tion scenarios:
> Powder with high fusion systems control and > Can be complex - Large OEM
purity and a very > System providers enhancement and demanding - Contract manu-
narrow distribution with low levels of software > Done by system facturer/service
of the granular size vertical integration, > Process control providers, software provider
(usually 30 µm) standard from system prov. developers and/or - Specialized part
> Hard to get from components > Add-on software service providers manufacturer
large providers due usually made by such as automatic > Not every service
to small orders contract support provider is able to
> Usually sold by manufacturers generation, design design applications
AM system > Providers optimization
providers integrate by specialized
components companies
system & software

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Advantages
Design complexity and freedom:
The advent of 3D printing has seen a proliferation of products (designed in digital environments), which involve
levels of complexity that simply could not be produced physically in any other way. While this advantage has been
taken up by designers and artists to impressive visual effect, it has also made a significant impact on industrial
applications, whereby applications are being developed to materialize complex components that are proving to be
both lighter and stronger than their predecessors.

Speed:
You can create complex parts within hours, with limited human resources. Only machine operator is needed for
loading the data and the powder material, start the process and finally for the finishing. During the manufacturing
process no operator is needed.

Customisation
3D printing processes allow for mass customisation — the ability to personalize products according to individual
needs and requirements. Even within the same build chamber, the nature of 3D printing means that numerous
products can be manufactured at the same time according to the end users’ requirements at no additional process
cost.

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Advantages
Tool-less
For industrial manufacturing, one of the most cost-, time- and labour-intensive stages of the product
development process is the production of the tools. For low to medium volume applications, industrial 3D
printing — or additive manufacturing — can eliminate the need for tool production and, therefore, the costs,
lead times and labour associated with it. This is an extremely attractive proposition, that an increasing number
or manufacturers are taking advantage of. Furthermore, because of the complexity advantages stated above,
products and components can be designed specifically to avoid assembly requirements with intricate
geometry and complex features further eliminating the labour and costs associated with assembly processes.

Extreme Lightweight design

AM enable weight reduction via topological optimization

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Advantages
Sustainable / Environmentally Friendly
3D printing is also emerging as an energy-efficient technology that can provide environmental efficiencies in
terms of both the manufacturing process itself, utilizing up to 90% of standard materials, and, therefore,
creating less waste, but also throughout an additively manufactured product’s operating life, by way of lighter
and stronger design that imposes a reduced carbon footprint compared with traditionally manufactured
products.

No storage cost
Since 3D printers can “print” products as and when needed, and does not cost more than mass manufacturing,
no expense on storage of goods is required.

Increased employment opportunities

Widespread use of 3D printing technology will increase the demand for designers and technicians to operate
3D printers and create blueprints for products.

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Disadvantages
Questionable Accuracy
3D printing is primarily a prototyping technology, meaning that parts created via the technology are mainly test
parts. As with any viable test part, the dimensions must be precise for engineers to get an accurate read on whether
a part is feasible. While 3D printers have made advances in accuracy in recent years, many of the plastic materials
still come with an accuracy disclaimer. For instance, many materials print to +/- 0.1 mm in accuracy, meaning there is
room for error.

Support material removal

When production volumes are small, the removal of support material is usually not a big issue. When the volumes
are much higher, it becomes an important consideration. Support material that is physically attached is of most
concern.

Limitations of raw material

At present, 3D printers can work with different raw materials. This is insignificant when compared with the
enormous range of raw materials used in traditional manufacturing. More research is required to devise methods to
enable 3D printed products to be more durable and robust.

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Disadvantages
Considerable effort required for application design and for setting process parameters:
Complex set of around 180 material, process and other parameters and specific design required
to fully profit from the technology

Material cost:
Today, the cost of most materials for additive systems (Powder) is slightly greater than that of
those used for traditional manufacturing .

Material properties:
A limited choice of materials is available. Materials and their properties (e.g., tensile property,
tensile strength, yield strength, and fatigue) have not been fully characterized. Also, in terms of
surface quality, even the best RM processes need perhaps secondary machining and polishing to
reach acceptable tolerance and surface finish.

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Disadvantages
Intellectual property issues:
The ease with which replicas can be created using 3D technology raises issues over intellectual property rights. The
availability of blueprints online free of cost may change with for-profit organizations wanting to generate profits from this
new technology.

Limitations of size:
3D printing technology is currently limited by size constraints. Very large objects are still not feasible when built using 3D
printers.

Cost of printers:
The cost of buying a 3D printer still does not make its purchase by the average householder feasible. Also, different 3D
printers are required in order to print different types of objects. Also, printers that can manufacture in color are costlier
than those that print monochrome objects.

Unchecked production of dangerous items:

Liberator, the world’s first 3D printed functional gun, showed how easy it was to produce one’s own weapons, provided
one had access to the design and a 3D printer. Governments will need to devise ways to check this.

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Additive Manufacturing
Over the last years AM technology became valid for the hole lifecycle of a product
Production planning

Testing

Design

Concept

Rapid Rapid Rapid Rapid

Prototyping Manufacturing Tooling Spareing
Idea Death of
the part

PRODUCT LIVE CYCLE

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Additive Manufacturing

Complexity
of the part

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Time Cost

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Additive Manufacturing

Conventionally designed and produced

cast steel nacelle hinge bracket for an
Airbus A320 (top) and optimised titanium
version of the nacelle hinge bracket made
by additive manufacturing technology.

Commercial airplanes can have up to several

hundred seed belt buckles. A standard buckle
weight is around 155g in St. and 120g in Al.
With AM the weight was reduced to 68 g in Ti.

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Additive Manufacturing
Short introduction to the technology
Part manufacturing
- Advantage for sport shoe manufacturer is the data exchange
between development and production overnight. e.g.,
ADIDAS with the development in Germany and the
production side in China.

Example for medical application

- 3D printing can be personalised
- Giving back life quality

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Additive Manufacturing

The assembly can be

personalised and printed
in one process.

NASA has carried out parabolic flights that mimic

microgravity to test "additive manufacturing“

Many other applications for printing on-site

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Chocolate printer

Concrete Printer

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Part Build
CAD Design

Chemical
CAD Translator Build Process properties

CAD Model

Material
File PART
Verification Physical
properties
Preparation
Cleaning
Support remove
Orientation Post Process
Support

Post curing
Parameters

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Easy Cutting Path

Angled surfaces

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Supports

Holes

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Risks
Risk or damage to respiratory tract and lungs when handling metal powders and filter dust and suspected carcinogenic
effect of the metal powder and filter dust. It is strongly recommended to wear breathing protection (respiratory mask;
particle filter P2D or P3D) and NEVER inhale the dust when filling, emptying and cleaning the build envelope (build
module, dosing chamber, coater, powder overflow) and when emptying the collecting container and filter cartridge of the
extraction and filter unit.

Risk of eye damage when handling metal powder and filter dust. It is strongly recommended to wear eye protection
(close-fitting safety goggles) when filling, emptying and cleaning the build envelope (build module, dosing chamber,
coater, powder overflow) and when emptying the collecting container and filter cartridge of the extraction and filter unit.

Risk of compressed air outlet. Compressed air can escape if compressed air lines and union joints are opened or damaged.
It is strongly recommended to wear safety gloves due to risk of skin damage. The toxic nickel in the metal powder and
filter dust can cause irreversible damage or a sensitization through skin contact (allergic reaction).

Risk of suspected carcinogenic effect of the metal powder and filter dust. A longer period inhaling of powder dust may
cause accumulation of powder in lungs, blood and other organs which has a strong carcinogenic effect.

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Risks
Laser system
Laser is “invisible” (Class 1). This means that the human eye cannot detect the beam if it impacts the eye. It is highly
recommended to activate the laser only when the door is closed due to protective action of the door crystal. Special precaution
should be made with docking/undocking of the build chamber. The laser may impact with the part and suffer severe damage.

3D printers are energy hogs

When melting plastic with heat or lasers, 3D printers consume about 50 to 100 times more electrical energy than injection
molding to make an item of the same weight, according to research by Loughborough University. In 2009, research at MIT's
Environmentally Benign Manufacturing program showed that laser direct metal deposition (where metal powder is fused
together) used hundreds of times the electricity as traditional casting or machining. Because of this, 3D printers are better for
small batch runs. Industrial-sized 3D printers may not be the answer to lessening our use of coal power any time soon.

Unhealthy air emissions

3D printers may pose a health risk when used in the home, according to researchers at the Illinois Institute of Technology. The
emissions from desktop 3D printers are like burning a cigarette or cooking on a gas or electric stove. The 2013 study was the first
to measure these airborne particle emissions from desktop 3D printers. While heating the plastic and printing small figures, the
machines using PLA filament emitted 20 billion ultrafine particles per minute, and the ABS emitted up to 200 billion particles per
minute. These particles can settle in the lungs or the bloodstream and pose health risk, especially for those with asthma.

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Risks
Reliance on plastics
One of the biggest environmental movements in recent history has been to reduce reliance on plastics, from grocery bags
to water bottles to household objects that can be made from recycled materials instead. The most popular—and
cheapest—3D printers use plastic filament. Though using raw materials reduces the amount of waste in general, the
machines still leave unused or excess plastic in the print beds. PLA is biodegradable, but ABS filament is still the most used
type of plastic. The plastic byproduct ends up in landfills. If 3D printing is going to be industrialized, that byproduct or
other recycled plastic needs to be reused.

IP and licensing deals

In January, 3D Systems acquired Gentle Giant Ltd., which owned the licensing rights to toy franchises such as The Hobbit,
The Walking Dead, Harry Potter, Alien, and Star Wars. Gartner has said that companies may lose at least $100 billion in
four years to licensing or IP owners. 3D printing will change the business market—and the black market for these items—
and the legislation will have to rush to catch up. This potential digital piracy situation is comparable to the way the
internet challenged the movie and music industries for copyrights, trademarks, and illegal downloads.

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Risks
Gun control loopholes
The first successful 3D printed gun is old news, but its ramifications are very important. Companies are
popping up around the world, attempting to sell these guns and/or the CAD designs for them. Engineering firm
Solid Concepts has even fired rounds out of the first 3D printed metal gun. Congress' Undetectable Firearms
Act, which bans guns that can't be detected by metal detectors or x-ray scanners, was renewed for 10 years. It
left a loophole in the law, however: 3D printed guns with a tiny piece of metal aren't banned by the Act.
Legislators are attempting to close that loophole now, after Congress ignored the issue for quite some time,
with special requirements for printed guns.

Responsibility of manufacturers
Weapons can be 3D printed. So can safety equipment such as helmets, wheels for bikes, and toys for small
children. Of course, there is the issue of intellectual property and trademark, but the larger issue involves
responsibility. If a person shoots a gun and harms or kills someone, stabs someone with a 3D printed knife, or
breaks their neck while riding on a bike with a 3D printed helmet, who is held accountable? The owner of the
printer, the manufacturer of the printer, or the irresponsible person who thought it was a good idea to produce
and use an untested product?

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Risks
Bioprinting ethics and regulation
Cornell bioengineers and physicians created an artificial ear that looks and acts like a natural one. The conversations
about the ethics of bioprinting have already begun. Organovo is printing liver cells as well as eye tissue cells in a
partnership with the National Eye Institute and National Center for Advancing Translational Sciences. Scientists have
also proposed mixing human stem cells with canine muscle cells to create enhanced organ tissue. Printing cartilage is
still the most realistic type of bioprinting, and printing whole organs is still many years away, but 3D printing is
growing in medicine quite rapidly. Conversations about the moral, ethical, and legal issues surrounding bioprinting
have started, but they will inevitably cause a lot more controversy as it becomes more commonplace.
Possibility of 3D printed drugs
Assembling chemical compounds on a molecular level using a 3D printer is possible. A researcher at the University of
Glasglow created a prototype of a 3D "Chemputer" that makes drugs and medicine. He wants to revolutionize the
pharmaceutical industry by allowing patients to print their own medicine with a chemical blueprint they get from
the pharmacy. Of course, this is a very long way off, but it stands to enable DIY chemists to create anything from
cocaine to ricin.
Safety of items that come into contact with food
Kitchenware is popular to 3D print, but the safety of the materials used is questionable. You can print out a fork or
spoon with your MakerBot, but if you use ABS plastic, it is not BPA-free. Luckily, new filaments that are safer to put in
your mouth are being created for this specific reason, but they aren't widely available yet. Many 3D printers have
spaces where bacteria can easily grow if they aren't cleaned properly, as well. In order to more safely-produced 3D
printed food and kitchenware, there may be a need for an FDA-approved machine. People probably don't want to
eat genetically-engineered pizza off toxic plates.

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Investment casting
• Working principles
Modified Brayton cycle
Te
η = 1−
Ti
• Increasing Ti by 10 oC, increases ƞ by 1%.
• Increase of Ti from 982 oC to 1427 oC in last 30 years.
• Approaches for increasing Ti
o Application of ceramic and metallic coatings.
o Design and implementation of elaborate cooling schemes.
o Development of creep and fatigue resistant superalloy.

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Gas Turbines (Aircraft Engines)
Components are subjected to 90%
of their melting temperature

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Background on nickel-base superalloys
Specific strength as a function of temperature

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Niclek-Based Superalloys

http://www.tms.org/meetings/2016/superalloys2016/home.aspx

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Superalloy Composition
®
CM247LC CMSX-4 IN100 IN738LC K418 MAR-M247 René 142 René 80 René N5
Cr 8.1 7.6 10 16 12.5 8 6.8 14 7.1
Co 9.2 9.3 15 8.5 - 10 12 10 8
Cr = chromium, Co = Mo 0.5 0.4 3 1.75 4.3 - 1.5 4 2
cobalt, Mo =
molybdenum, Re = Re - 1 - - - - 2.8 - 3
rhenium, W = tungsten, W 9.5 2 - 2.6 - 10 4.9 4 5
Al = aluminum, Ti = Al 5.6 12.6 4.7 3.4 6.2 6 6.15 3 6
titanium, Ta = tantalum,
Hf = hafnium, N = Ti 0.7 1.3 5.5 3.4 0.7 1 - 5 -
nitrogen, B = boron, C = Ta 3.2 2.2 - 1.7 - 3 6.35 - 7
carbon, Zr =zirconium, Hf 1.4 0.03 - - - 1 1.5 - -
Fe = iron, Ni = nickel.
Nb - - - 0.9 2.1 - - - -
B 0.015 - 0.014 0.1 0.014 0.015 0.015 - -
C 0.07 - 0.18 0.11 0.12 0.15 0.12 - -
Zr 0.015 - 0.06 0.05 - 0.05 0.02 - -
Fe - - - - 1 - - - -
Ni Bal Bal Bal Bal Bal Bal Bal Bal Bal
https://cannonmuskegon.com/products/vacuum-alloys/

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Evolution of Turbine Blades

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Content

http://sciffunn.blogspot.com/2012/08/growing-simple-sugar-crystal-on-string.html

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Content

http://sciffunn.blogspot.com/2012/08/growin
g-simple-sugar-crystal-on-string.html

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State-of-the art on superalloy processing
Superalloy components are typically fabricated using
traditional manufacturing methods such as investment
casting.

• Only few foundries are capable of fabricating single-

crystal/directionally solidified components.

• Component design limited by the manufacturing processes.

• Component manufacturing is not feasible for functionally

graded materials, microstructures, properties.

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State-of-the art on superalloy processing

A set of 40 single crystal turbine blades costs above USD 600,000

and requires 60–90 weeks for production.

Additionally, if the components suffer from material loss due to

prolonged service or manufacturing defects, the traditional
manufacturing methods cannot restore the parent metallurgy at
the damage locations.

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Content
Composition-Process-Structure-Property Linkages

https://www.scie
ncedirect.com/sci
ence/article/pii/S
09639969183057
14

Baking Boiling Frying

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Content
Composition-Process-Structure-Property Linkages
Baking
Types of Potato Boiling Taste
Crispiness
Frying
Feedstock Process Structure Property
Cast High temperature
Types of Turbine Alloy Wrought Strength
3D Printing
Corrosion
resistance
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Properties of Materials (9 different catagories)

• Electrical (electrical conductivity, dielectric constant…)

• Optical (index of refraction..)
• Magnetic (magnetic permeability..)
• Mechnanical (elastic modulus, strength, hardness..)
• Thermal (Heat capacity, thermal conductivity..)
• Corrosion (or Chemical or deteriorative) ( …)
• Nuclear
• Physical
• Fabrication properties

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Physical and Optical Properties
• Crystal structure
• Atomic weight
• Density
• Melting point
• Boiling point
• Vapor pressure
• Viscosity
• Porosity
• Permeability
• Reflectivity
• Transparency
• Optical properties
• Dimensional stability

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Electrical properties

• Conductivity
• Resistivity
• Dielectric constant
• Superconducting temperature

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Magnetic properties

• Magnetic susceptibility
• Magnetic permeability
• Coercive force
• Saturation magnetization
• Transformation (Curie) temperature
• Magnetostriction

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Nuclear properties
• Half-life
• Stability

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Mechanical properties
• Hardness • Shear
• Modulus of elasticity • Bearing
• Creep
• Compression • Fatigue properties
• Stress rupture
• Smooth •
• Poisson's ratio Damping properties
• Notched • Wear properties
• Stress-strain curve
• Corrosion fatigue • Galling
• Yield strength •
• Rolling contact Abrasion
• Compression • Fretting • Erosion
• Ultimate strength • Charpy transition temperature • Cavitation
• Tension • Spalling
• Fracture toughness (KIc)
• Ballistic impact
• High-temperature behavior

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Thermal properties

• Conductivity
• Specific heat
• Coefficient of thermal expansion
• Latent heat of fusion
• Emissivity
• Absorptivity
• Fire resistance
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Chemical properties
• Position in electromotive series
• Galvanic corrosion
• Corrosion and degradation
• Atmospheric
• Fresh water
• Salt water
• Acids
• Hot gases
• Ultraviolet
• Oxidation
• Thermal stability
• Biological stability
• Stress corrosion
• Hydrogen embrittlement

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Fabrication properties

• Castability
• Heat treatability
• Hardenability
• Formability
• Machinability
• Weldability

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In order for us to
control part
properties, we need
to have control in
nm/angstrom scale.

https://www.sciencedirect.com/science/article/pii/S1359028616300833

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