Solid-State Metal Additive Manufacturing -

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Résumé :

Preface xiii

Part I Introduction 1

1 Introduction and Overview 3
Hang Z. Yu, Nihan Tuncer, and Zhili Feng

1.1 Overview and History of Metal Additive Manufacturing 4

1.2 Liquid-State Bonding Versus Solid-State Bonding 7

1.2.1 Liquid-State Bonding 7

1.2.2 Solid-State Bonding 8

1.3 Nonbeam-Based, Solid-State Metal Additive Manufacturing 9

1.3.1 Deformation-Based Metal Additive Manufacturing 9

1.3.2 Sintering-Based Metal Additive Manufacturing 11

1.4 Additive Manufacturing Categorization Based on the Relationship Between Shape Forming and Consolidation 12

1.5 Organization of the Book 14

References 15

Part II Cold Spray Additive Manufacturing 19

2 Impact-Induced Bonding: Physical Processes and Bonding Mechanisms 21
David Veysset and Mostafa Hassani

2.1 Introduction 21

2.2 Fundamentals of Impact Bonding 23

2.2.1 Plate Impacts and Explosive Welding 23

2.2.1.1 The Shock Equations of State 23

2.2.1.2 Limiting Conditions for Explosive Welding 24

2.2.2 Laser Impact Bonding 30

2.3 Bonding Mechanisms in Cold Spray 32

2.3.1 Proposed Mechanisms 32

2.3.1.1 The Role of Jetting and Impact Pressure in Particle Bonding 32

2.3.1.2 The Limiting Case of Impact Melting 33

2.3.1.3 Adiabatic Shear Instability 36

2.3.1.4 Dissimilar Materials Impact 40

2.3.2 Influence of Particle Characteristics 41

2.3.2.1 Particle Temperature 41

2.3.2.2 Particle Size 42

2.3.2.3 Surface Oxide and Hydroxide Effects 42

References 43

3 Microstructures and Microstructural Evolution in Cold-Sprayed Materials 49
Luke N. Brewer and Lorena I. Perez-Andrade

3.1 Introduction 49

3.2 Defect Structures 50

3.2.1 Vacancies 51

3.2.2 Dislocation Structure 52

3.2.3 Grain Structure 55

3.2.4 Precipitate Structure 56

3.2.5 Porosity 60

3.3 Microstructural Evolution of Thermally Treated Cold-Sprayed Materials 61

3.3.1 Recovery, Recrystallization, and Grain Growth 62

3.3.2 Precipitation 65

3.3.3 Heat Treatment of Feedstock Powders and its Impact on Microstructure 66

3.4 Conclusions 67

Acknowledgements 67

References 68

4 Mechanical Properties of Cold Spray Deposits 75
Sara Bagherifard and Mario Guagliano

4.1 Introduction 75

4.2 Mechanical Properties 76

4.2.1 Adhesive Strength 77

4.2.1.1 Adhesive Strength Test Methods 77

4.2.1.2 The Effect of Process Parameters on Adhesive Strength 80

4.2.1.3 The effect of Pre-/Post-treatments on Adhesive Strength 80

4.2.2 Cohesive Strength 83

4.2.2.1 Cohesive Strength Test methods 84

4.2.2.2 Cohesive Strength Under Static Loading 84

4.2.2.3 Cohesive Strength Under Fatigue Loading 86

4.2.2.4 Anisotropy in Cohesive Strength 90

4.2.3 Summary and Future Perspectives 91

References 94

5 Cold Spray in Practical and Potential Applications 101
Jingjie Wei, Yong He, Phuong Vo, and Yu Zou

5.1 Introduction 101

5.1.1 The Cold Spray Process 101

5.1.2 Cold Spray Additive Manufacturing (CSAM) 103

5.2 Materials 103

5.2.1 Cu and Cu Alloys 103

5.2.1.1 2Cu-Ga and Cu-In-Ga 107

5.2.1.2 Cu-Sn 107

5.2.1.3 Cu-W 107

5.2.2 Al and Al Alloys 108

5.2.3 Ni and Ni Alloys 110

5.2.4 Stainless Steels 111

5.2.5 Body Center Cubic (BCC) Metals 112

5.2.5.1 Tantalum 112

5.2.5.2 Niobium 114

5.2.6 Hexagonal Close-Packed (HCP) Metals 114

5.2.6.1 Titanium 114

5.2....

Biographie:

Hang Z. Yu, PhD, is an Associate Professor in the Department of Materials Science and Engineering at Virginia Tech, USA. His research focuses on materials processing and manufacturing science, emphasizing the underlying process physics, mechanics, and kinetics. His work also aims to leverage the process fundamentals to drive material sustainability to new heights, e.g., via solid-state metal recycling, structural repair, and austere condition-resilient manufacturing.

Nihan Tuncer, PhD, is a Principal Scientist at Desktop Metal Inc. since 2016, where she has been developing solid-state 3D printing technologies and equipment. She holds several patents in addition to research papers and review articles. Her expertise includes powder metallurgy, processing-microstructure-property relationships in ferrous and non-ferrous alloys, porous metals, and shape memory alloys.

Zhili Feng, PhD, currently leads the Materials Joining Group and is a Distinguished R&D Staff Member of Oak Ridge National Laboratory, USA. His research covers various aspects of thermal-mechanical-metallurgical behaviors of materials in materials joining....

Sommaire:
Solid-State Metal Additive Manufacturing

Timely summary of state-of-the-art solid-state metal 3D printing technologies, focusing on fundamental processing science and industrial applications

Solid-State Metal Additive Manufacturing: Physics, Processes, Mechanical Properties, and Applications provides detailed and in-depth discussion on different solid-state metal additive manufacturing processes and applications, presenting associated methods, mechanisms and models, and unique benefits, as well as a detailed comparison to traditional fusion-based metal additive manufacturing.

The text begins with a high-level overview of solid-state metal additive manufacturing with an emphasis on its position within the metal additive manufacturing spectrum and its potential for meeting specific demands in the aerospace, automotive, and defense industries. Next, each of the four categories of solid-state additive technologies-cold spray additive manufacturing, additive friction stir deposition, ultrasonic additive manufacturing, and sintering-based processes-is discussed in depth, reviewing advances in processing science, metallurgical science, and innovative applications. Finally, the future directions of these solid-state processes, especially the material innovation and artificial intelligence aspects, are discussed.

Sample topics covered in Solid-State Metal Additive Manufacturing include:

• Physical processes and bonding mechanisms in impact-induced bonding and microstructures and microstructural evolution in cold sprayed materials
• Process fundamentals, dynamic microstructure evolution, and potential industrial applications of additive friction stir deposition
• Microstructural and mechanical characterization and industrial applications of ultrasonic additive manufacturing
• Principles of solid-state sintering, binder jetting-based metal printing, and sintering-based metal additive manufacturing methods for magnetic materials
• Critical issues inherent to melting and solidification, such as porosity, high residual stress, cast microstructure, anisotropic mechanical properties, and hot cracking

Solid-State Metal Additive Manufacturing is an essential reference on the subject for academic researchers in materials science, mechanical, and biomedicine, as well as professional engineers in various manufacturing industries, especially those involved in building new additive technologies....