MATERIALS AND MANUFACTURING
• Describe considerations for polymer selection in additive manufacturing • Describe the microstructure of metals
Additive Manufacturing Materials Science This course provides a comprehensive overview of the materials that can be used with additive manufacturing (AM) processes. AM materials include a variety of polymers, metals, composites, and ceramics. Each material is distinguished from another material by microstructure, mechanical and physical properties, and life cycle. Different AM processes require the use of different AM materials. Therefore, an individual must understand materials’ science to ensure proper material selection. Understanding the materials that are compatible with additive manufacturing processes is an essential part of AM process success. After completing this class, users will not only be able to distinguish between thermoplastic and thermoset polymers, ferrous metals and nonferrous alloys, and ceramic and composite materials, but users will also be able to determine which material type is most appropriate for use with a specific AM process.
• Describe the mechanical and physical properties of metal • Describe the different steels commonly used in AM processes • Describe the different nonferrous alloys commonly used in AM processes • Describe the types of superalloys commonly used in AM processes • Distinguish between water and gas atomization • Describe considerations for metal selection in additive manufacturing • Describe the microstructure and properties of ceramics • Describe AM composites and their properties • Describe considerations for ceramic and composite selection in additive manufacturing Integrating Additive Manufacturing with Traditional Manufacturing This course discusses the factors manufacturers should consider when adding an additive manufacturing (AM) component to a traditional manufacturing operation, including cost, logistics, and best uses of AM with traditional manufacturing, among other concerns. Originally used for prototyping, AM has increasingly found more roles in traditional manufacturing processes, such as creating tooling or end-use parts. However, because the procedures and tools are so different, combining the two kinds of manufacturing requires considerable adjustments. Logistical concerns of integrating AM with traditional manufac- turing include purchasing the correct machines and updating safety protocols. Design concerns involve upskilling engineers so that they can take full advantage of AM capabilities. After taking this course, users will understand how to take full advantage of AM as a tool to augment a traditional manufacturing operation.
Topical Outline • Introduction to Additive Manufacturing • Additive Manufacturing Materials • Mechanical Properties • Physical Properties • Review: AM Materials • Polymers • Polymer Properties • Thermosets • Thermoplastics • AM Thermosets and Thermoplastics • Selecting Polymers • Review: AM Polymers • Metals • Metal Properties • Steels • Nonferrous Alloys • Superalloys • Metal Powdering Processes • Selecting Metals • Review: AM Metals • Ceramics • Composites • Selecting Ceramics and Composites • Review: Other AM Materials Learning Objectives • Describe additive manufacturing
Topical Outline • Traditional Manufacturing Operations • Additive Manufacturing Operations • Additive Manufacturing Processes • AM Basics Review • Combining Traditional and Additive Manufacturing • Economics of AM: Production Costs • Economics of AM: Manufacturing System Costs • Product Development and Production • Economics of AM Review • AM Tools and Material • Upskilling Engineers and Operators • AM Production Considerations: Part Orientation and Support Structures • AM Production Considerations: Thermal Distortion • AM Production Considerations: Post-Processing
• Distinguish between different mechanical properties • Distinguish between different physical properties • Describe the microstructure of polymers • Describe the properties of polymers • Describe thermosets • Describe thermoplastics • Describe the different polymers commonly used in AM processes
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