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Abstract:
Additive Manufacturing or Direct Manufacturing, popularly known as 3D Printing has become the leading edge manufacturing technology. Today Metal Additive Manufacturing (MAM) is a reality, not only for prototype fabrication, also for functional parts in Aerospace applications. As MAM matures by implementing more critical metal parts in aerospace, new materials and processes will emerge. Current materials used in MAM are based on the existing wrought, cast, powder metallurgy (P/M) and weld materials that may not be suitable for MAM, as they clearly do not produce the same structure in meso scale and cause uncertainty in mechanical properties similar to those in welding. This makes the MAM products vulnerable in critical components leading to use of knock down factors during design, similar to those in welded joint design. In order to fully exploit the advantages of MAM it is necessary to design new AM materials that respond better to the processing methods yet have superior mechanical properties than current wrought, cast, or P/M materials. This presentation will discuss the current status of conventional alloy development techniques for this very rapidly growing industry and lay out a simple, inexpensive, yet comprehensive test program for new material and corresponding MAM process development. This presentation will provide step by step methodology for new and existing material and process development protocol for Powder Bed Fusion (PBF) as well as Directed Energy Deposition (DED) methods of MAM.
Additive Manufacturing or Direct Manufacturing, popularly known as 3D Printing has become the leading edge manufacturing technology. Today Metal Additive Manufacturing (MAM) is a reality, not only for prototype fabrication, also for functional parts in Aerospace applications. As MAM matures by implementing more critical metal parts in aerospace, new materials and processes will emerge. Current materials used in MAM are based on the existing wrought, cast, powder metallurgy (P/M) and weld materials that may not be suitable for MAM, as they clearly do not produce the same structure in meso scale and cause uncertainty in mechanical properties similar to those in welding. This makes the MAM products vulnerable in critical components leading to use of knock down factors during design, similar to those in welded joint design. In order to fully exploit the advantages of MAM it is necessary to design new AM materials that respond better to the processing methods yet have superior mechanical properties than current wrought, cast, or P/M materials. This presentation will discuss the current status of conventional alloy development techniques for this very rapidly growing industry and lay out a simple, inexpensive, yet comprehensive test program for new material and corresponding MAM process development. This presentation will provide step by step methodology for new and existing material and process development protocol for Powder Bed Fusion (PBF) as well as Directed Energy Deposition (DED) methods of MAM.
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Biography:
Dr. Prabir Chaudhury is the Group Technical Director at Element Materials Technology focused on Metals Technology. Element is a global testing, quality assurance, and advising company with more than 200 laboratories in 33 countries including more than 70 metals technology laboratories around the globe. Dr. Chaudhury is very active in Additive Manufacturing industry through his involvement in America Makes, ASTM F42 committee and ISO TC 261, ASM International, SME, SAE, and other industry programs. Dr. Chaudhury is a Metallurgical Engineer by trade and has long association with Aerospace and Defense manufacturing industry. He earned his B.Tech from Indian Institute of Technology, Kharagpur and Ph.D. in Engineering from University of California, Irvine. He began his professional career at National Center for Metalworking Technology where he developed and managed several forging and forming related programs for US Navy Manufacturing Technology Program. He also served as the Chief Metallurgist at General Dynamics - Ordnance and Tactical Systems and Senior Principal Engineer at Orbital Sciences Corporation. He has the requisite metallurgical and structure-property relations knowledge and Materials and Processing background to help the metal 3D printing industry, including the machine developers, part manufacturers and the component designers. |
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