Additive Manufacturing of Metals: From Fundamental Technology to Rocket Nozzles, Medical Implants, and Custom Jewelry

by John O. Milewski

Overview

This engaging volume presents the exciting new technology of additive manufacturing (AM) of metal objects for a broad audience of academic and industry researchers, manufacturing professionals, undergraduate and graduate students, hobbyists, and artists. Innovative applications ranging from rocket nozzles to custom jewelry to medical implants illustrate a new world of freedom in design and fabrication, creating objects otherwise not possible by conventional means.

The author describes the various methods and advanced metals used to create high value components, enabling readers to choose which process is best for them. Of particular interest is how harnessing the power of lasers, electron beams, and electric arcs, as directed by advanced computer models, robots, and 3D printing systems, can create otherwise unattainable objects.

A timeline depicting the evolution of metalworking, accelerated by the computer and information age, ties AM metal technology to the rapid evolution of global technology trends. Charts, diagrams, and illustrations complement the text to describe the diverse set of technologies brought together in the AM processing of metal. Extensive listing of terms, definitions, and acronyms provides the reader with a quick reference guide to the language of AM metal processing. The book directs the reader to a wealth of internet sites providing further reading and resources, such as vendors and service providers, to jump start those interested in taking the first steps to establishing AM metal capability on whatever scale. The appendix provides hands-on example exercises for those ready to engage in experiential self-directed learning.

Product Details

ISBN-13:	9783319863481
Publisher:	Springer International Publishing
Publication date:	08/14/2018
Series:	Springer Series in Materials Science , #258
Edition description:	Softcover reprint of the original 1st ed. 2017
Pages:	343
Product dimensions:	6.10(w) x 9.25(h) x (d)

About the Author

John O. Milewski received his B.S. in Computer Engineering from the University of New Mexico and his M.S. in Electrical Engineering from Vanderbilt University. He began his technical career with five years’ metal fabrication experience ranging from heavy industry production as an ASME code welder to light manufacturing and applied research. He spent 32 years at Los Alamos National Laboratory, in positions including Welding Technologist, Engineer, Team Leader, Experimental Component Fabrication Program Manager, and Group Leader for Manufacturing Capability. He is currently retired from the Lab, writing and consulting as APEX3D LLC regarding the new and exciting applications of AM technology.

His technical expertise includes arc systems electron beam, laser welding, robotics, sensing and controls, and the joining of less common metals. His work experience also includes CAD/CAM/CNC model based engineering, process modeling, and simulation with validation methods to include residual stress measurement. In addition, he served 2 years in the late 1980s as Vice President of Synthemet Corporation, an entrepreneurial high tech start-up, with the goal of development and commercialization of 3D additive manufacturing of metals.

He is author and co-author of numerous publications related to high energy beam processing and process modeling. His awards include an R&D 100 Award for Directed Light Fabrication, Fellow of the American Welding Society (AWS) and the AWS Robert L. Peaslee Award. He is inventor or co-inventor for a number of patents related to laser welding and additive manufacturing.

He has had extensive formal collaborations with universities and sponsored students resulting in refereed publication and patenting. His professional society involvement included Chairman, Co-Chairman, and advisor of AWS committees related to High Energy Beam, Electron Beam, and Laser Beam Welding. In addition, he currently serves as an advisor to the AWS D20 Additive Manufacturing committee and provides peer review to technical publications of AWS and ASM International.

His international technical contributions include US Delegate to the High Energy Beam Welding Commission of the IIW (International Institute of Welding), Invited Keynote Lecturer at the 58th Annual Assembly and International Conference of IIW, and the AWS R.D. Thomas Award winner for his international contributions and committee work on the harmonization of international standards.

Table of Contents

Preface.- Acknowledgements.- List of Acronyms.- About the Author.- AM Road Map and Hitchhiker’s Guide.- Chapter 1: Envision.- Chapter 2: Additive Manufacturing Metal, The Art of the Possible.- Chapter 3: On the Road to AM.- Chapter 4: Understanding Metal for Additive Manufacturing.- Chapter 5: Lasers, Electron Beams, Plasma Arcs.- Chapter 6: Computers, Solid Models, and Robots.- Chapter 7: Origins of 3D Metal Printing.- Chapter 8: Current System Configurations.- Chapter 9: Inspiration to 3D Design.- Chapter 10: Process Development.- Chapter 11: Building, Post Processing, and Inspecting.- Chapter 12: Trends in AM, Government, Industry, Research, Business.- Professional Society and Organization Links.- Glossary.- Bibliography.- AM Machine and Service Resource Links.- Appendix A: Safety in Configuring a 3D Metal Printing Shop.- Appendix B: Exercises in Metal Fusion.- Appendix C: OpenSCAD Programming Example.- Appendix D: 3D Printer Control Code Example.- Appendix E: Building an Arc-Based3D Shape Welding System.- Appendix F: Exercises in 3D Printing.- Appendix G: Score Chart of AM Skills.- Index.

Editorial Reviews

This book is dedicated to the special aspects valid for metals. … The fresh writing style, sometimes more like a storyteller, makes reading these many facts quite easy and understandable. … The interested reader can get a Jot of information about the topics one should deal with when working with additively manufactured metallic parts. lt gives a general roadmap where to start, what to learn and how it fits together.” (Ralph Bäßler, Materials and Corrosion, Vol. 69 (12), December, 2018)

“This book … covers subjects from fundamental technology to rocket nozzles, medical implants, and custom jewelry. The author shares a multitude of useful footnotes and pages of references at the end. Also included are practical appendices for users. … I can heartedly recommend this book as a valuable reference and a good read for all interested in additive manufacturing.” (David Belforte, Industrial Laser Solutions For Manufacturing, industrial-lasers.com, November, 2017)

From the Publisher