Advances in Additive Manufacturing: Artificial Intelligence, Nature-Inspired, and Biomanufacturing

522 Pages·2022·18.429 MB·English

by  Ajay Kumar, Ravi Kant Mittal, Abid Haleem

Advances in Additive Manufacturing:
Artificial Intelligence, Nature-Inspired,
and Biomanufacturing
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Additive Manufacturing Materials and Technologies
Advances in Additive
Manufacturing:
Artificial Intelligence,
Nature-Inspired,
and Biomanufacturing
Edited by
Ajay Kumar
Department of Mechanical Engineering, School of Engineering, JECRC University, Jaipur,
Rajasthan, India
Ravi Kant Mittal
(Retired Professor) Department of Mechanical Engineering, Birla Institute of Technology and Science,
Pilani, Rajasthan
Abid Haleem
Department of Mechanical Engineering, Jamia Millia Islamia, New Delhi, Delhi, India
Series Editor
Ma Qian
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Contents
Listofcontributors xv 2.4 Additivemanufacturing 16
Abouttheeditors xix 2.5 Whatandwhyofadditivemanufacturing 17
2.6 Developmenttrendsinadditive
manufacturing 17
Part I
2.7 Classificationofadditivemanufacturing
Introduction methodsbasedonmaterialcharacteristics 18
2.7.1 Powder-basedadditive
manufacturing 18
1. Introduction to additive
2.7.2 Liquid-basedadditive
manufacturing technologies 3
manufacturing 19
RasheedatM.Mahamood,T-C.Jen,S.A.Akinlabi, 2.7.3 Solid-/filament-basedadditive
SunirHassanandEstherT.Akinlabi manufacturing 20
2.8 Extensivecapabilitiesofadditive
1.1 Introduction 3
manufacturinginthecurrentscenario 20
1.2 Briefhistoryofadditivemanufacturing 4
2.9 Applicationareasofadditive
1.3 Classesofadditivemanufacturing 4
manufacturing 20
1.3.1 Vatphotopolymerization 4
2.9.1 Medicalmanufacturing 21
1.3.2 Materialjetting 5
2.9.2 Aerospaceandautomotive
1.3.3 Binderjettingprocess 5
manufacturing 21
1.3.4 Materialextrusion 6
2.9.3 Architecturalandjewelry
1.3.5 Sheetlamination 6
manufacturing 21
1.3.6 Powderbedfusion 6
2.10 Challengesbeingtakenupbyadditive
1.3.7 Directedenergydeposition(DED) 7
manufacturing 21
1.4 Areasofapplicationofadditive
2.11 Futureapplicationsandtechnologiesof
manufacturing 8
additivemanufacturing 23
1.4.1 Foodsandhousing 9
2.12 Conclusion 23
1.4.2 Healthcare 10
References 23
1.4.3 Automobilesandaerospace 10
Furtherreading 25
1.4.4 Electronics 10
1.4.5 Consumersproductandjewelry 10
3. Addictive manufacturing in the
1.5 Summary 11
Health 4.0 era: a systematic review 27
References 11
Furtherreading 13 VineetJain,PuneetaAjmera,
SheetalKalraandSheetalYadav
2. Trends in additive manufacturing: 3.1 Backgroundandintroduction 27
an exploratory study 15 3.2 Additivemanufacturingprocessand
technologies 28
MohdShoeb,LokeshKumar,
3.3 Applicationinthehealth-careindustry 28
AbidHaleemandMohdJavaid
3.4 Materialsandmethods 29
2.1 Introduction 15 3.4.1 Informationsources 29
2.2 Researchobjectivesofthechapter 16 3.4.2 Searchstrategyandstudyselection 30
2.3 Comparisonofadditivemanufacturing 3.4.3 Datacollectionprocess 30
withtraditionalmanufacturingprocesses 16 3.5 Results 31
v
vi Contents
3.6 Discussion 37 5.3 InnovativeAMtechnologies 71
3.6.1 Globaladditivemanufacturing 5.3.1 AMbasedonFDMorfusedfilament
market 38 fabrication 71
3.6.2 Advantagesofadditive 5.3.2 AMbasedonVAT
manufacturingprocesses 38 photopolymerization:SLAor
3.6.3 Challengesofadditive digitallightprocessing(DLP) 77
manufacturingprocesses 39 5.3.3 AMbasedonpowderbedfusion
3.6.4 Roleofadditivemanufacturing (PBF)orSLS 83
duringpandemicCOVID-19 39 5.4 Conclusionsandfutureperspective 84
3.7 Conclusion 40 Acknowledgments 84
References 40 References 84
4. Integration of reverse engineering
with additive manufacturing 43 6. Printing file formats for additive
manufacturing technologies 87
AjayKumar,ParveenKumar,HariSingh,
AbidHaleemandRaviKantMittal AjayKumar,ParveenKumar,RaviKantMittaland
HariSingh
4.1 Introduction 43
4.2 ConceptofRE 44 6.1 Introduction 87
4.3 ProductdevelopmentbyREandAM 45 6.2 3Dmodelrepresentationdataformatsin
4.4 IntegratingREwithAM 46 additivemanufacturingtechniques 88
4.4.1 IntegrationofREandAMby 6.2.1 Standardtessellationlanguage
constructinga3DCADmodelfrom format 88
thepointcloudandobtainingan 6.2.2 Additivemanufacturingformat 90
STLmodelfortheAMsystem 46 6.2.3 3Dmanufacturingformat 92
4.4.2 IntegratingREandAMbydirect 6.2.4 OBJformat 92
generationofSTLmodelfilefrom 6.2.5 Virtualrealitymodelinglanguage
pointcloud 52 format 92
4.4.3 IntegrationofREandAMbyDirect 6.2.6 JupiterTessellationformat 93
ConversionofDataPointsto 6.2.7 Extensible3Dformat 93
SlicedFile 53 6.2.8 CubitalFacetListformat 93
4.5 DatadigitizationtechniquesinRE 55 6.2.9 Solidinterchangeformat 93
4.5.1 NoncontactdataacquisitionRE 6.2.10 Surfacetrianglehintedformat 94
techniques 56 6.3 Comparisonof3Dmodelrepresentation
4.6 Summary 63 dataformats 94
References 63 6.4 Slicedmodelrepresentationdata
formatsinadditivemanufacturing 95
6.4.1 Commonlayerinterfaceformat 96
Part II
6.4.2 LayerexchangeASCIIformat 96
Additive manufacturing 6.4.3 Stereolithographycontourformat 96
6.4.4 HewlettPackardGraphics
technologies
Languageformat 96
6.4.5 Comparisonofslicedmodel
5. Recent innovative developments on
representationdataformatsin
additive manufacturing technologies additivemanufacturing 96
using polymers 69 6.5 Otheradditivemanufacturinginterfaces 97
6.5.1 Layeredmanufacturinginterface 98
CarmenM.Gonza´lez-Henr´ıquez,
6.5.2 Rapidprototypinginterface 98
DanA.Pe´rez-Monje,FernandoE.Rodrı´guez-
6.5.3 Voxel-basedmodelingmethod 98
Umanzor,MauricioA.Sarabia-Vallejosand
6.6 Dataexchangestandardsutilizationin
JuanRodrı´guez-Herna´ndez
additivemanufacturing 99
5.1 AbriefintroductiontoAMtechnologies 69 6.6.1 StandardfortheExchangeof
5.2 AMmarketandinnovationopportunities 70 ProductModelstandard 99
Contents vii
6.6.2 Initialgraphicsexchange 8.5 Concludingremarksontheuseof
specificationstandard 100 CSasnature-inspiredand/or
6.7 Discussion 100 biomanufacturing 137
6.8 Summary 101 References 139
References 101
9. Preprocessing and postprocessing
7. Additive manufacturing techniques in additive manufacturing 141
used for preparation of scaffolds in
AjayKumar,ParveenKumar,RaviKantMittaland
bone repair and regeneration 103
HariSingh
SudipDasguptaandYogendraPratapSingh
9.1 Introduction 141
7.1 Introduction 103 9.2 Preprocessinginadditivemanufacturing 142
7.2 Scaffolddesign 106 9.2.1 PreparationofCADmodel 142
7.2.1 Computer-aideddesign-based 9.2.2 ConversiontoSTLfile 143
methods 106 9.2.3 DiagnosisofSTLfileerror 146
7.2.2 Optimizationoftopology 107 9.2.4 Partorientation 149
7.2.3 Reversemodeling 107 9.2.5 Generation/designofsupport 151
7.2.4 Mathematicalmodeling 107 9.2.6 Typesofsupportstructure 152
7.3 Additivemanufacturingtechniques 108 9.2.7 Slicing 153
7.3.1 Selectivelasersintering 108 9.2.8 Generationoftoolpathpattern
7.3.2 Selectivelasermelting 110 andinternalhatchingpattern 155
7.3.3 Extrusion-basedprinting 111 9.3 Postprocessinginadditivemanufacturing 160
7.3.4 Fuseddepositionmodeling 113 9.3.1 Removalofsupportmaterial 160
7.3.5 Electronbeammelting 114 9.3.2 Improvementinsurfacefinish 161
7.3.6 Stereolithography 114 9.3.3 Improvementinaccuracy 162
7.3.7 Powderinkjetprinting 116 9.3.4 Estheticimprovementofadditive
7.3.8 Electrospinning 117 manufacturingproducts 162
7.4 Posttreatments 118 9.3.5 Modifyingpropertyofadditive
7.4.1 Heattreatment 118 manufacturingproducts 162
7.4.2 Surfacetreatment 119 9.4 Summary 162
7.4.3 Coatings 120 References 164
7.5 Challengesandconclusions 121
References 121
10. Computer vision based online
monitoring technique: part quality
8. Cold spray technology: a perspective
enhancement in the selective laser
of nature-inspired feature melting process 167
processing and biomanufacturing
BrahmanshKaushikandS.AnandKumar
by a heatless additive method
using nanopowders 129 10.1 Introduction 167
10.2 Experimentalmethods 168
RijaNirinaRaoelison
10.2.1 Designofexperiment 168
8.1 Introduction:aheatlessadditivemethod 10.2.2 Methodsandalgorithmsof
fornature-inspired,bio-andnanofeatures 129 analysis 168
8.2 Coldsprayingprincipleandprocessing 10.3 Resultsanddiscussion 170
conditionsfornanopowders 131 10.3.1 Edgedetectionanalysis 170
8.3 Developmentofsuperhydrophobic 10.3.2 Greyscalepixelvalueanalysis 182
propertiesusingthecoldsprayadditive 10.3.3 Layerclassification 184
method 132 10.4 Conclusions 190
8.4 Coldsprayadditivebiomanufacturing 10.5 Futurescopeandindustrial
ofbiocompatiblecoatingforsurgical application 192
implant 134 References 193
viii Contents
11. Fundamentals of thermo-fluid- 12.2 MaterialsforAMtechnology 218
mechanical modeling in additive 12.2.1 Polymers 218
manufacturing processes 195 12.2.2 Ceramics 220
12.2.3 Composites 221
AnshulYadav 12.2.4 Metals 222
12.3 BiomaterialsforAMtechnology 223
11.1 Introduction 195
12.3.1 Metallicbiomaterials 226
11.2 Fundamentalsofthermalphenomena
12.3.2 Ceramicbiomaterials 227
modeling 196
12.3.3 Polymericbiomaterials 227
11.2.1 Generalclassificationofheated
12.3.4 Compositebiomaterials 228
bodymodelsandheatsources
12.4 Smartmaterialsand4Dprinting
models 196
perspectives 228
11.2.2 Steady-statepointmovingheat
12.5 MaterialsprocessingissuesinAMand
source 197
characterizationtechniques 230
11.2.3 Transitoryshiftingpointheat
12.5.1 Liquidmaterialsprocessingissues
source 198
andtheircharacterization
11.2.4 Semiellipticaltransientmoving
techniques 231
heatsource 198
12.5.2 Solidmaterialsprocessingissues
11.2.5 Doubleellipticaltransient
andtheircharacterization
movingheatsource 199
techniques 231
11.2.6 Uniformtransientmovingheat
12.5.3 Powdermaterialsprocessing
source 200
issuesandtheircharacteristic
11.3 Mathematicaldescriptionof
techniques 231
temperaturefield 200
12.6 NewlydevelopedmaterialsforAM 232
11.3.1 Analyticalsolutionsoftheheat
12.7 Summary 232
conductionequationforpoint
References 232
source 202
11.3.2 Surfaceandvolumetricheat
(cid:1)
13. Ceramic metal interface: In-situ
sourcemodels 203
11.3.3 Volumetricheatsourcemodels 203 microstructural characterization
11.4 Numericalmodelingofthethermal aid vacuum brazing additive
fieldconsideringsolid(cid:1)liquidchanges 204 manufacturing technology 235
11.4.1 Thermalandfluidflow
S.StalinandK.Kalaichelvan
modelingofthemoltenpool 205
11.5 Quantitativedescriptionofphase 13.1 Introduction 235
transformationsinsolidstate 207 13.2 Wettability 236
11.5.1 Calculatingstructuralshares 13.3 Wettingversusbrazing 238
duringthesinglethermalcycle 208 13.4 Ceramic(cid:1)metalinterface:
11.5.2 Keyparametersindetermining Microstructuralcharacterization 240
thesolidificationstructure 208 13.5 Effectofbrazingparametersonthe
11.6 Modelingstressandstrainsduring interfacialmicrostructureevolution 242
additivemanufacturing 210 13.6 Ceramic(cid:1)metalinterface:
11.6.1 Analyticalmodelingofresidual Nanoindentationcharacterization 245
stressinadditivemanufacturing 210 13.7 Ceramic(cid:1)metalinterface:Brazing
11.7 Summary 213 mechanism 247
References 213 13.8 Conclusion 248
References 249
Part III
Materials in AM 14. Processing challenges in additively
manufactured single crystal alloys:
(cid:1) (cid:1)
12. Materials processed by additive a process structure property
manufacturing techniques 217 relationship approach 253
AjayKumar,ParveenKumar, RajkumarVelu,S.AnandKumarandRuban
RaviKantMittalandVictorGambhir Whenish
12.1 Introduction 217 14.1 Introductionandbackground 253
Contents ix
14.2 ChallengesinthedepositionofSX 17. Selective laser melting of functionally
structure 254 graded material: current trends and
14.2.1 Influencinglaserprocessing future prospects 281
parameters 254
14.2.2 Influencingofseedinglayer AshishKumarMishra,KuldeepYadavand
substrate 255 ArvindKumar
14.2.3 Influenceofthermalgradient 255
17.1 Introduction 281
14.3 Suitablepre-andpostprocessing
17.2 FGMsinnature 282
strategies 257
17.3 ClassificationofFGM 283
14.3.1 Preprocessingschemes 257
17.4 MathematicalrepresentationofFGMs
14.3.2 Influenceofpostprocessing
andmodelsforpropertyprediction 283
schemes 259 17.4.1 Mori(cid:1)Tanakascheme 284
14.4 Casestudy:remanufacturingof
17.4.2 Voigtmodel 284
high-valuedcomponent 261
17.4.3 Powerlawgradation 285
14.5 Conclusions 261
17.4.4 Exponentiallawgradation 285
14.6 Futurescope 262
17.4.5 Sigmoidallawgradation 285
References 262
17.5 ApplicationsofFGMs 286
Furtherreading 264
17.6 ManufacturingmethodsforFGMs 286
17.6.1 Legacymanufacturingmethods
forFGMs 286
15. Transient thermal analysis in friction-stir 17.6.2 Stateoftheartofthelegacy
additive manufacturing of dissimilar manufacturingmethodsfor
wrought aluminum alloys 265 FGMs 286
17.6.3 Challengeswiththelegacy
U.SudhakarandJ.Srinivas manufacturingmethodsfor
FGMs 287
15.1 Introduction 265
17.7 AMmethodsforFGMs 288
15.2 Materialsandmodeling 267
17.8 ManufacturingofSS316(cid:1)AlSi10Mg
15.2.1 Thermomechanicsoftheprocess 268
FGM 290
15.3 Finiteelementmodeling 269
17.8.1 Themotive 290
15.3.1 Microstructureandhardness
17.8.2 Attempt1:BuildingSS316L
evaluation 270
overAlSi10MgBase 290
15.4 Conclusion 271
17.8.3 Attempt2:Buildingthe
References 271
AlSi10MgoverSS316L
baseplate 291
17.8.4 Attempt3:In-house
16. Processing of biomaterials by
manufacturingofSS316L-IN718
additive manufacturing 273
FGMthroughSLM 291
17.9 Conclusion 295
MayurkumarA.MakhesanaandKaushikM.Patel
17.10 FutureprospectsofFGM 295
16.1 Introductiontoadditivemanufacturing References 296
andbiomaterials 273
16.1.1 Introductionofadditive
manufacturing 273 18. Nondestructive evaluation of
16.1.2 Additivetechnologyselection 274 additively manufactured parts 299
16.1.3 Materialselection 274
P.R.SreerajandSantoshKr.Mishra
16.1.4 Additivemanufacturingpolymers 274
16.2 Additivemanufacturingtechnologyfor 18.1 Introduction 299
biomaterials 276 18.2 DefectsassociatedwithAMparts 300
16.3 Limitationsofadditivemanufacturing 18.2.1 Cracking 300
withbiomaterials 277 18.2.2 Porosity 301
16.4 Furtherdevelopmentofadditive 18.2.3 Inclusions 301
manufacturingapplications 278 18.2.4 Voids 302
References 278 18.2.5 Lackoffusion 302