COURSE OVERVIEW

The purpose of this workshop is to familiarize participants with current additive manufacturing (AM) processes; current AM practice for metals, polymers and ceramics; modeling of AM processes, microstructural evolution, and service properties; and current challenges and research opportunities.

This workshop is designed for people in the materials community already familiar with AM processes who want to learn more; academics and researchers will also benefit from discussions about current challenges to the full adoption of AM. The workshop is also designed to prepare participants to fully engage in the TMS 2015 Annual Meeting Symposium on "Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control."

TOPICAL OUTLINE

1. Introduction: 75 Minutes
   1. Short History of Process Development
   2. Application Space for AM
   3. Review of the 7 (ASTM) Categories of AM
   4. Current Materials for AM
   5. Overview of Relationship between Processes, Microstructural Development and Service
2. AM for Service Part Production: 45 Minutes
   1. Microstructural Issues (Microstructure, Defects)
   2. Post Processing (HIP, surface finishing, infiltration,…)
   3. Qualification and Certification of Materials and Processes
   4. Design Process Disruption
   5. Supply Chain Disruption
3. Modeling of AM Materials and Processes: 45 Minutes
   1. Design for additive manufacturing – Modeling Perspective
   2. Heat Transfer During Additive Manufacturing Processes (powder bed and powder blow)
   3. Solidification Phenomena
   4. Solid-State Transformations
   5. Ex-situ and In-situ Characterization for Verification and Validation
[15 Minute Break]
4. Emerging Research Areas: 60 Minutes
   1. Productivity
   2. Quality
   3. Reliability
   4. Surface Finish/Tolerance
   5. Materials Development
   6. In Process Monitoring and Control [Bio-AM]
      [Micro/Meso AM]
      [Sustainability in AM]
5. Panel Discussion with Q&A: 45 Minutes
   1. Opportunity for General Comments from Each Instructor
   2. Q&A

PRESENTERS

James W. Sears is senior mechanical engineer at GE Global Research Center - Additive Manufacturing Laboratory. Prior roles include director of the Additive Manufacturing Laboratory (AML), adjunct professor for the Materials and Metallurgical Engineering Department, professor for biomedical engineering at the South Dakota School of Mines & Technology, and executive director of the Quad Cities Manufacturing Laboratory (QMCL), a not-for-profit (501.c.3) research and development company embedded within the Rock Island Arsenal - Joint Manufacturing and Technology Center (JMTC). His research interests include additive manufacturing, rapid solidification processing, powder metallurgy, plasma and laser processing, and spray deposition and fabrication with nano-particles. Sears has written more than 80 published papers and holds three U.S. patents. He is a past TMS board member and past chair of the TMS Materials Processing and Manufacturing Division. In 2014, Sears received the TMS Materials Processing and Manufacturing Division Distinguished Service Award.

David L. Bourell is the Temple Foundation Professor of Mechanical Engineering at The University of Texas at Austin. He is currently director of the Laboratory for Freeform Fabrication. Bourell’s areas of research include particulate processing with emphasis on sintering kinetics and densification, and materials issues associated with laser sintering (LS). He holds nine primary patents dealing with materials innovations in LS dating back to 1990, and has published more than 200 papers in journals, conference proceedings and book chapters. Bourell is a leading expert in advanced materials for LS, having worked in this area since 1988. He was the lead author on the original materials patent for LS technology. Issuing in 1990, this patent has been cited by 150 other patents. Bourell is a Fellow of ASM International and TMS, and a lifetime member of TMS. In 2009, he received the TMS Materials Processing and Manufacturing Division Distinguished Scientist/Engineer Award.

Sudarsanam Suresh Babu holds the University of Tennessee/Oak Ridge National Laboratory (UT/ORNL) governor’s chair in advanced manufacturing at the University of Tennessee-Knoxville, and serves in the Department of Mechanical, Aerospace and Biomedical Engineering. Babu has a joint professorship with the Department of Materials Science and Engineering (MSE). As a governor's chair, he leads basic and applied research in a wide range of additive and other advanced manufacturing processes, including product design implications in collaboration with industry, faculty, and students at UT as well as with researchers at the Manufacturing Demonstration Facility (MDF) at ORNL. Babu has published more than 150 journal papers and numerous conference proceedings.

Jack Beuth is Professor of Mechanical Engineering at Carnegie Mellon University. Jack Beuth received his Ph.D. in Engineering Sciences from Harvard in 1992. He has been on the Carnegie Mellon faculty since that time. Dr. Beuth’s research is in the disciplines of solid mechanics, heat transfer and manufacturing, with over 75 publications across the areas of additive manufacturing, interfacial mechanics, thin film mechanics and fracture mechanics. His current research includes modeling of additive manufacturing (AM) processes, the study of micro-scale strength size effects in MEMS materials, and research in education. Dr. Beuth’s modeling research in additive manufacturing has led to the development of "process map" approaches for mapping out the role of principal process variables on process characteristics such as melt pool geometry, microstructure and residual stress. By characterizing direct metal AM processes over their full process variable ranges, Dr. Beuth’s research is allowing unique insights into process control, expansion of process operating ranges, identification of tests needed to characterize a process, and unique comparisons of AM processes operating in very different regions of processing space. Dr. Beuth’s current AM research projects include 20 industrial collaborators, 5 government laboratories and 6 universities. Dr. Beuth was a recipient of the 1998 Ralph R. Teetor Educational Award. In 2000, he was awarded George Tallman and Florence Barrett Ladd Development Professorship in Mechanical Engineering. In 2005 Dr. Beuth was co-recipient of the ASME Curriculum Innovation Award. In 2009 Dr. Beuth received the Benjamin Richard Teare Teaching Award from the Carnegie Mellon Engineering College.

REGISTRATION INFORMATION

REGISTRATION FEES *
Before February 9, 2015

• Member $125
• Nonmember $175
• Student $75

After February 9, 2015

• Member $175
• Nonmember $225
• Student $125