SCOPE

Additive manufacturing (AM) has become popular in the last few years, although seminal developments took place 25–30 years ago. The purpose of this workshop is to familiarize participants with current 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.

WHO ATTENDS?

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.

TOPICAL OUTLINE

1. Introduction: 75 Minutes [Bourell]
   1. VERY 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 Properties
2. AM for Service Part Production: 45 Minutes [Sears]
   1. History of Metal Powder Deposition for Part Manufacturing (Why AM?)
   2. Technologies
   3. Process Properties
   4. ASTM Specifications
   5. Post Processing (Inspection, Finishing, Heat Treatments, Hot Isostatic Pressing {HIP})
   6. Limitations
   7. What’s next?
      
      Break: 15 Minutes
      
      
3. Modeling in AM: 90 Minutes [Babu and Beuth]
   1. Heat Transfer During Additive Manufacturing Processes (powder bed and powder stream) (Beuth)
   2. Process Mapping Approach (Beuth)
   3. Design for additive manufacturing – Process Design (Beuth)
   4. Mapping of Microstructure across Processing Space (Beuth)
   5. Solidification Phenomena (Babu)
   6. Solid-State Transformations (Babu)
   7. Ex-situ and In-situ Characterization for Verification and Validation (Babu)
4. Panel Discussion with Q&A: 45 Minutes [All Instructors]
   1. Opportunity for General Comments from Each Instructor
   2. Q&A

INSTRUCTOR BIOS

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. Issued 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 (CMU). Beuth received his Ph.D. in engineering sciences from Harvard University in 1992 and has been on the CMU faculty since that time. 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. In 2000, he was awarded George Tallman and Florence Barrett Ladd Development Professorship in Mechanical Engineering at CMU. In 2005, Beuth was co-recipient of the ASME Curriculum Innovation Award. In 2009, he received the Benjamin Richard Teare Teaching Award from the CMU College of Engineering.

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 at the South Dakota School of Mines & Technology (SDSMT), professor for biomedical engineering at SDSMT, and executive director of the Quad Cities Manufacturing Laboratory (QMCL), a nonprofit 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 published more than 80 papers and holds three US 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.

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