DOE OSTI2017
Additive manufacturing (also known as 3D printing) of metals is considered to be a disruptive technology, able to produce limited number of high value components with topologically optimized geometries and functionalities. Realization of the above potential for real-world applications is stifled by lack of standard computational design tools; component certifications, varied starting powder feed stock compositions, methods to probe thermomechanical processes, microstructural homogeneity, residual stress, as well as, anisotropic static- and dynamic-material properties. Detailed research of direct energy deposition, laser- and electron-powder bed additive manufacturing demonstrates that the underlying physics of these processes are very similar to welding, except for complex boundary conditions. This paper will review published literature and on-going research with reference to fundamental aspects of heat and mass transfer, solidification under large (103 to 105 K/m) thermal gradients and (10-3 to 100 m/s) liquid solid-interface velocities, as well as, solid->solid transformation under repeated thermal excursions. Case studies on model based qualification of Ni- and Ti- alloy builds made by additive manufacturing (AM), based on the above fundamental knowledge will be discussed.