Understanding Metal Additive Manufacturing — Lesson 2

This lesson covers the fundamental aspects of Metal Additive Manufacturing, focusing on the basic processes involved. It delves into the powder bed fusion method, direct energy deposition, binder jetting, and emerging metal additive manufacturing processes like material extrusion, material jetting, and sheet lamination. The lesson also discusses the learning objectives, including understanding various commercial AM machines, technology developments, major process parameters, and AM alloys. It further explains the powder bed fusion process, the role of lasers and electron beams, and the importance of process parameters. The lesson concludes with a discussion on Directed Energy Deposition (DED) and its applications.

Video Highlights

00:32 - Explanation of Powder Bed Fusion method
06:17 - Explanation of the process of Powder Bed Fusion
10:24 - Discussion on the process of Electron Beam Powder Bed Fusion
14:18 - Explanation of the differences between Selective Laser Sintering (SLS) and Selective Laser Melting (SLM)
33:14 - Discussion on the process of Directed Energy Deposition (DED)
42:57 - Discussion on the challenges and remedies in DED

Key Takeaways

- Metal Additive Manufacturing involves several processes including powder bed fusion and direct energy deposition.
- The powder bed fusion process uses a heat source like a laser or electron beam to fuse powder placed in a bed.
- The process parameters play a crucial role in the quality of the final product in Metal Additive Manufacturing.
- Directed Energy Deposition (DED) is a metal additive manufacturing process based on laser and electron beam welding, material feeding, injection, and CNC machine.
- DED is predominantly used for repairing and refurbishing processes and can handle reactive metals in a vacuum.