FOUNDRY PRACTICE

By P. KAERD

Chapter 1 Introduction1 11 Precision Manufacturing1 12 Market for Precision Manufacturing2 13 Machine Tools and Processes3 131 Mechanical Machining3 132 Electric Discharge Machining5 133 Laser Machining7 134 Status of Precision Surface Manufacturing8 14 Additive Manufacturing Technology11 141 Powder Bed Fusion (PBF) Processes12 142 Directed Energy Deposition (DED)15 15 Concluding Remarks18 Chapter 2 Unique Properties of AM Metals29 21 Material Characterization and Testing Techniques29 211 Chemical Composition Analysis29 212 Microstructure and Phase Composition31 213 Physical Properties34 214 Mechanical Properties36 22 Characterization and Testing of AM Metals38 221 Surface Morphology39 222 Internal Defects39 223 Chemical Composition and Element Distribution43 224 Microstructure Characterization44 225 Phase Composition and Transformation46 226 Mechanical Properties49 23 Concluding Remarks52 Chapter 3 Manufacturing Workflow57 31 Manufacturing Process Chain57 311 3D Model Creation57 312 Raw Material Preparation59 313 AM Parameter Selection62 32 Support Structure Removal65 321 Role of the Support Structure66 322 Methods of Removing Support Structures67 323 Balance of Support Structures69 33 Microstructure Modification70 331 Conventional Heat Treatment70 332 Hot Isostatic Pressing75 34 Concluding Remarks77 Chapter 4 Machinability of AM Metals85 41 Aluminum- Based Alloys85 42 Iron- Based Alloys87 43 Titanium Alloys90 44 Superalloys92 45 High- Entropy Alloys94 46 Other Metals94 47 Concluding Remarks97 Chapter 5 Abrasive- based Finishing Processes103 51 Definition and Classification103 52 Bonded Abrasive Finishing Processes104 521 Grinding104 522 Mass Finishing105 523 Magnetically Driven Internal Finishing106 53 Unbonded Abrasive Finishing Processes108 531 Sandblasting108 532 Abrasive Flow Machining109 533 Magnetic Abrasive Finishing111 534 Cavitation Abrasive Finishing112 54 Concluding Remarks113 Chapter 6 Thermal- Based Finishing Processes117 61 Definition and Working Principle117 611 Classification of Laser Polishing117 612 Process Parameters in Laser Polishing119 613 Surface Defects in Laser Polishing122 62 Laser Polishing of AM Metallic Parts124 621 Challenges124 622 Steel (Stainless Steel and Tool Steel)125 623 Titanium and Its Alloys125 624 Other Alloys (Inconel, CoCr, Al)125 63 Concluding Remarks138 Chapter 7 Chemical- based Finishing Processes143 71 Definition and Classification143 711 Chemical Etching (CE)143 712 Electrochemical Polishing (ECP)143 713 Hybrid Electrochemical Polishing144 72 Chemical Etching of AM Parts145 73 Electrochemical Polishing of AM Parts149 731 External Surfaces152 732 Internal Surfaces155 74 Hybrid Polishing156 75 Concluding Remarks160 Chapter 8 Theoretical Modeling Considerations for Post- Processing165 81 Modeling Methodology165 82 Finite Element Method Modeling166 821 Thermal Modeling168 822 Simulating the AM Process169 823 Distortion after Additive Manufacturing172 824 Development of Residual Stresses from Additive Manufacturing174 825 AM Microstructure Modeling175 826 Mechanical Modeling179 827 Material Model for Large Deformation of Metals183 828 Post- Process Residual Stresses186 829 Post- Processing of Support Structures187 83 Molecular Dynamics Simulations189 831 Melting and Solidification190 832 Defect Modeling192 84 Concluding Remarks195 Chapter 9 Hybrid Additive Manufacturing203 91 Successful Integrations203 911 Hybrid Additive/ Subtractive Manufacturing203 912 Multi- Energy Field Coupled Hybrid Additive Manufacturing209 913 Hybrid Additive/ Semi- Forming Manufacturing211 92 Multi- Material, Structural, and Functional Manufacturing213 921 Multi- Material Manufacturing213 922 Multi- Structural Manufacturing214 923 Multi- Functional Manufacturing216 93 Concluding Remarks218 Chapter 10 Case Studies225 101 Lightweight Optical Surface Fabrication225 1011 Application225 1012 Material Selection226 1013 Process Flow226 1014 Shape Generation by Diamond Turning227 1015 Microstructure Modifications231 1016 Alternative Shape Generation Method 1: Ultrasonic Elliptical Vibration- Assisted Machining233 1017 Alternative Shape Generation Method 2: Replacing Optical Surface with Nickel- Phosphorous Coating235 1018 Finishing Processes237 1019 Summarized Workflow242 102 Intravascular Stent Production243 1021 Application243 1022 Process Chain244 1023 Design and Fabrication245 1024 Mechanical- Based Finishing246 1025 Performance of Micro- Blasting247 1026 Performance of Electrochemical Polishing249 1027 Summarized Workflow250 Chapter 11 Future of Post- Processing257 111 Review on Post- Processing Technologies257 112 Surface Processing Innovations257 1121 Surface Effects260 1122 Field- Assisted Machining263 1123 Internal Finishing266 113 Hybrid Additive Manufacturing266 1131 Artificial Intelligence267 1132 Field- Assisted Integrations268