Advanced Manufacturing Processes

AIM

This course aims to establish a basic understanding of additive manufacturing (AM) as an industrial method for prototyping and manufacturing advanced metallic parts, and to provide an overview of metal AM techniques, along with their limitations and potential.

CONTENT

This course contains; Course Info, Introduction and Couse Motivation ,Overview of the 7 standard ASTM/ISO additive manufacturing categories ,Wire and sheet feedstock for alternative processes ,Binder jetting for metals and secondary sintering steps ,Sheet Lamination ,Powder Bed Fusion (PBF) Systems ,Directed Energy Deposition (DED) Processes - powder ,Directed Energy Deposition (DED) Processes - wire ,Electron Beam Melting (EBM): EBM technology, vacuum efect and differences from SLM ,Wire Arc Directed Energy Deposition (Wire Arc Additive Manufacturing - WAAM) ,Residual Stresses and Warpage, Defects (porosity, cracks, surface roughness) in AM parts ,Post-deposition reatments and associated microstructure evolutions ,Industrial Applications and Future: Case studies from the aerospace, defense, medical (implants), and automotive industries. .

1. 1

   Explain the fundamentals of metal additive manufacturing.

   Taught by: Question - Answer Technique, Lecture Method · Assessed by: Traditional Written Exam, Homework

2. 2

   Describe the defects commonly encountered in additively manufactured metal parts and post-deposition treatments.

   Taught by: Question - Answer Technique, Lecture Method · Assessed by: Traditional Written Exam, Homework

3. 3

   Evaluate the advantages and limitations of various AM processes.

   Taught by: Question - Answer Technique, Lecture Method · Assessed by: Traditional Written Exam, Homework

4. 4

   Select appropriate AM technologies for specific engineering applications.

   Taught by: Question - Answer Technique, Lecture Method · Assessed by: Traditional Written Exam, Homework

WEEKLY PLAN

1. WEEK 1

   Course Info, Introduction and Couse Motivation

2. WEEK 2

   Overview of the 7 standard ASTM/ISO additive manufacturing categories

3. WEEK 3

   Wire and sheet feedstock for alternative processes

4. WEEK 4

   Binder jetting for metals and secondary sintering steps

5. WEEK 5

   Sheet Lamination

6. WEEK 6

   Powder Bed Fusion (PBF) Systems

7. WEEK 7

   Directed Energy Deposition (DED) Processes - powder

8. WEEK 8

   Directed Energy Deposition (DED) Processes - wire

9. WEEK 9

   Electron Beam Melting (EBM): EBM technology, vacuum efect and differences from SLM

10. WEEK 10

    Wire Arc Directed Energy Deposition (Wire Arc Additive Manufacturing - WAAM)

11. WEEK 11

    Residual Stresses and Warpage, Defects (porosity, cracks, surface roughness) in AM parts

12. WEEK 12

    Post-deposition reatments and associated microstructure evolutions

13. WEEK 13

    Industrial Applications and Future: Case studies from the aerospace, defense, medical (implants), and automotive industries.

ASSESSMENT

• Rate of Midterm Exam to Success30%
• Rate of Final Exam to Success70%

WORKLOAD

READING

• Ian Gibson and David W. Rosen, Additive Manufacturing Technologies, Springer,
• Additive Manufacturing of Metals, Li Yang, Keng Hsu, et al., Springer

TEACHING STAFF

• Assist.Prof. Engin SANSARCICOORDINATOR
• Assist.Prof. Engin SANSARCI
• Prof.Dr. Gürel ÇAM