Additive Manufacturing Technology: Enhancing Process Optimisation and Part Performance through Simulation

This presentation was made at NAFEMS UK Conference 2018, Taking Engineering Analysis and Simulation to the Next Level".

The NAFEMS UK Conference 2018 brought together all those involved in analysis and simulation from every corner of industry and academia, giving them an opportunity to advance their knowledge, give their organisations a competitive advantage, and a chance to be part of improving the technology itself.

Resource Abstract

Metal Additive Manufacturing (AM) technology has developed rapidly in the last decade and has demonstrated significant potential to reduce the costs and improve the quality and efficiency of parts and components across all industry sectors. This can be realised through improved design freedom and light-weighting via topology optimisation; improved buy-to-fly ratios; and a reduction of tooling costs – all of which have a demonstrable impact on the carbon footprint and waste in manufacture.

However, there are many factors that affect the final quality (and certification) of AM parts, including the feedstock material characteristics and the thermal transients seen buy the part during processing. The complex geometry of topology optimised parts – designed to take advantage of the flexibility of AM processing – means that almost every location in the build sees a unique thermal history. As thermal history controls microstructure, distortion and residual stress, there is significant uncertainty in the performance of and lack of homogeneity within metal AM parts.

This presentation highlights some of the ways the Integrated Computational Materials Engineering (ICME) concepts are influencing how industry approaches and realises the potential impacts of AM technology. It considers multiple AM methods (selective laser melting and wire-arc additive) and how engineering analysis can significantly reduce trial-and-error costs and improve our fundamental understanding of AM processes.