The RAPID 2013 Conference & Exposition Directory - Society of ...

ConferenCe Details
4:30–4:55 pm
Panel Presentation
Moderator: Ryan Larson, Nike Inc.
Panel Participants:
Dave Abbott, GE Aviation
Chris Gravelle, Bell Helicopter
Garrett Grindle, Human Engineering and Research Laboratories
at VA Pittsburgh
Jim Kor, KOR EcoLogic
This panel is composed of experienced practitioners and users of
additive manufacturing to build parts. The discussion will include
benefits and challenges of bringing additive manufacturing
into production, printing final parts, and how the finished parts
contribute to lower labor costs, speed up assembly times, and
increase final product quality.
Additive Manufacturing Research
1:30–5 pm
Learn about the efforts to advance the uses of additive
manufacturing technologies. A variety of processes and
materials will be covered.
1:30–1:55 pm
Laser Additive Manufacturing of Pure Copper
Federico Sciammarella, PhD, Assistant Professor,
Northern Illinois University
The deposition of pure Copper via additive manufacturing poses
some difficult issues. This presentation highlights the additive
manufacturing (via LENS) work being done in parallel by the Laser
Materials processing group at the National Laser Centre and the
Macro/Micro Manufacturing Lab at Northern Illinois University.
At this stage, deposition of higher than 2 to 6 mm was not possible
due to the high conductivity of the first few deposited layers of
Cu. The high reflectivity also makes it difficult to build beyond this
threshold level of layers as most of the light is reflected back,
thus reducing the amount of energy absorbed by the melt pool.
Some further efforts were carried out at NIU which involved preheating
the substrate prior to deposition, it is anticipated that this
may increase the deposition amount.
2–2:25 pm
Powder-Based Electron Beam Additive
Manufacturing—Process Modeling with
Applications to Novel Overhang Support Designs
Kevin Chou, PE, ASME Fellow, Professor, University of Alabama
This presentation will discuss the powder-based EBAM
technology. In particular, modeling of the EBAM process physics,
by finite element (FE) analysis, will be addressed. The key points
of the model will be elucidated using different examples, and
process improvements derived from FE simulations/analyses will
be demonstrated. One improvement is novel overhang support
structure designs, which will eliminate the need of mechanical
ways for support removals, and thus, simplify post-processing
and enhance EBAM performance. The study demonstrates
the powerful potential of FE modeling in studying the EBAM
fundamentals and in capturing the complexity of the process,
which in turn helps understand and advance metal-based rapid
manufacturing technologies.
2:30–2:55 pm
Modeling and Validation of Residual Stress and
Distortion in Direct Metal Deposition Processes
Michael F. Gouge, Graduate Research Assistant,
Penn State University
Direct metal deposition processes are becoming increasingly
important in the repair of high-value components. Unfortunately,
the high temperature gradients experienced by the deposited
material, as well as the substrate material during processing, lead
to the formation of high levels of residual stress and distortion.
In this work, thermo-mechanical finite element analysis of the
process is performed using a moving heat source model for the
multilayer laser cladding of Inconel® 625 at a laser power of
2500 W on 12.5-mm thick plates. Both powder and wire-fed metal
deposition methods are evaluated with depositions paths in both
longitudinal and transverse orientations. In order to validate
the modeling results, in-situ temperature and deformation
measurements are performed using pre-placed thermocouples
and by fixturing the plate on one end and measuring deflection on
the opposite end. These results are validated using pre- and postprocess
coordinate measurement machine (CMM) measurements
at several points on each plate and residual stress measurements
made using the blind hole drilling (BHD) method. Both layer-based
42 sme.org/rapid