MTE6886 · Additive manufacturing of metallic materials

Overview

Additive Manufacturing (AM) of metallic materials is an integral part of modern manufacturing. AM allows to produce complex engineering products from a powder stock using a layer-by-layer deposition. This unit will provide an overview of existing additive manufacturing processes such as 'selective laser melting', 'electron beam melting' and 'direct energy deposition'. The first part of the unit will focus on powder metallurgy covering aspects of powder production, blending and characterisation. The second part of the unit will investigate different additive manufacturing processes and establish a relationship between processing parameters, resulting in microstructure and mechanical properties of 3D printed materials. Furthermore, various post-processing techniques for additive manufactured products will be reviewed. Examples of the use of these technologies for the design and fabrication of production parts for aerospace and biomedical application will be critically assessed. The students will undertake a 3D printing project and obtain practical skills in computer-aided design and 3D printing of metals.

Offerings

Assessment

The Handbook lists an examination for this unit.

Continuous assessment: 50% Final assessment: 50% Final grades: PGO (pass grade only) or NGO (fail) This unit contains hurdle requirements that you must achieve to be able to pass the unit. You are required to achieve at least 45% in the total continuous assessment component and at least 45% in the final assessment component. The consequence of not achieving a hurdle requirement is a fail grade (NGO).

Assessment details may change. Please refer to the assessment information in Moodle closer to the start of the teaching period.

Requisites

Learning outcomes

1. Describe powder feedstock in terms of its particle shape, size, and distribution and assess its effect on the accuracy and surface finish for different Additive Manufacturing processes.
2. Recognise the benefits and drawbacks of different metal additive manufacturing technologies.
3. Demonstrate in-depth understanding of processing parameters such as laser-related parameters or scan-related parameters governing different Additive Manufacturing processes and their relationship to mechanical properties of 3D printed materials.
4. Discuss in detail the factors that affect the density, surface finish and detail resolution of parts produced by AM processes.
5. Choose appropriate strategy for the orientation of a 3D printed part on the build platform and the generation of the support structure in order to minimise post-processing activities.
6. Demonstrate practical skills in computer-aided design and 3D printing of metals.

Workload

The minimum total expected workload to achieve the learning outcomes for this unit is 144 hours per semester typically comprising a mixture of 3-6 hours of scheduled learning activities and 6-9 hours of independent study per week. Scheduled activities may include a combination of teacher-directed learning, peer-directed learning and online engagement. Independent study may include associated readings, assessment and preparation for scheduled activities.

Student experience, not official rules. Nothing here changes what the Handbook says.