Metal Additive Manufacturing MSc

The aim of this module is to cover the fundamental physics of heat-source - material interaction in additive manufacturing, to then introduce various AM techniques (selective laser melting, electron beam melting, wire arc AM, blown powder). The mechanisms of the individual techniques will be explored to include the benefits, challenges, limitations and suitability of each process. Practical examples will be used throughout to enable selection of a suitable process for a particular application.

• ​Fundamentals of arc processing.
• Fundamental of laser/beam processing.
• Metal AM processes.
• AM process selection.

On successful completion of this module you should be able to:
1. Describe various heat sources and their interaction with different feedstocks.
2. Compare the different AM processes and describe machine architectures.
3. Evaluate the different AM processes for a specific application.
4. Appraise the benefits, challenges and limitations associated with the use of AM techniques.

This module will enable you to understand, describe and evaluate the different post processing techniques currently used on AM parts and allow them to select the most appropriate one for a specific AM process and application. It will explore the underlying material science concepts for these processes.

• Post-processing techniques.
• Shot-peening.
• Heat treatments.
• Hot isostatic pressing.
• Materials science.

On successful completion of this module you should be able to:
1. ​​Evaluate the different post processing techniques used on AM parts, including those required for removal of support structures, improvement of surface characteristics and structural integrity.
2. Appraise the benefits and limitations of each post processing technique with respect to each AM process.
3. Propose the most suitable post processing technique for a specific AM process and application.
4. Assess the benefits of in-process cold work on the properties and microstructure of parts.​

The aim of this module is to provide you with an understanding of the microstructures and metallurgical characteristics of Additively Manufactured (AM) structures in a range of alloys, and how the metal and heat source interaction affects microstructure and strengthening behaviour of different alloys.

• Mechanical properties of metals.
• Dislocations and strengthening mechanisms.
• Failure.
• Grain structure and recrystallisation.
• Phase Diagrams.
• Phase transformations: Development of microstructure and alteration of mechanical properties.
• Principles of metallographic examinations.
• Steel/Stainless Steels/Nickel.
• Aluminium, copper, and other non-ferrous alloys.
• Titanium.
• Heat treatments.
• Dissimilar AM.
• Corrosion.

On successful completion of this module you should be able to:
1. Analyse phase diagrams and continuous temperature transformation diagrams for a range of alloys to explain the microstructural changes that occur.
2. Relate material microstructure to mechanical performance.
3. Evaluate specific materials for different applications to ensure they meet the requirements of the design brief.
4. Relate the heat treatment to the microstructure, mechanical properties, residual stress and defects.
5. Compose procedures and methods for preventing formation of undesirable phases and defects for dissimilar metallic AM parts.

The aim of this module is to provide you with an understanding of the fundamentals of quality management related to additive manufacturing, welding, and other processes, including quality systems and non-destructive examination, and to provide you with the knowledge to manage health and safety in the work place.

• Overview of standards and their function.
• Introduction to quality assurance.
• Quality control during manufacture.
• Welder and operator qualification.
• Introduction to Non-destructive examination (NDE) and types of defects.
• Destructive testing methods.
• Non-destructive testing methods (dye penetrant, magnetic particle, eddy current, acoustic emission, radiographic inspection, tomography, ultrasonic inspection).

This module will enable you to design their own additive manufacturing cell (including manipulation equipment, and sensing), or integrate an existing additive manufacturing machine in a broader production line. It also introduces you to experimental design and how to develop suitable parameters for part production.

• Sensors for Additive manufacturing.
• Manipulation.
• Jigs and fixtures.
• Cell design.
• Project planning.
• Factory layout.
• Experimental design.
• Part shielding.
• Thermal management.

On successful completion of this module you should be able to:

1. ​​Design and justify a programme of experiments for producing a simple structure and demonstrate the effect of the main input parameters, and analyse data produced from these experiments so that the relationship between process inputs and outputs is understood.

2. Plan an AM cell for manufacturing a specific AM part that includes selection of a robot, and methods to manipulate the part, fixturing and sensing of the part, equipment for loading and unloading, labour requirements and an estimation of the time to manufacture.

3. Calculate and justify the cost of a typical additive manufacturing operation including labour costs, overhead costs, and consumable costs.

4. Plan a factory layout that incorporates all required operations (feedstock storage, machine preparation, material preparation, AM cell and the finishing operations for the part).

5. Construct a project plan for the installation of the AM system.

Provide both an introduction to the theory underpinning finite element analysis, and hands on experience using a well-established package named Abaqus, to understand finite element analysis in the context of metal additive manufacturing.

• Introduction to finite element analysis.
  o Overview of the FEA method.
  o Concepts, procedure and terminology of FEA.
  o Advantages and general applications of FEA.
  o FEA in metal additive manufacturing.
• Theory of FEA method.
  o Mathematical theory for obtaining approximate solution.
  o Finite element formulation for solid mechanics.
  o Finite element formulation for heat transfer.
• Implementation of FEA.
  o Simplification and specification.
  o Solution techniques.
  o Assessment of results.
  o Mistakes, errors, accuracy and limitations.
• Introduction to FEA software ABAQUS
  o Pre-processing.
  o Running job and troubleshooting.
  o Post-processing.
• FEA of metal additive manufacturing.
  o Key phenomena and problems.
  o Thermal analysis.
  o Mechanical analysis.
o Other sophisticated aspects, e.g., molten pool fluid dynamics, solidification, grain growth, and solid state phase transformation.
• Practice: modelling wire arc additive manufacturing of a small metal wall using ABAQUS.

To introduce you to core factors of managing operations.

• An introduction to manufacturing and service activities.
• Capacity, demand and load; identifying key capacity determinant; order-size mix problem; coping with changes in demand.
• Standard times, and how to calculate them; process analysis and supporting tools; process simplification.
• What quality is; standards and frameworks; quality tools; quality in the supply chain.
• Scheduling rules; scheduling and nested set-ups.
• Roles of inventory; dependent and independent demand; Economic Order Quantity; uncertain demand; inventory management systems and measures.
• Information systems – at operational, managerial, and strategic levels; bills of material; MRP, MPRll and ERP systems.
• Ohno’s 7 wastes; Just-in-Time systems (including the Toyota Production System, and Kanbans).
• Class discussion of cases, exercises, and videos to support this syllabus.