February 13–15, 2023 • Online Course

Course Curriculum

The course will include three virtual modules with supporting materials. Registrants receive access to all course materials. Registrants will have access to materials and on-demand recordings until March 17, 2023.

Course Schedule

Course Modules

Module 1: Process Development in Direct Metal Additive Manufacturing Technologies

Instructors: Sneha P. Narra, Nadia Kouraytem

This module will present a high-level overview of processing in direct metal additive manufacturing technologies and their industrial applications. It will provide a deep dive into the process design framework using the laser powder bed fusion technology as an example. This module will specifically focus on (i) identifying the processing parameters, (ii) developing and utilizing experimental and computational process models, and (iii) discussing available experimentation, process monitoring, and data analysis techniques. Finally, the latest studies using advanced characterization methods to understand multiphysics phenomena will be presented.

Learning Objectives

• Recall and discuss general principles of direct metal additive manufacturing processes that are currently available in the market
• Recognize the key processing parameters and how these are varied in a design of experiment to understand process-structure-property relationships
• Apply analytical modeling approaches to AM, report the assumptions, differentiate between a complex numerical model and a simple model, assess the applicability of a simple model to the problem of interest
• Learn about the various lab-scale and commercial in-situ monitoring techniques used in gathering operando MAM data and how to analyze the data.

Format: Live instruction and breakout sessions. Optional hands-on activities which can be performed at home.

Module 2: Microstructure Development

Instructors: Alex Plotkowski, Andrew Polonsky

Solidification behavior primarily governs microstructural development during the build process for most AM technologies, which is highly dependent on material chemistry, AM processing variables, and thermal transport. Solid-state microstructural evolution can also occur within prior deposited layers during the build process and within the entire component during post-build thermal processing. The interplay of the local nature of AM processing with a complex thermal history, including post-processing, can lead to the development of unique microstructures that are critical to controlling material properties. This module will introduce the fundamental relationships between AM processing variables and the thermal profile (in situ and post-build) experienced by the component on microstructure development in AM materials. Various characterization methods for interrogating and quantifying AM microstructures will also be presented.

Learning Objectives

• Describe how solid-liquid interface velocity and thermal gradient affect solidification microstructure and understand the effects of fusion-based AM processing variables on solidification behavior
• Identify the types of solid-state phase transformations that may occur both during the build process and post-build thermal processing
• Apply knowledge of processing-structure relationships in AM to describe microstructural development during AM fabrication of a common material
• Understand the available suite of methods used to characterize AM microstructures

Format: Live instruction with interactive group discussions

Module 3: Properties

Instructors: Amber Andreaco, Joy Gockel (Lead Instructor)

This module will cover the properties of AM materials. It will compare AM static and dynamic properties to other manufacturing processes and the test methods will be reviewed. Material mechanisms influencing failure will be discussed, including microstructure and defects. Ultimately, the failure mechanisms and properties behavior will be connected back to AM processing and post-processing conditions.

Learning Objectives

• Explain similarities and differences in AM properties versus other manufacturing processes
• Describe key processing influences and material mechanisms causing failure of AM metallic materials
• Understand processing and post-processing effects on AM properties

Format: Live instruction. Breakout sessions. Poll. Hands-on activity: Analysis and interpretation of AM properties example data.

For More Information

For more information about this course, please contact: