January 10–13, 2022

Online Course

Monday, 9 a.m.–12 p.m. EST, 1 p.m.–4 p.m. EST
Tuesday, 9 a.m.–12 p.m. EST, 1 p.m.–4 p.m. EST
Wednesday, 9 a.m.–12 p.m. EST, 1 p.m.–4 p.m. EST
Thursday, 9 a.m.–12 p.m. EST

Course Curriculum

Curriculum Flyer

The course will include four virtual modules with supporting materials. Registrants receive access to all course materials, live question-and-answer sessions, and module recordings until February 28, 2022.

Course Schedule

Go to the Instructors section to view bios and learn more about their research and professional experience.

Course Modules

Module 1: Process Development in Direct Metal Additive Manufacturing Technologies

Instructors: Nadia Kouraytem, Sneha Narra

This module will present a high-level overview of processing in direct metal additive manufacturing technologies and their industrial applications. Then, we will provide a deep dive into the process design framework using the laser powder bed fusion technology as an example. We 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, we will present the latest studies using advanced characterization methods to understand multiphysics phenomena.

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: Eric A. Lass, Alex Plotkowski

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. Other AM technologies, for example binder-jet, ultrasonic, and friction-stir AM, are entirely solid-state processes where material microstructures are affected by variables such as binder burn-off and sintering behavior, mechanical deformation heat imparted by a friction stir tool, or by subsequent post-build thermal processing. 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.

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 primary process variables of solid-state AM techniques and recognize how they may affect material deposition behavior and microstructure
• 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

Format: Live instruction with interactive group discussions

Module 3: Properties

Instructors: Amber Andreaco, Joy Gockel

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
• Analyze case studies of various AM properties

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

Module 4: Project Kick-off

Instructor: Joy Gockel

The final module will be an optional, self-paced project where participants will apply knowledge from the previous processing, structure and properties modules to analyze an additive manufacturing material data set. Example analysis tasks will be provided while each individual also has the freedom to drive the project in a direction that is of most interest to them. Project participants will have the option to present a poster at the TMS Annual conference showcasing their analysis and insights in connecting the processing-structure-properties relationships for AM.

Learning Objectives

• Apply knowledge gain in previous modules to new data
• Analyze AM processing, microstructure, defects, and properties experimental data
• Explain the processing-structure-properties relationship for AM

Format: Hands-on activity (project). Office hours.

For More Information

For more information about this course, please contact: