Additive Manufacturing Handbook Product Development for the Defense Industry

Theoretical and practical interests in additive manufacturing (3D printing) are growing rapidly. Engineers and engineering companies now use 3D printing to make prototypes of products before going for full production. In an educational setting faculty, researchers, and students leverage 3D printing to enhance project-related products. Additive Manufacturing Handbook focuses on product design for the defense industry, which affects virtually every other industry. Thus, the handbook provides a wide range of benefits to all segments of business, industry, and government. Manufacturing has undergone a major advancement and technology shift in recent years.

Table of Contents Acknowledgments Dedication Preface SECTION I: INTRODUCTORY SECTION Chapter 1: From Traditional Manufacturing to Additive Manufacturing Adedeji B. Badiru Chapter 2: A Novice’s Guide to 3D Printing Making the Process Less Magical and More Understandable Kim Brand Chapter 3: Comprehensive Project Management of High End Additive Manufacturing Equipment Adedeji B. Badiru Chapter 4: 3D-Printing Impacts on Systems Engineering In Defense Industry Jason Deters Chapter 5: 3D Printing Design Using Systems Engineering Bradford Shields and Vhance Valencia Chapter 6: Evaluation of Existing Modeling Software Shesh Srivatsa Chapter 7: Additive Manufacturing Research and Development Needs Shesh Srivatsa Chapter 8: Operational Aspects and Regulatory Gaps in Additive Manufacturing Adeola Adediran and Akinola Oyedele Chapter 9: Additive Manufacturing and Its Implications for Military Ethics John Mark Mattox Chapter 10: Additive manufacturing technologies: state of the art and trends Julien Gardan Chapter 11: A new global approach to design for additive manufacturing R. Ponche, J. Y. Hascoet, O. Kerbrat, P. Mognol Chapter 12: A new methodological framework for design for additive manufacturing Martin Kumke, Hagen Watschke and Thomas Vietor SECTION II: TECHNICAL SECTION Chapter 13: Development and Implementation of Metals Additive Manufacturing Ian D. Harris Chapter 14: Selective Laser Melting (SLM) of Ni-based Superalloys - A Mechanics of Materials Review Sanna F. Siddiqui, Abiodun A. Fasoro, and Ali P. Gordon Chapter 15: A Review on Powder Bed Fusion Technology of Metal Additive Manufacturing Valmik Bhavar, Prakash Kattire, Vinaykumar Patil, Shreyans Khot, Kiran Gujar, Rajkumar Singh Chapter 16: Additive Manufacturing of Titanium Alloys B. Dutta and Francis H. Froes Chapter 17: Ultrasonic Additive Manufacturing Paul J. Wolcott and Marcelo J. Dapino Chapter 18: Printing Components for Reciprocating Engine Applications Michael D. Kass and Mark W. Noakes Chapter 19: Developing Practical Additive Manufacturing Design Methods David Liu, Alan Jennings, K. Rekedal, David Walker, and H. Richards Chapter 20: Optical Diagnostics for Real-Time Monitoring and Feedback Control of Metal Additive Manufacturing Processes Glen P. Perram and Grady T. Phillips Chapter 21: 3D Printed Structures for Nano-Scale Research Tod V. Laurvick Chapter 22: Additive Manufacturing at the Micron Scale Ronald A. Coutu, Jr. Chapter 23: Computer Modeling of Sol-Gel Thin Film Deposition Using Finite Element Analysis Alex Li Chapter 24: Additive Manufacturing Technology Review: From Prototyping To Production Larry Dosser, Kevin Hartke, Ron Jacobson, and Sarah Payne Chapter 25: Mechanical Property Optimization of Fused Deposition Modeled Polylactic Acid Components via Design of Experiments Jonathan Torres and Ali P. Gordon Chapter 26: Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges W. E. King, A. T. Anderson, R. M. Ferencz, N. E. Hodge, C. Kamath, S. A. Khairallah, and A. M. Rubenchik Chapter 27: Calculation of laser absorption by metal powders in additive manufacturing C. D. Boley, S. A. Khairallah, A. M. Rubenchik Chapter 28: The Accuracy and Surface Roughness of Spur Gears Processed by FDM Additive Manufacturing Junghsen Lieh, Bin Wang and Omotunji Badiru Chapter 29: Surface Roughness of Electron Beam Melting Ti-6Al-4v Effect on Ultrasonic Testing Evan Hanks, David Liu, and Anthony Palazotto Chapter 30: Dynamic Failure Properties of Additively Manufactured Stainless Steel Allison Dempsey, David Liu, Anthony Palazotto, and Rachel Abrahams Chapter 31: Fatigue Life of Selective Laser Melted and Hot Isostatically Pressed Ti-6Al-4v Absent of Surface Machining Kevin D. Rekedal and David Liu Chapter 32: Development and Implementation of Metals Additive Manufacturing Ian D. Harris Chapter 33: Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones Saad A. Khairallah, Andrew T. Anderson, Alexander Rubenchik, and Wayne E. King Chapter 34: Measurement Science Needs for Real-time Control of Additive Manufacturing Powder Bed Fusion Processes Mahesh Mani, Shaw Feng, Brandon Lane, Alkan Donmez, Shawn Moylan, and Ronnie Fesperman Chapter 35: Denudation of metal powder layers in laser powder bed fusion processes Manyalibo J. Matthews, Gabe Guss, Saad Khairallah, Alexander M. Rubenchik, Philip J. Depond, and Wayne E. King Chapter 36: Tension-compression fatigue of an oxide/oxide ceramic composite at elevated temperature Marina B. Ruggles-Wrenn and R. L. Lanser Chapter 37: Effects of steam environment on fatigue behavior of two SiC/[SiC+Si3N4] ceramic composites at 1300°C Marina B. Ruggles-Wrenn and Vipul Sharma SECTION III: APPLICATION SECTION Chapter 38: 3D Product Design, Evaluation, Justification, and Integration Adedeji B. Badiru Chapter 39: 3D Printing Rises to the Occasion: ORNL group shows how it’s done, one layer at a time Leo Williams Chapter 40: 3D Printing Implications for STEM education John L. Irwin Chapter 41: Additive Manufacturing Applicability for United States Air Force Civil Engineer Contingency Operations Seth N. Poulsen and Vhance V. Valencia Chapter 42: Additive Manufacturing Applications for Explosive Ordnance Disposal (EOD) Using the Systems Engineering Spiral Process Model Tracy Meeks, Bradford Shields, Eric Holm, and Vhance Valencia Chapter 43: Proof-of-Concept Applications of Additive Manufacturing in Air Force Explosive Ordnance Disposal Training and Operations Abdulrahman Suliman Alwabel, Nathan Greiner, Sean Murphy, William Page, Shane Veitenheimer, and Vhance Valencia Chapter 44: Wing Design Utilizing Topology Optimization and Additive Manufacturing David Walker, David Liu, and Alan Jennings Chapter 45: Topology Optimization of a Penetrating Warhead William T. Graves, Jr., David Liu, and Anthony N. Palazotto Chapter 46: Iteration Revolution: DMLS Production Applications Erin Stone and Chad Cooper Chapter 47: Information Storage on Additive Manufactured Parts Larry Dosser, Kevin Hartke, Ron Jacobson, and Sarah Payne INDEX

Dr. Adedeji B. Badiru is a professor of systems engineering at the Air Force Institute of Technology (AFIT), Wright-Patterson Air Force Base, Ohio. He is a registered professional engineer (PE). He is a fellow of the Institute of Industrial & Systems Engineers and a fellow of the Nigerian Academy of Engineering. He is also a certified project management professional (PMP). He is PhD in industrial engineering from the University of Central Florida, Orlando, Florida. Dr. Badiru is the author of several books and technical journal articles. His areas of interest include manufacturing systems, technology transfer, project management, mathematical modeling and simulation, economic analysis, learning curve analysis, quality engineering, and productivity improvement. Dr. Vhance V. Valencia is an assistant professor in the Systems Engineering and Management Department, Air Force Institute of Technology (AFIT), Wright-Patterson Air Force Base, Ohio. He earned his PhD in systems engineering (2013) from AFIT; an MS in engineering management (2007) from AFIT; and a BS in mechanical engineering (2001) from San Diego State University, San Diego, California. Dr. Valencia is also a military officer and has held various engineering positions within the United States Air Force including facility construction and infrastructure program management, project management, and various staff and other leadership positions. A prolific writer, he has coauthored one book and written numerous journal articles and conference papers. His research interests include engineering applications for additive manufacturing, management of infrastructure assets and systems, systems engineering, and systems modeling and analysis. Dr. Valencia is a registered professional engineer and a member of the Society of American Military Engineers. Dr. David Liu is an aerospace engineer at the Weapons Directorate, Air Force Lifecycle Management Center (AFLCMC) on Eglin Air Force Base (AFB), Florida. He also serves as an adjunct assistant professor of aerospace engineering at the Air Force Institute of Technology (AFIT), Wright-Patterson AFB, Ohio. He is also a member of the America Institute for Aeronautics and Astronautics (AIAA) and is currently on the Survivability Technical Committee. Dr. Liu is the author of several technical journal articles on the subject of aircraft survivability, ballistic effects, propulsion, and additive manufacturing.