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Title: Additive manufacturing of materials: Opportunities and challenges

Abstract

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.

Authors:
 [1];  [2];  [2];  [2];  [2];  [3]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. SABIC Americas (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1286848
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
MRS Bulletin
Additional Journal Information:
Journal Volume: 40; Journal Issue: 12; Journal ID: ISSN 0883-7694
Publisher:
Materials Research Society
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; metal; crystallographic structure; neutron scattering; simulation; joining

Citation Formats

Babu, Sudarsanam Suresh, Love, Lonnie J., Dehoff, Ryan R., Peter, William H., Watkins, Thomas R., and Pannala, Sreekanth. Additive manufacturing of materials: Opportunities and challenges. United States: N. p., 2015. Web. doi:10.1557/mrs.2015.234.
Babu, Sudarsanam Suresh, Love, Lonnie J., Dehoff, Ryan R., Peter, William H., Watkins, Thomas R., & Pannala, Sreekanth. Additive manufacturing of materials: Opportunities and challenges. United States. doi:https://doi.org/10.1557/mrs.2015.234
Babu, Sudarsanam Suresh, Love, Lonnie J., Dehoff, Ryan R., Peter, William H., Watkins, Thomas R., and Pannala, Sreekanth. Sun . "Additive manufacturing of materials: Opportunities and challenges". United States. doi:https://doi.org/10.1557/mrs.2015.234. https://www.osti.gov/servlets/purl/1286848.
@article{osti_1286848,
title = {Additive manufacturing of materials: Opportunities and challenges},
author = {Babu, Sudarsanam Suresh and Love, Lonnie J. and Dehoff, Ryan R. and Peter, William H. and Watkins, Thomas R. and Pannala, Sreekanth},
abstractNote = {Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.},
doi = {10.1557/mrs.2015.234},
journal = {MRS Bulletin},
number = 12,
volume = 40,
place = {United States},
year = {2015},
month = {11}
}

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Cited by: 9 works
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