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MAT SCI 298 > Lecture 1 - Introduction > Flashcards

Lecture 1 - Introduction Flashcards

1
Q

additive manufacturing

A

a process of joining materials to make objects from 3D model data, usually layer upon layer

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2
Q

3D printing

A

the fabrication of objects through the deposition of a material using a print head, nozzle, or another printer technlogy

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3
Q

What is the downside of complex microstructures in additive manufacturing?

A

Very difficult to achieve uniformity and therefore certification.

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4
Q

What are two differences between conventional and additive manufacturing?

A

Conventional manufacturing produces more scrap/waste and both have different material and mechanical properties.

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5
Q

What are the three types of manufacturing techniques?

A
  1. Subtractive
  2. Near net shape
  3. Additive
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6
Q

What is the general sequence of additive manufacturing?

A
  1. CAD and slice
  2. Convert to .STL file
  3. Transfer to AM machine and .STL file manipulation
  4. Machine setup (processing parameters selection)
  5. Build
  6. Postprocessing/removal
  7. Certification
  8. Application
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7
Q

What are the seven AM process categories?

A
  1. binder jetting
  2. directed energy deposition
  3. material extrusion
  4. material jetting
  5. powder bed fusion
  6. sheet lamination
  7. vat photopolymerization
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8
Q

binder jetting

A

an AM process in which a liquid bonding agent is selectively deposited to join powder materials. metal or ceramic powdered parts are typically fired in a furnace after they are printed.

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9
Q

directed energy deposition

A

an AM process in which focused thermal energy (laser, electron beam, plasma) is used to fuse materials by melting as they are being deposited.

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10
Q

material extrusion

A

an AM process in which material is selectively dispensed through a nozzle or orifice

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11
Q

material jetting

A

an AM process in which droplets of build material are selectively deposited (photopolymer, wax)

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12
Q

powder bed fusion

A

an AM process in which thermal energy selectively fuses regions of a powder bed. powder surrounding the consolidated part acts as support material for overhanging features.

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13
Q

sheet lamination

A

an AM process in which sheets of material are bonded to form an object

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14
Q

vat photopolymeriation

A

an AM process in which liquid photopolymer in a vat is selectively cured by light activated polymerization, converting exposed areas to a solid part

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15
Q

What are six benefits to additive manufacturing?

A
  1. One-of-a-kind item or small number parts
  2. Shape of object in computer form
  3. Complex shape and complex microstructures
  4. automated process planning
  5. generic tooling
  6. minimal human intervention
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16
Q

AM is the intersection of what three fields?

A

Materials Science, Mechanical Engineering, and Software/Machine Learning/Computer Science

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17
Q

What are the five traditional technologies of Materials Science?

A
  1. powdered metallurgy
  2. welding
  3. extrusion
  4. CNC machining
  5. lithography
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18
Q

What are the three enabling component technologies of Mechanical Engineering?

A
  1. lasers
  2. ink-jet printers
  3. motion control
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19
Q

Software/Machine Learning/Computer Science contributes what technology to AM

A

CAD (solids modeling)

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20
Q

What is the role of Materials Science in AM?

A
  1. Processing
  2. Structure
  3. Properties
  4. Performance
    All forming characterization.
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21
Q

What is the accuracy of PBF?

A

10s of micrometers

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22
Q

PBF is the dominant AM technique for what materials?

A

metals, alloys, and ceramics

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23
Q

What are three advantages of PBF?

A

high level of complexity,
powder acts as support material, wide range of materials

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24
Q

What are typical materials of PBF?

A

plastics, metal and ceramic powders, sand, composite

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25
What six techniques are included in PBF?
selective laser sintering, direct metal laser sintering, selective laser melting, electron beam melting, selective heat sintering, multi-jet fusion
26
What is the speed typical for PBF (low, medium, high)?
Medium
27
Is powder in PBF cheap or expensive?
Expensive
28
What are the two common types of PBF?
Laser and EBM
29
What are the trace amounts of Helium for in EB-PBF?
to prevent static electron build-up
30
What is the main difference between laser and electron beam PBF?
Laser has a higher cooling rate
31
Laser spattering produces what in PBF?
Pores, which result in weaker material structure
32
What are four alternates names to DED?
Laser Metal Deposition, Laser Engineered Net Shaping, Direct Metal Deposition, Wire Arc Additive Manufacturing
33
What are five strengths of DED?
not limited by direction or axis effective for repairs and adding features multiple materials in a single part highest single-point deposition rates larger build volumes
34
What are typical materials for DED?
metal wire and powder, ceramics
35
How popular is DED?
it is the second most popular AM technique for metals
36
What is the disadvantage to DED?
Less dimensional accuracy (200 micron builds)
36
What are alternative names to binder jetting?
3D printing ExOne Voxeljet
37
What are four strengths to binder jetting?
full color printing high productivity wide range of materials low temperature and residual stresses
38
What are five typical materials for binder jetting?
powdered plastic, metal, ceramics, glass, sand
39
What are two disadvantages to binder jetting?
low dimensional accuracy postprocessing required
40
What are four characteristics to metal binder jetting?
equipment is cheap extensive post-processing geometry inaccuracy often contains contaminations
41
What are four alternative names to material jetting?
Polyjet Smooth Curvatures Printing Multi-Jet Modeling Projet
42
What are two varieties of material jetting?
jetting a photocurable resin and curing with UV light jetting thermally molten materials that solidify at ambient temperatures
43
What are three strengths to material jetting?
high level of accuracy full color parts multiple materials in a single part
44
What are three typical materials for material jetting?
photopolymers, polymers, waxes
45
What are two alternative names to material extrusion?
fused filament fabrication fused deposition modeling
46
What are four strengths to material extrusion?
inexpensive and economical multiple colors used in office environment good structural properties
47
What are three typical materials?
thermoplastic filaments and pellets, liquids, slurries
48
What are four applications for material extrusion?
battery materials, ceramics, glasses, and composites
49
Which two stacking designs are used in DIW? Which distributes stress better?
Face centered tetragonal (distributes better), simple cubic.
50
What are alternative names for sheet lamination?
laminated object manufacturing, selective deposition lamination, ultrasonic additive manufacturing
51
What are three strengths to sheet lamination?
high volumetric build rates low cost combinations of metal foils and embedding components
52
What are typical materials for sheet lamination?
paper, plastic sheets, and metal foils/tapes
53
What is one negative to sheet lamination?
limited interest from academia
54
What are four lamination methods for sheet lamination?
adhesives, chemical, ultrasonic welding, brazing
55
What are four alternative names to vat photopolymerization?
stereolithography apparatus digital light processing scan, spin, and selectively photocure continuous liquid interface production
56
What are three strengths of vat polymerization?
highest level of accuracy and complexity smooth surface finish accommodates large build areas
57
What materials are used for vat photopolymerization?
UV-curable photopolymer resins and piezo-electric materials.
58
What is projection microstereolithography?
3D printing technique based upon light and photochemistry
59
What is one disadvantage to material extrusion?
Nozzle gets clogged
60
What does the resolution depend on in material extrusion?
Nozzle diameter and pressure
61
For material extrusion, what method achieves the best precision?
Moving the platform rather than the nozzle
62
What is one disadvantage to vat photopolymerization?
Slow process
63
What is two photon polymerization
a sub-100nm resolution process from vat photopolymerization that uses photons from both sides on photon sensitive materials
64
Which AM technique has the highest spatial resolution during the build?
DED
65
What techniques are commonly used for metals and alloys?
PBF, DED, binder jetting, sheet lamination
66
What techniques are commonly used for polymers?
material jetting, vat photopolymerization
67
The resultant materials of laser and EB PBF differ in what ways?
grain size, phase, composition, residual stress, and dimension accuracy
68
3D printer
a machine used for 3D printing
69
CAM
computer-aided manufacturing - systems that use surface data to drive CNC machines
70
CNC
computer numerical control - computerized control of machines for manufacturing
71
IGES
initial graphics exchange specification - platform neutral data exchange, superseded by STEP
72
PDES
product data exchange specification
73
STEP
standard for exchange of product model data
74
STL
file format for 3D model data, originated from stereolithography. standard interface for AM systems
75
3D scanning
method of acquiring shape and size of an object as a 3D representation by recording xyz coordinates and converting to digital data
76
additive systems
machines used for AM
77
direct metal laser sintering
pbf process to make metal parts directly
78
facet
three or four sided polygon that represents an element of a 3D polygonal mesh surface or model. triangular facets used in STL files
79
fused deposition modeling
material extrusion process used to make thermoplastic parts through heated extrusion and deposition of materials layer by layer
80
laser sintering
pbf process that fuses particles at the surface layer by layer
81
prototype tooling
molds, dies, and other devices used to produce prototypes (bridge/soft tooling)
82
rapid prototyping
iterative AM of a design for form, fit, and functional testing
83
rapid tooling
use of AM to make tools or tooling quickly
84
reverse engineering
method of creating a digital representation to define shape, dimensions, and internal and external features
85
selective laser sintering
denotes the LS process from 3D systems corporation
86
sterolithography
a vat photopolymerization process used to produce parts from photopolymer materials in a liquid state
87
stereolithography apparatus
denotes SL machines from 3D systems corporation
88
subtractive manufacturing
making objects by removing material
89
surface model
mathematical representation of an object as a set of surfaces
90
tool/tooling
mold, die, or other device used in various manufacturing and fabricating processes
91
CAD
computer-aided design - use of computers for design of real/virtual objects
92
What two processes does EBM include?
PBF and DED
93
What is electron energy determined by?
acceleration voltage, beam size
94
What is the EBM material feed sources?
powder, wire, sheet
95
What are the properties of graphene aerogel?
large surface areas (700-1000 m^2/g) lightweight (15 mg/cm^3) electrically conductive (300 S/m) ultra-compressible (up to 90% strain)
96
What is graphene aerogel used for?
DIW

MAT SCI 298 (11 decks)

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