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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
Q

What six techniques are included in PBF?

A

selective laser sintering, direct metal laser sintering, selective laser melting, electron beam melting, selective heat sintering, multi-jet fusion

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26
Q

What is the speed typical for PBF (low, medium, high)?

A

Medium

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27
Q

Is powder in PBF cheap or expensive?

A

Expensive

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28
Q

What are the two common types of PBF?

A

Laser and EBM

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29
Q

What are the trace amounts of Helium for in EB-PBF?

A

to prevent static electron build-up

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30
Q

What is the main difference between laser and electron beam PBF?

A

Laser has a higher cooling rate

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31
Q

Laser spattering produces what in PBF?

A

Pores, which result in weaker material structure

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32
Q

What are four alternates names to DED?

A

Laser Metal Deposition, Laser Engineered Net Shaping, Direct Metal Deposition, Wire Arc Additive Manufacturing

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33
Q

What are five strengths of DED?

A

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

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34
Q

What are typical materials for DED?

A

metal wire and powder, ceramics

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35
Q

How popular is DED?

A

it is the second most popular AM technique for metals

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36
Q

What is the disadvantage to DED?

A

Less dimensional accuracy (200 micron builds)

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36
Q

What are alternative names to binder jetting?

A

3D printing
ExOne
Voxeljet

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37
Q

What are four strengths to binder jetting?

A

full color printing
high productivity
wide range of materials
low temperature and residual stresses

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38
Q

What are five typical materials for binder jetting?

A

powdered plastic, metal, ceramics, glass, sand

39
Q

What are two disadvantages to binder jetting?

A

low dimensional accuracy
postprocessing required

40
Q

What are four characteristics to metal binder jetting?

A

equipment is cheap
extensive post-processing
geometry inaccuracy
often contains contaminations

41
Q

What are four alternative names to material jetting?

A

Polyjet
Smooth Curvatures Printing
Multi-Jet Modeling
Projet

42
Q

What are two varieties of material jetting?

A

jetting a photocurable resin and curing with UV light
jetting thermally molten materials that solidify at ambient temperatures

43
Q

What are three strengths to material jetting?

A

high level of accuracy
full color parts
multiple materials in a single part

44
Q

What are three typical materials for material jetting?

A

photopolymers, polymers, waxes

45
Q

What are two alternative names to material extrusion?

A

fused filament fabrication
fused deposition modeling

46
Q

What are four strengths to material extrusion?

A

inexpensive and economical
multiple colors
used in office environment
good structural properties

47
Q

What are three typical materials?

A

thermoplastic filaments and pellets, liquids, slurries

48
Q

What are four applications for material extrusion?

A

battery materials, ceramics, glasses, and composites

49
Q

Which two stacking designs are used in DIW? Which distributes stress better?

A

Face centered tetragonal (distributes better), simple cubic.

50
Q

What are alternative names for sheet lamination?

A

laminated object manufacturing, selective deposition lamination, ultrasonic additive manufacturing

51
Q

What are three strengths to sheet lamination?

A

high volumetric build rates
low cost
combinations of metal foils and embedding components

52
Q

What are typical materials for sheet lamination?

A

paper, plastic sheets, and metal foils/tapes

53
Q

What is one negative to sheet lamination?

A

limited interest from academia

54
Q

What are four lamination methods for sheet lamination?

A

adhesives, chemical, ultrasonic welding, brazing

55
Q

What are four alternative names to vat photopolymerization?

A

stereolithography apparatus
digital light processing
scan, spin, and selectively photocure
continuous liquid interface production

56
Q

What are three strengths of vat polymerization?

A

highest level of accuracy and complexity
smooth surface finish
accommodates large build areas

57
Q

What materials are used for vat photopolymerization?

A

UV-curable photopolymer resins and piezo-electric materials.

58
Q

What is projection microstereolithography?

A

3D printing technique based upon light and photochemistry

59
Q

What is one disadvantage to material extrusion?

A

Nozzle gets clogged

60
Q

What does the resolution depend on in material extrusion?

A

Nozzle diameter and pressure

61
Q

For material extrusion, what method achieves the best precision?

A

Moving the platform rather than the nozzle

62
Q

What is one disadvantage to vat photopolymerization?

A

Slow process

63
Q

What is two photon polymerization

A

a sub-100nm resolution process from vat photopolymerization that uses photons from both sides on photon sensitive materials

64
Q

Which AM technique has the highest spatial resolution during the build?

A

DED

65
Q

What techniques are commonly used for metals and alloys?

A

PBF, DED, binder jetting, sheet lamination

66
Q

What techniques are commonly used for polymers?

A

material jetting, vat photopolymerization

67
Q

The resultant materials of laser and EB PBF differ in what ways?

A

grain size, phase, composition, residual stress, and dimension accuracy

68
Q

3D printer

A

a machine used for 3D printing

69
Q

CAM

A

computer-aided manufacturing - systems that use surface data to drive CNC machines

70
Q

CNC

A

computer numerical control - computerized control of machines for manufacturing

71
Q

IGES

A

initial graphics exchange specification - platform neutral data exchange, superseded by STEP

72
Q

PDES

A

product data exchange specification

73
Q

STEP

A

standard for exchange of product model data

74
Q

STL

A

file format for 3D model data, originated from stereolithography. standard interface for AM systems

75
Q

3D scanning

A

method of acquiring shape and size of an object as a 3D representation by recording xyz coordinates and converting to digital data

76
Q

additive systems

A

machines used for AM

77
Q

direct metal laser sintering

A

pbf process to make metal parts directly

78
Q

facet

A

three or four sided polygon that represents an element of a 3D polygonal mesh surface or model. triangular facets used in STL files

79
Q

fused deposition modeling

A

material extrusion process used to make thermoplastic parts through heated extrusion and deposition of materials layer by layer

80
Q

laser sintering

A

pbf process that fuses particles at the surface layer by layer

81
Q

prototype tooling

A

molds, dies, and other devices used to produce prototypes (bridge/soft tooling)

82
Q

rapid prototyping

A

iterative AM of a design for form, fit, and functional testing

83
Q

rapid tooling

A

use of AM to make tools or tooling quickly

84
Q

reverse engineering

A

method of creating a digital representation to define shape, dimensions, and internal and external features

85
Q

selective laser sintering

A

denotes the LS process from 3D systems corporation

86
Q

sterolithography

A

a vat photopolymerization process used to produce parts from photopolymer materials in a liquid state

87
Q

stereolithography apparatus

A

denotes SL machines from 3D systems corporation

88
Q

subtractive manufacturing

A

making objects by removing material

89
Q

surface model

A

mathematical representation of an object as a set of surfaces

90
Q

tool/tooling

A

mold, die, or other device used in various manufacturing and fabricating processes

91
Q

CAD

A

computer-aided design - use of computers for design of real/virtual objects

92
Q

What two processes does EBM include?

A

PBF and DED

93
Q

What is electron energy determined by?

A

acceleration voltage, beam size

94
Q

What is the EBM material feed sources?

A

powder, wire, sheet

95
Q

What are the properties of graphene aerogel?

A

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
Q

What is graphene aerogel used for?

A

DIW

MAT SCI 298 (11 decks)

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