Sunday, October 23, 2016
Additive Manufacturing of Metals
8:30 a.m. – 12 p.m.
Instructor: Eric Bono, Vice President, Engineering Solutions at Puris.
Description: The basic building block of any powder-based AM system is the input metal powder. The quality of the final part directly relates to that starting powder and how it was manipulated during the additive process. Microstructural and chemical changes to that base powder must be tightly controlled and intimately understood in order to produce predictable and acceptable components. Powders can experience a wide range of heat, pressure, humidity, vibration and other environmental conditions during the processing path. This course will look at some of those conditions and what impact they may have on final components as well as how to manage and control them to yield the best possible parts. Different AM processes will be compared and contrasted as to how they manipulate the starting powder and what that means to the ultimate material properties.
A Design Mindset for Additive Manufacturing
8:30 a.m. – 4:30 p.m.
Instructor: Howard A Kuhn, PhD, FASM, Adjunct Professor – University of Pittsburgh, Technical Advisor – America Makes
Description: Additive manufacturing (AM), more commonly known as 3D Printing, has captured the attention and fascination of the world of materials and manufacturing. However, exaggerated claims regarding shape capability and exclamations that “complexity is free” have painted an inaccurate picture of AM process capabilities. On the other hand, AM provides the opportunity for revolutionary approaches to product development through part integration, tooling for conventional processes, and unique geometries for weight savings. Recognizing genuine opportunities for AM requires a deep understanding of the benefits and limitations of the processes, plus a completely new mental approach to design. This short course focuses on a formalized approach to design for additive manufacturing by reviewing briefly the materials and characteristics of AM processes, describing various research accomplishments and successful commercial applications, and summarizing these observations into a set of rules, procedures, and mindset for realizing genuine value propositions for AM in metallic and ceramic materials.
Computational Modeling of Thermal Processes for Metallic Parts
8:30 a.m. – 4:30 p.m.
Instructor: B. Lynn Ferguson, Dante Solutions
Description: This one-day course covers just a portion of the broad field of computation modeling of materials, but it will illustrate the concepts of integrated computational materials engineering (ICME). We will focus on computational modeling of thermal processing of metallic parts, with emphasis on microstructure control, dimensional change and stress during and as a consequence of the process. The main discussion will be on heat treatment processes, and most examples will be on steel components, although aluminum, nickel and titanium alloys will be touched on. While there are many modeling methods in use, the method of choice for this course will be the finite element method. Modeling of thermal processing of components involves heat and mass transport, possible surface reactions, solid state transformations, thermal stress, and transformation induced stress. The models employed include thermal and chemical diffusion, mechanical, and metallurgical models. These will be discussed as applied to furnace heating, induction heating, carburization, immersion quenching, gas quenching, and aging and tempering processes. The material and process data needed for these models will be discussed, including the testing methods used to determine the data.
Correlative Light and Electron Microscopy of Metals
Noon – 4:30 p.m.
Instructor: John Peppler, Lab Manager, ASM International
Description: Light microscopy and electron microscopy each offer specific advantages and limitations when applied to the analysis of metallic materials. Correlating light microscopy images obtained with a variety of illumination and contrast techniques to SEM/EDS images at the same locations provides valuable information for interpretation of results. Finding the exact locations across separate platforms and equipment can be a time consuming barrier to utilization of these techniques without suitable tools for workflow improvement. Examples of applications in failure analysis, interpretation of microstructures, and non-metallic inclusion identification and analysis will be discussed to illustrate power of correlative microscopy in the characterization of metallic materials.
Essential Microstructure Interpretation
8:30 a.m. – 4:30 p.m.
Instructor: Frauke Hogue, FASM, Hogue Metallography
Description: Do you interpret microstructures on a regular basis, for quality control, failure analysis or research? Are you just curious about what the structures mean that you have been seeing all these years? Or is metallography a new field for you? In any case, this Sunday class before the MS&T conference is for you! This is a one day version of the 4 day class that has been presented to rave reviews at the ASM Headquarters at Materials Park for the last 20 years. The focus is on practical interpretation, NOT theory, phase diagrams and thermodynamics. There are no prerequisites. We will look at slides of over 200 structures and find out and discuss what each structure tells us about the type of material, manufacturing methods used, heat treatment, mechanical properties and sometimes even failure modes.
Failure Mechanisms and Analysis
8:30 a.m. – 12 p.m.
Instructor: Ronald J. Parrington, P.E., FASM, Director of Industrial Services, Sr. Managing Consultant – Engineering Systems, Inc. (ESI).
Description: This half-day short course is based on the very popular ASM course: Principles of Failure Analysis. Whether made of metallic or nonmetallic materials, components fail by distortion, corrosion, wear, and/or fracture. The primary objective of failure analysis is to accurately identify the failure mechanism, so that appropriate preventive actions can be taken. The important mechanisms for each type of failure (distortion, corrosion, wear, and fracture) will be reviewed in detail, including the key macro- and microscale features used by the failure analyst to identify the various failure mechanisms. Numerous examples and case studies are illustrated with photographs, fractographs, and photomicrographs.
Testing and Qualification in Additive Manufacturing
8:30 a.m. – 4:30 p.m.
Instructor: Dr. Prabir K. Chaudhury, PhD, Technical Director Designate, Metals Technology, Exova
Description: Additive Manufacturing, known as 3D Printing or Direct Manufacturing, has become the leading edge manufacturing technology today. Based on the current status of 3D printing of metallic parts there are no inspection, testing, and quality assurance guidelines nor is there a consensus among the participants on how to qualify these parts and inspect when in production. In order for Additive Manufacturing to become mainstream manufacturing technology for its widespread application in all engineered products, inspection, testing and qualification must be addressed as early as possible. This short course will address the role of testing and qualification for industrial implementation of various additive manufacturing processes. Processing related effects on microstructure and property will be discussed to provide guidance on process development and optimization through testing, inspection, and qualification. The short course will cover various mechanical, physical, and microstructural property measurement requirements for part design, material and process selection, machine qualification, product and process development, process optimization, qualification, and monitoring, and finally product quality assurance. This course will be beneficial for machine developers, part manufacturers, product designers, and Original Equipment Manufacturers engaged in Additive Manufacturing.
Thursday-Friday, October 27-28, 2016
Sintering of Ceramics
Thursday, October 27: 9:00 a.m. – 4:30 p.m.
Friday, October 28: 9:00 a.m. – 2:30 p.m.
Instructor: Mohamed N. Rahaman, Missouri University of Science and Technology
Description: This two-day course will follow the key topics in the textbook, Sintering of Ceramics, by M. N. Rahaman (book is included with course) and will be supplemented by detailed case studies of the sintering of specific ceramics and systems. Students will develop sufficient background in the principles and practice of sintering to be able to (i) do sintering to achieve specified target microstructures, (ii) understand the difficulties encountered in practical sintering, and (iii) take practical steps to rectify the problems encountered in producing required target microstructures.