Additive Manufacturing Handbook : Product Development for the Defense Industry book cover
1st Edition

Additive Manufacturing Handbook
Product Development for the Defense Industry

ISBN 9781482264081
Published May 24, 2017 by CRC Press

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Book Description

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

Table of Contents





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


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


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


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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.