Additive manufacturing

The virtual world of additive manufacturing

· We explore the virtual world of additive manufacturing with mechanistic models and machine learning.

· Our mechanistic models of powder bed fusion, directed energy deposition and wire-arc additive manufacturing calculate the important factors that affect metallurgical product quality such as temperature and velocity fields, cooling rates and solidification parameters.

· Our physics informed machine learning programs seek to reduce defects in printed metal parts.

· Our recent reviews published in Nature Reviews Materials (2021), Nature Materials (2019), and Progress in Materials Science (2021 and 2018) critically evaluate the recent progress and uncover opportunities for impactful research.

Publications

1. T. DebRoy, T. Mukherjee, H.L. Wei, J.W. Elmer, J.O. Milewski, Metallurgy, mechanistic models and machine learning in metal printing, Nature Reviews Materials, 2021, vol. 6(1), pp. 48-68. (pdf)

2. H.L. Wei, T. Mukherjee, W. Zhang, J.S. Zuback, G.L. Knapp, A. De, T. DebRoy, Mechanistic models for additive manufacturing of metallic components, Progress in Materials Science, 2021, vol. 116, article # 100703. (pdf)

3. Y. Du, T. Mukherjee, T. DebRoy, Physics-informed machine learning and mechanistic modeling of additive manufacturing to reduce defects, Applied Materials Today, 2021, vol. 24, article # 101123. (pdf)

4. T. Mukherjee, T. DebRoy, T.J. Lienert, S.A. Maloy, P. Hosemann, Spatial and temporal variation of hardness of a printed steel part, Acta Materialia, 2021, vol. 209, article # 116775. (pdf)

5. W Ou, GL Knapp, T Mukherjee, Y Wei, T DebRoy, An improved heat transfer and fluid flow model of wire-arc additive manufacturing, International Journal of Heat and Mass Transfer, 2021, vol. 167, article # 120835. (pdf)

6. J.S. Zuback, G.L. Knapp, T.A. Palmer, T. DebRoy, Deposit geometry and oxygen concentration spatial variations due to composition change in printed functionally graded components, International Journal of Heat and Mass Transfer, 2021, vol. 164, article #120526. (pdf)

7. P. Zagade, B.P. Gautham, A. De, T. DebRoy, Analytical estimation of fusion zone dimensions and cooling rates in part scale laser powder bed fusion, Additive Manufacturing, 2021, vol. 46, article # 102222. (pdf)

8. D.R. Gunasegaram, A.B. Murphy, A. Barnard, T. DebRoy, M.J. Matthews, Towards developing multiscale-multiphysics models and their surrogates for digital twins of metal additive manufacturing, Additive Manufacturing, 2021, vol. 46, article # 102089. (pdf)

9. P Hosemann, J Duckering, A Dong, J Bickel, S Maloy, T Lienert, C Lear, T. Mukherjee and T. DebRoy, Additive Manufacturing of structural materials for nuclear application and rapid mesoscale mechanical testing, Microscopy and Microanalysis 2021, 27 (S1), 2154-2155. (pdf)

10. D.R. Gunasegaram, A.B. Murphy, M.J. Matthews, T. DebRoy, The case for digital twins in metal additive manufacturing, Journal of Physics: Materials, 2021, vol. 4 (4), article # 040401. (pdf)

11. HL Wei, T Mukherjee, T DebRoy, Preface to the special issue ‘Additive Manufacturing’, Computational Materials Science, 2021, vol. 191, article #110330. (pdf)

12. T. Mukherjee, T. DebRoy, Control of asymmetric track geometry in printed parts of stainless steels, nickel, titanium and aluminum alloys, Computational Materials Science, 2020, vol. 182, article #109791. (pdf)

13. Q. Wu, T. Mukherjee, A. De, T. DebRoy, Residual stresses in wire-arc additive manufacturing–Hierarchy of influential variables, Additive Manufacturing, 2020, vol. 35, article #101355. (pdf)

14. T. DebRoy, T. Mukherjee, J.O. Milewski, J.W. Elmer, B. Ribic, J.J. Blecher, W. Zhang. Scientific, technological and economic issues in metal printing and their solutions. Nature Materials, 2019, vol. 18, pp. 1026-1032. (pdf)

15. Q. Wu, T. Mukherjee, C. Liu, J. Lu, T. DebRoy. Residual stresses and distortion in the patterned printing of titanium and nickel alloys. Additive Manufacturing, 2019, vol. 29, 100808. (pdf)

16. T. Mukherjee, T. DebRoy. Printability of 316 stainless steel. Science and Technology of Welding and Joining, 2019, vol. 24 (5), pp. 412-419. (pdf)

17. H.L. Wei, H.K.D.H. Bhadeshia, S.A. David, T. DebRoy. Harnessing the scientific synergy of welding and additive manufacturing. Science and Technology of Welding and Joining, 2019, vol. 24 (5), pp. 361-366. (pdf)

18. G.L. Knapp, N. Raghavan, A. Plotkowski, T. DebRoy. Experiments and simulations on solidification microstructure for Inconel 718 in powder bed fusion electron beam additive manufacturing. Additive Manufacturing, 2019, vol. 25, pp. 511-521. (pdf)

19. H.L. Wei, G.L. Knapp, T. Mukherjee, T. DebRoy. Three-dimensional grain growth during multi-layer printing of a nickel-based alloy Inconel 718. Additive Manufacturing, 2019, vol. 25, pp. 448-459. (pdf)

20. T. Mukherjee, T. DebRoy. A digital twin for rapid qualification of 3D printed metallic components. Applied Materials Today, 2019, vol. 14, pp. 59-65. (pdf)

21. J.S. Zuback, T.A. Palmer, T. DebRoy. Additive manufacturing of functionally graded transition joints between ferritic and austenitic alloys. Journal of Alloys and Compounds, 2019, vol. 770, pp. 995-1003. (pdf)

22. T. Mukherjee, T. DebRoy. Mitigation of lack of fusion defects in powder bed fusion additive manufacturing. Journal of Manufacturing Processes, 2018, vol. 36, pp. 442-449. (pdf)

23. J.S. Zuback, T. DebRoy. The Hardness of Additively Manufactured Alloys. Materials, 2018, vol. 11, no. 11, 2070. (pdf)

24. W. Ou, T. Mukherjee, G.L. Knapp, Y. Wei, T. DebRoy. Fusion zone geometries, cooling rates and solidification parameters during wire arc additive manufacturing. International Journal of Heat and Mass Transfer, 2018, vol. 127, pp. 1084-1094. (pdf)

25. T. Mukherjee, H.L. Wei, A. De, T. DebRoy. Heat and fluid flow in additive manufacturing — Part I: Modeling of powder bed fusion. Computational Materials Science, 2018, vol. 150, pp. 304-313. (pdf)

26. T. Mukherjee, H.L. Wei, A. De, T. DebRoy. Heat and fluid flow in additive manufacturing — Part II: Powder bed fusion of stainless steel, and titanium, nickel and aluminum base alloys. Computational Materials Science, 2018, vol. 150, pp. 369-380. (pdf)

27. T. Mukherjee, J.S. Zuback, W. Zhang, T. DebRoy. Residual stresses and distortion in additively manufactured compositionally graded and dissimilar joints. Computational Materials Science, 2018, vol. 143, pp. 325-337. (pdf)

28. T. DebRoy, H.L. Wei, J.S. Zuback, T. Mukherjee, J.W. Elmer, J.O. Milewski, A.M. Beese, A. Wilson-Heid, A. De, W. Zhang. Additive manufacturing of metallic components–process, structure and properties. Progress in Materials Science, 2018, vol. 92, pp. 112–224. (pdf)

29. G.L. Knapp, T. Muhkerjee, J.S. Zuback, H.L. Wei, T.A. Palmer, A. De, T. DebRoy. Building blocks for a digital twin of additive manufacturing. Acta Materialia, 2017, vol. 135, pp. 390-399. (pdf)

30. T. Mukherjee, V. Manvatkar, A. De, T. DebRoy. Dimensionless numbers in additive manufacturing. Journal of Applied Physics, 2017, vol. 121, 064904. (pdf)

31. T. DebRoy, W. Zhang, J. Turner, S. S. Babu. Builiding digital twins of 3D printing machines. Scripta Materialia, 2017, vol. 135, pp. 119-124. (pdf)

32. H. L. Wei, J. W. Elmer, T. DebRoy. Three-dimensional modeling of grain structure evolution during welding of an aluminum alloy. Acta Materialia, 2017, vol. 126, pp. 413-425. (pdf)

33. T. Mukherjee, W. Zhang, T. DebRoy. An improved prediction of residual stresses and distortion in additive manufacturing. Computational Materials Science, 2017, vol. 126, pp. 360-372. (pdf)

34. T. Mukherjee, V. Manvatkar, A. De, T. DebRoy. Mitigation of thermal distortion during additive manufacturing. Scripta Materialia, 2017, vol. 127, pp. 79-83. (pdf)

35. H. L. Wei, T. Mukherjee, T. DebRoy. Grain growth modeling for additive manufacturing of nickel based superalloys. Proceedings of the 6th International Conference on Recrystallization and Grain Growth, 2016, pp. 265-269. (pdf)

36. H. L. Wei, J. W. Elmer, T. DebRoy. Origin of grain orientation during solidification of an aluminum alloy. Acta Materialia, 2016, vol. 115, pp. 123-131. (pdf)

37. T. Mukherjee, J. S. Zuback, A. De, T. DebRoy. Printability of alloys for additive manufacturing. Scientific Reports, 2016, 6, 19717, doi: 10.1038/srep19717. (pdf)

38. T. Mukherjee, J. S. Zuback, A. De, T. DebRoy. Heat and fluid flow modeling to examine 3D printability of alloys. 7th International Symposium on High-Temperature Metallurgical Processing, 2016, pp. 469-478. John Wiley & Sons, Inc. (pdf)

39. H. L. Wei, J. Mazumder, T. DebRoy. Evolution of solidification texture during additive manufacturing. Scientific Reports, 2015, 5, 16446, doi: 10.1030/srep16446. (pdf)

40. V. Manvatkar, A. De, T. DebRoy. Spatial variation of melt pool geometry, peak temperature and solidification parameters during laser assisted additive manufacturing process. Materials Science and Technology, 2015, vol. 31, pp. 924-930. (pdf)

41. R. Martukanitz, P. Michaleris, T. A. Palmer, T. DebRoy, Zi-Kui Liu, R. Otis, T. W. Heo, and L. Q. Chen, Toward an integrated computational system for describing the additive manufacturing process for metallic materials, Additive Manufacturing, 2014, vol. 1-4, pp. 52–63. (pdf)

42. V. Manvatkar, A. De, T. DebRoy. Heat transfer and material flow during laser assisted multi-layer additive manufacturing. Journal of Applied Physics, 2014, vol. 116, 124905. (pdf)

43. A. Raghavan, H. L. Wei, T. A. Palmer, T. DebRoy. Heat transfer and fluid flow in additive manufacturing. Journal of Laser Applications, 2013, 25, doi: 10.2351/1.4817788. (pdf)

44. T. DebRoy. Picture to parts, one thin metal layer at a time. (Unpublished) (pdf)