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Additive manufacturing

 

Our models of powder bed fusion, directed energy deposition and wire-arc additive manufacturing calculate the most important factors that affect metallurgical product quality such as temperature and velocity fields, cooling rates and solidification parameters. They solve the equations of conservation of mass, momentum and energy in three-dimensional transient form for multi-layer, multi-hatch deposition using an efficient numerical algorithm. When integrated with a genetic algorithm, these models can switch traditional input and output variables, tailor product attributes and optimize production variables.  We work closely with many leading research and development groups worldwide.

 

 

Publications

1. 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)

2. 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)

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

4. 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)

5. 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)

6. 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)

7. 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)

8. 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)

9. 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)

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

11. 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)

12. 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)

13. 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)

14. 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)

15. 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)

16. 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)

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

18. 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)

19. 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)

20. 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)

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

22. 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)

23. 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)

24. 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)

25. 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)

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

27. 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)

28. 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)

29. 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)

30. 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)

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