Ehsan Hosseini: Catalogue data in Autumn Semester 2022

Name Dr. Ehsan Hosseini
Rällikerstrasse 28b
8617 Mönchaltorf
Telephone+41 79 823 9151
DepartmentMechanical and Process Engineering

151-0544-00LMetal Additive Manufacturing - Mechanical Integrity and Numerical Analysis4 credits3GE. Hosseini
AbstractAn introduction to Metal Additive Manufacturing (MAM) (e.g. different techniques, the metallurgy of common alloy-systems, existing challenges) will be given. The focus of the lecture will be on the employment of different simulation approaches to address MAM challenges and to enable exploiting the full advantage of MAM for the manufacture of structures with desired property and functionality.
ObjectiveThe main objectives of this lecture are:
- Acknowledging the possibilities and challenges for MAM (with a particular focus on mechanical integrity aspects),
- Understanding the importance of material science and metallurgical considerations in MAM,
- Appreciating the importance of thermal, fluid, mechanical and microstructural simulations for efficient use of MAM technology,
- Using different commercial analysis tools (COMSOL, ANSYS, ABAQUS) for simulation of the MAM process.
Content- Introduction to MAM (concept, application examples, pros & cons),
- Powder-bed and powder-blown metal additive manufacturing,
- Thermo-fluid analysis of additive manufacturing,
- Continuum-based thermal modelling and experimental validation techniques,
- Residual stress and distortion simulation and verification methods,
- Microstructural simulation (basics, analytical, kinetic Monte Carlo, cellular automata, phase-field),
- Mechanical property prediction for MAM,
- Microstructure and mechanical response of MAM material (steels, Ti6Al4V, Inconel, Al alloys),
- Design for additive manufacturing
- Artificial intelligence for AM
Exercise sessions use COMSOL, ANSYS, ABAQUS packages for analysis of MAM process. Detailed video instructions will be provided to enable students to set up their own simulations. COMSOL, ANSYS and ABAQUS agreed to support the course by providing licenses for the course attendees and therefore the students can install the packages on their own systems.
Lecture notesHandouts of the presented slides.
LiteratureNo textbook is available for the course (unfortunately), since it is a dynamic and relatively new topic. In addition to the material presented in the course slides, suggestions/recommendations for additional literature/publications will be given (for each individual topic).
Prerequisites / NoticeA basic knowledge of mechanical analysis, metallurgy, thermodynamics is recommended.
Subject-specific CompetenciesConcepts and Theoriesassessed
Techniques and Technologiesassessed
Method-specific CompetenciesAnalytical Competenciesassessed
Personal CompetenciesCreative Thinkingassessed
Critical Thinkingassessed