Markus Bambach: Catalogue data in Spring Semester 2021

Name Prof. Dr. Markus Bambach
FieldAdvanced Manufacturing
Neue Fertigungstechnologien
ETH Zürich, PFA L 55
Technoparkstrasse 1
8005 Zürich
Telephone+41 44 633 78 12
DepartmentMechanical and Process Engineering
RelationshipFull Professor

151-0740-00LMetal Additive Manufacturing – Fundamentals and Process Technology4 credits2V + 2UM. Bambach, L. Deillon, A. K. Eissing
AbstractThis lecture gives an introduction to the fundamentals and process technology of additive manufacturing processes with a focus on metals. The principles and technologies of laser powder bed fusion, directed energy deposition as well as sintering processes will be introduced.
ObjectiveThe students will learn
- the physics of the most important metal additive manufacturing processes including the interaction of energy sources (laser, electron beams, arc/plasma) and metals, the phenomena occurring during melting and solidification, the generation of stresses and defects
- the capabilities and limits of these processes
- the digital aspects of the process chains including preparation of geometries, slicing, hatching etc. including assessment of printability of a design
- working principles of machines, equipment and technology
- basics of sensors and process control
- post processing steps and interaction with AM material
- future trends in metal AM

1. Introduction / motivation

2. From fusion welding to AM (Basics of fusion welding, moving heat sources, melt pool dynamics, solidification of weld beads, part properties)

3. Wire-arc Additive Manufacturing (Process technology, Digital process chain: Slicing and process definition, Overlapping weld beads, Sensors and control, materials for WAAM)

4. Laser-based metal additive manufacturing I – Basics of laser technology (Laser principles, Gaussian beams and beam quality, Inteaction laser-material / laser-plasma)

5. Laser-based metal additive manufacturing II – Laser powder bed fusion (Process technology, digital process chain, parameters and properties, support structures, process control, applications & trends)

6. Laser-based metal additive manufacturing III – Laser-based directed Energy deposition (Process technology, digital process chain, Sensors & control, materials, applications & trends)

7. Electron beam based AM (Process technology, b. Interaction electron beams – matter, sensors & control, materials, applications & trends)

8. Binder Jetting / Sintering based AM (Process technology, Sinter theory, compensation of shrinkage, applications)

9. Post-processing (removal of supports, hot isostatic pressing, Machining / Finishing)

10. Materials for AM (Alloy systems for AM, Production and quality of powder, Computational materials design)

11. Future trends (Multi-material AM, Hybrid AM processes, ...)
Lecture notesThe lecture slides will be distributed.
LiteratureA list of references be given in the lecture.
Prerequisites / NoticeWerkstoffe und Fertigung or a similar course