Novel Processes for Advanced Manufacturing Summary of a Workshop (2013) / Chapter Skim
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This report is a record of the workshop event prepared by the workshop rapporteur, and any statements or views summarized in the report must be considered an opinion expressed by an individual participant at the workshop, not a consensus view. To organize its workshop on new and novel processes, the DMMI standing committee first organized a workshop planning group to identify workshop topics and agenda items, speakers, and invited guests.
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The recurring themes are as follows: • Additive manufacturing -- Qualification and certification -- New materials for additive manufacturing -- Access to manufacturing capabilities and resources -- Surface finish -- Unlawful uses of additive manufacturing • Electromagnetic field manipulation of materials -- Understanding the physical phenomena -- Research prioritization -- Permanence of the material changes made • Design of materials -- Materials databases -- Balancing experiment and modeling -- Model fidelity -- Materials qualification After briefly describing each recurring theme in this overview, the report goes on to summarize the workshop presentations and discussions. Appendix A contains the statement of task for the workshop, Appendix B lists the workshop participants, and Appendix C contains the workshop agenda.
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Richard Martukanitz, in response to a question following his presentation, pointed out that the welding industry might be a good qualification model for the additive manufacturing industry; a welded structure has a design code to provide guidelines, qualified materials, qualified operators, processes, and repeatability within a range of process parameters. New Materials for Additive Manufacturing Several participants questioned whether it would be either needed or desirable to develop new materials that would be optimized for the additive manufacturing process.
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Further, participants noted that designers are not very involved in the materials process; they are the ones who should be giving materials scientists the specifications for the new materials. Access to Manufacturing Capabilities and Resources The lack of access to processing equipment, raw materials, and appropriate modeling tools was consistently noted as a potential handicap for the additive manufacturing community.
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Other participants responded that research in the United States is more fundamental, and when it proves useful, the hope is that it will work its way into industry by market forces. During the open discussion period, participants noted that while there is a U.S.
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Electromagnetic Field Manipulation of Materials Themes Understanding the Physical Phenomena Overall, participants noted that processing with electromagnetic fields offers a wealth of opportunities. However, participants also noted the need to better un derstand the underlying phenomena that explain the physical changes caused by processing with electromagnetic fields.
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Gerhardt asked the group if, once a field is used to induce a particular change, the resulting material is in a metastable state. Would the treated material revert to its original state at different temperatures?
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Olson reiterated his belief that focused support is necessary to make significant progress. Other par ticipants asked what was needed to make significant progress in federal support for fundamental materials databases, as six NRC reports have discussed this need in the last 15 years.
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Another opportunity is to hand off the material plus the associated information system for adapting to future manufacturing/field experience; this would allow moving beyond discrete properties into a system based on microstructural state variables. Krishna Rajan also discussed materials databases in his presentation and said that his goal is to retrieve such data from their repositories and transmit them to laboratories where users can make new and unexpected discoveries.
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Others pointed out that the Materials Genome Initiative may result in new experimental protocols that will generate new data, rapidly expanding fundamental materials databases. Model Fidelity There was some discussion of the DFT as the basis for calculation of phase diagrams (CALPHAD)
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