Keynote
QUALIFICATION OF ADDITIVELY MANUFACTURED METALLIC COMPONENTS WITH TAILORED MICROSTRUCTURES

Additive manufacturing of metals is considered as a disruptive technology to produce limited number of high value components with topologically optimized geometries and functionalities. Realization of the above potential for real-world applications is stifled by lack of standard qualification of computational design-tools; material feed stock characteristics, methods to probe thermo-mechanical processes under in-situ conditions, and microstructural homogeneity, as well as, anisotropic static- and dynamic-properties. This presentation will discuss the needed interdisciplinary science and technology ranging from robotics and automation, process control, multi-scale in-situ and ex-situ characterization methodologies, as well as, high-performance computational tools to address these challenges. Specific focus on understanding and controlling physical processes will be stressed, including powder/wire/tape, powder sintering, adsorption and dissolution of gases, microstructure evolution under extreme thermal gradients, and residual stress evolution under complex thermal gyrations. Case studies demonstrating the usefulness of these strategies will be presented. Emerging pathways to scale up metal additive manufacturing) in Fe-, Al- and Ti- alloys to large sizes (>1 m) and higher productivity (5 to 20 kg/h), while maintaining the mechanical performance and geometrical flexibility expected by the additive manufacturing, will be discussed