Additive Manufacturing Practice Flashcards

Comprehensive vocabulary flashcards covering additive manufacturing types, processes, safety regulations, powder testing, post-processing techniques, and inspection methods.

Additive Manufacturing

The process of joining materials to make parts from 3D model data, usually layer upon layer following ASTM F2792.

Subtractive Manufacturing

A manufacturing type characterized by milling or removing material to create a part.

Formative Manufacturing

Manufacturing processes involving injection moulding or casting to shape material.

Fabrication

A manufacturing type involving assembly or welding to join components together.

ASTM F2792

The standard that governs the Additive Manufacturing process.

Powder Bed Fusion (PBF)

The most widespread Additive Manufacturing process in which thermal energy selectively fuses regions of a powder bed.

Sheet Lamination

An Additive Manufacturing process in which sheets of material are bonded to form an object.

Vat Photopolymerisation

An Additive Manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerisation.

Material Extrusion

An Additive Manufacturing process in which material is selectively dispensed through a nozzle or orifice.

Material Jetting

An Additive Manufacturing process in which droplets of build material are selectively deposited using inkjet heads.

Binder Jetting

An Additive Manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials.

Directed Energy Deposition (DED)

An Additive Manufacturing process in which focused thermal energy is used to fuse materials by melting as they are deposited.

PBF Polymer Technologies

Technologies including Selective Laser Sintering (SLS) and High Speed Sintering (HSS).

PBF Metal Technologies

Technologies including Laser Powder Bed Fusion (L-PBF) and Electron Beam Powder Bed Fusion (EB-PBF).

Internal Defects (Metal PBF)

Common defects including Cracking, Key Hole Porosity, Gas Porosity, Lack of Fusion, Roughness, Distortion, Delamination, and Balling.

ATEX

Stands for Atmospheres Explosible; relates to health and safety standards for handling metal powders.

DSEAR 2002

The Dangerous Substances and Explosive Atmospheres Regulations 2002.

COSHH 2002

Control of Substances Hazardous to Health 2002.

STELs

Short Term Exposure Limits, typically measured over larger amounts for a duration of $15\,mins$.

TWAs

Time Weighted Average, typically measured for smaller amounts over an $8\,hour$ period.

Inert Gases in AM

Gases used in the process including Argon, Helium, and Nitrogen.

5S Methodology

A workplace organization method consisting of Sort, Set in order, Shine, Standardise, and Sustain.

Tap Density

A powder feedstock test comparing the density of poured powder against vibrated powder.

Hall Flow

A test measuring how long it takes a mass of powder to flow through a funnel.

ONH Testing

A test that combusts powder to measure the concentration of Oxygen, Nitrogen, and Hydrogen ($O$, $N$, $H$).

Morphology

Measuring the shape of powder to determine how spherical it is.

Particle Size Distribution (PSD)

Determining particle size using sieves, microscopes, or laser distraction.

Wire EDM

A baseplate removal technology that is cleaner and more accurate than a band saw, but more expensive and slower.

Hirtisation

An automated technology used for the removal of support structures in post-processing.

Hot Isostatic Pressing (HIP)

A heat treatment process in which a part is placed in a machine that applies a gas to uniformly compress it, increasing density and microstructure.

Aging

A thermal post-processing method used to form a second phase in metal to improve strength, toughness, or ductility.

Solutioning

A process to dissolve a second phase by heating metal to a high temperature and quenching it to improve strength and ductility.

X-ray Computed Tomography (XCT)

A non-destructive testing method that is the only way to measure all internal dimensions of AM products during inspection.