Additive Manufacturing of Metals

John O. Milewski received his B.S. in Computer Engineering from the University of New Mexico and his M.S. in Electrical Engineering from Vanderbilt University. He began his technical career with five years' metal fabrication experience ranging from heavy industry production as an ASME code welder to light manufacturing and applied research. He spent 32 years at Los Alamos National Laboratory, in positions including Welding Technologist, Engineer, Team Leader, Experimental Component Fabrication Program Manager, and Group Leader for Manufacturing Capability. He is currently retired from the Lab, writing and consulting as APEX3D LLC regarding the new and exciting applications of AM technology. His technical expertise includes arc systems electron beam, laser welding, robotics, sensing and controls, and the joining of less common metals. His work experience also includes CAD/CAM/CNC model based engineering, process modeling, and simulation with validation methods to include residual stress measurement. In addition, he served 2 years in the late 1980s as Vice President of Synthemet Corporation, an entrepreneurial high tech start-up, with the goal of development and commercialization of 3D additive manufacturing of metals. He is author and co-author of numerous publications related to high energy beam processing and process modeling. His awards include an R&D 100 Award for Directed Light Fabrication, Fellow of the American Welding Society (AWS) and the AWS Robert L. Peaslee Award. He is inventor or co-inventor for a number of patents related to laser welding and additive manufacturing. He has had extensive formal collaborations with universities and sponsored students resulting in refereed publication and patenting. His professional society involvement included Chairman, Co-Chairman, and advisor of AWS committees related to High Energy Beam, Electron Beam, and Laser Beam Welding. In addition, he currently serves as an advisor to the AWS D20 Additive Manufacturing committee and provides peer review to technical publications of AWS and ASM International. His international technical contributions include US Delegate to the High Energy Beam Welding Commission of the IIW (International Institute of Welding), Invited Keynote Lecturer at the 58th Annual Assembly and International Conference of IIW, and the AWS R.D. Thomas Award winner for his international contributions and committee work on the harmonization of international standards.

Preface.- Acknowledgements.- List of Acronyms.- About the Author.- AM Road Map and Hitchhiker's Guide.- Chapter 1: Envision.- Chapter 2: Additive Manufacturing Metal, The Art of the Possible.- Chapter 3: On the Road to AM.- Chapter 4: Understanding Metal for Additive Manufacturing.- Chapter 5: Lasers, Electron Beams, Plasma Arcs.- Chapter 6: Computers, Solid Models, and Robots.- Chapter 7: Origins of 3D Metal Printing.- Chapter 8: Current System Configurations.- Chapter 9: Inspiration to 3D Design.- Chapter 10: Process Development.- Chapter 11: Building, Post Processing, and Inspecting.- Chapter 12: Trends in AM, Government, Industry, Research, Business.- Professional Society and Organization Links.- Glossary.- Bibliography.- AM Machine and Service Resource Links.- Appendix A: Safety in Configuring a 3D Metal Printing Shop.- Appendix B: Exercises in Metal Fusion.- Appendix C: OpenSCAD Programming Example.- Appendix D: 3D Printer Control Code Example.- Appendix E: Building an Arc-Based3D Shape Welding System.- Appendix F: Exercises in 3D Printing.- Appendix G: Score Chart of AM Skills.- Index.

"This book is dedicated to the special aspects valid for metals. ... The fresh writing style, sometimes more like a storyteller, makes reading these many facts quite easy and understandable. ... The interested reader can get a Jot of information about the topics one should deal with when working with additively manufactured metallic parts. lt gives a general roadmap where to start, what to learn and how it fits together." (Ralph Bäßler, Materials and Corrosion, Vol. 69 (12), December, 2018)

"This book ... covers subjects from fundamental technology to rocket nozzles, medical implants, and custom jewelry. The author shares a multitude of useful footnotes and pages of references at the end. Also included are practical appendices for users. ... I can heartedly recommend this book as a valuable reference and a good read for all interested in additive manufacturing." (David Belforte, Industrial Laser Solutions For Manufacturing, industrial-lasers.com, November, 2017)