Overview

Within the hyped industry 4.0 concept and implementation, additive Manufacturing (AM) is a visionary approach to flexible-cell manufacturing for components for their difficult-to- make shapes, including intricate passageways. Like welding, AM relies on a layer-by-layer deposition of fused-metal feed-stock. AM and welding involve an energy source (e.g., Laser, Electron beam, Electric Arc, or Plasma), one or several feedstocks (e.g., powder, wire, sheets, and ribbon), and spatial displacement, as provided by a CNC stage or a multi-axis robot. From materials and metallurgical standpoints, welding and additive manufacturing, bring into play: (1) a multitude of complex and interacting physical phenomena such as heat and mass transfer, continuum mechanics, phase changes (including melting, solidification, allotropic transformations and diffusion phenomena such as epitaxial growth, grain growth and crystal orientation), (2) a number of process variables associated to the moving heat source (e.g., its power, power distribution, relative speed, size, all affecting energy density), its paths (e.g., linear, circular, oscillatory, etc), and added metal feed rate via powder, wire, or ribbon feed, all controlling deposit dimensions, aspect-ratio, and deposit properties, including internal defects. The effect of successive thermal cycles, as induced by the heat source moving away from an already deposited material, further adds to the overall challenge of developing industry-compliant components. The theory and practice of advanced welding and additive manufacturing will be the core of this course. Examples from industrial projects will be detailed.

The course is oriented to make researchers and engineers take a multidisciplinary approach to manufacturing with focus on processes, materials with particular emphasis on the gap between theory and practice. The roadmap to implement transfer from lab to industry will be highlighted by taking some case studies from manufacturing and service provider sectors. The end aim is to give some insights on technology survey and how pitfalls that stem from an ever increasing research papers can be avoided through rational approach based on risk analysis inherent to processes and materials. With this in view, welding and additive manufacturing will be discussed both from material science and industrial perspectives.

OUTLINE OF THE COURSE

At the conclusion of this course, the participants are expected to:

• Understand the material basics that govern manufacturing potentials
• Identify the various options available to do additive manufacturing process from available welding sources.
• Understand through some examples, the contours of industry innovation projects

Eligibility

• Student at all levels (B. E. / B. Tech / M. Sc (Engg) / M. Tech / Ph. D) and Faculty from other academic institutions and technical institutions.
• Executives, engineers and researchers from manufacturing, service and government organizations including R & D laboratories.

Accommodation

The participants may be provided with hostel accommodation, depending on availability, on payment basis. Further details about accommodation will be communicated with the shortlisted individual participants via email.

Venue for classes

Classes will be held in the MSB 360, Mechanical Sciences Block (MSB), Department of Mechanical Engineering, IIT Madras.