MODULE – 1 : Processes

Module Duration:

12 hours of recorded videos and 4 live online interactive sessions.

Faculty Profile:

Prof. Murugaiyan Amirthalingam

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. D. Janaki Ram

Department of Materials Science and Metallurgical Engineering, IIT Hyderabad

Topics covered:

This module is designed to provide a basis about the background, nomenclature, advantages of additive manufacturing as compared to conventional subtractive and formative processes. This module will cover in detail about the operating principles of the 7 types of additive manufacturing processes, underlying principles on the feedstock consolidation strategies, defects formation and control and engineering limitations of these processes.

Learning Outcomes:

1. To understand the fundamentals of AM processes.
2. To critically evaluate the physical principles of an AM process.
3. To obtain an ability to choose correct AM process for a given material, design and service condition

Applications of the Module:

Upon completion of this module, the learner should be able to choose a correct AM process for a given material and in-service processing condition.

MODULE – 2 : Design

Module Duration :

12 hours of recorded video and 4 live online interactive sessions.

Faculty:

Prof. G. Saravana Kumar

Department of Engineering Design, IIT Madras

Module Description:

Design for additive manufacturing (DfAM) bring challenge to traditional computer aided design (CAD) and analysis since most of them can only deal with homogeneous materials as of now, and also in terms of understanding the constraints posed by the AM process
while employing generative design to obtain functional designs with complex geometry.
This module shall provide the participants outline on existing solid modeling framework, preprocessing CAD data for additive manufacturing, generative design concepts and analysis of distortions, stress evaluation in AM components.

Learning Outcomes:

• Part modeling in CAD, Solid modeling, B-rep data structure.
• Data file formats, STL, AMF, STL pathologies and its mitigation.
• Support structure generation, Slicing and Tool path generation.
• Process simulation of LPBF process to predict distortion and stress evaluation.
• Generative design with AM constraints

Applications of the Module:

• Explore design freedom offered by AM in all areas of industrial application.
• Explore light weighting by design and additive manufacturing.
• Explore AM for prototype molds and parts for vendor qualification.
• Explore one off design / very low volume production of metallic parts with enhanced properties.
• Explore tool and die design with conformal cooling channels.
• Explore part consolidation to reduce assembly and improve precision.
• Explore customised patient specific biomedical implants.

MODULE 3 : Materials

Module Duration:

12 hours of recorded video and 4 live online interactive sessions.

Faculty Profile:

Prof. Ravi Sankar Kottada

Department of Metallurgical and Materials Engineering, IIT Madras

Module Description:

This module is designed to provide a basic understanding of fundamentals of physical metallurgy, including role of alloying elements on solidification and phase transformation behavioural, classification of ferrous and non-ferrous alloys, alloy development strategy for additive manufacturing and introduction to polymer and ceramic feedstock materials used for additive manufacturing.

Learning Outcomes:

To provide a comprehensive understanding of the micro structural evolution of an alloy component during additive manufacturing

To provide a basis of feedstock thermal-mechanical behaviour during additive manufacturing of polymer and ceramic materials

Applications of the Module :

Any engineering or biomedical application where additive manufacturing is used to produce end-use components.

MODULE 4: Post Processing

Module Duration:

12 hours of recorded videos and 4 live online interactive sessions.

Faculty Profile:

Prof. Ratna Kumar Annabattula,

Department of Mechanical Engineering, IIT Madras

Prof. Lakshman Neelakantan

Department of Metallurgical and Materials Engineering, IIT Madras

Topics covered:

Additively manufactured materials and components are generally rough, which requires post processing using various conventional and novel processes. This module will provide an outline on general post processing strategies and specifically on the electrochemical processing of metals and alloy systems, to achieve smooth, bright and stress free surfaces.

Learning Outcomes

•  Differentiate various surface processing techniques.
• Identify the difference between conventional electrochemical and plasma electrolytic -processing.
• Identify the components and build electrochemical cells for electrochemical processing.
• Differentiate various mechanisms involved in electropolishing.
• Apply electrochemical principles to identify optimal electrochemical processing conditions.
• Evaluate the surface finish and corrosion properties of the modified surface.

Applications of the Module

The participants will be able to use the concept of surface finishing for 

• Additive manufactured components, 
• Tool for surface engineering, 
• Strategy for corrosion prevention
• Apply in biomedical 

MODULE 5: Testing and standardization 

Module Duration:

12 hours of recorded videos and 4 live online interactive sessions.

Faculty:

Prof. Murugaiyan Amirthalingam,

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. Ravi Sankar Kottada

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. D. Janaki Ram

Department of Materials Science and Metallurgical Engineering, IIT Hyderabad

Module Description:

This module is designed to provide a comprehensive overview of the various mechanical testing methods used to qualify an additive manufactured component for engineering and biomedical applications. The qualification strategies adapted for Aerospace, Defence, Automotive and Biomedical components made by additive manufacturing are also elicited. 

Learning Outcomes: 

To obtain a comprehensive understanding of various testing and qualification strategies used for additive manufactured components for Aerospace, Defense, Automotive and Biomedical applications

Applications of the Module: 

Aerospace, Defense, Automotive and Biomedical industries who are aspiring to commercialise additively manufactured components

MODULE 6: Application and Case Studies

Module Duration : 

12 hours of recorded videos and 4 live online interactive sessions.

Faculty Profile: 

Prof. Murugaiyan Amirthalingam,

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. Saravana Kumar

Department of Engineering Design, IIT Madras

Prof. G. D. Janaki Ram

Department of Materials Science and Metallurgical Engineering, IIT Hyderabad

Topics covered:

The module shall showcase industrially relevant, contemporary applications of AM in automotive, Aerospace, Defense and Medical industry.

Learning Outcomes:

Success stories where additive manufacturing led to disruptive technological breakthroughs in automotive, aerospace and biomedical applications. 

Identify candidate applications which can benefit from AM intervention.

Benchmark application case studies in AM, to aspire exploring AM to its fullest potential.

Applications of the Module :

Application development for the use of additive manufacturing in Automotive, Aerospace and Biomedical  applications.