Integrity of Joints & Metal Additive Manufacturing

This lecture covers the formation of residual stresses during welding, methods of distortion control, typical defects in weld joints, failure of weld joints, mechanical aspects of brazed joints, potential solutions to reduce thermal stresses, considerations for braze joint geometries, typical defects in braze or solder joints, effects of constrained plastic deformation, failure of braze and solder joints, mechanics of lap joints, and considerations for braze joint geometries. Additionally, it explores catastrophic failures of joints and introduces metal additive manufacturing, including laser powder bed fusion, electron beam melting, directed energy beam deposition, wire fed directed energy beam deposition, and 3D binder jetting. The advantages, disadvantages, applications, and key aspects of each metal additive manufacturing technique are discussed.

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Related concepts (77)

MSE-464: Assembly techniques

Introduction to the assembly of materials by homogeneous or heterogeneous joints (welding, bonding, mechanical assembly). Mechanical and environmental resistance of joints.

Congenital heart defect

A congenital heart defect (CHD), also known as a congenital heart anomaly, congenital cardiovascular malformation, and congenital heart disease, is a defect in the structure of the heart or great vessels that is present at birth. A congenital heart defect is classed as a cardiovascular disease. Signs and symptoms depend on the specific type of defect. Symptoms can vary from none to life-threatening. When present, symptoms are variable and may include rapid breathing, bluish skin (cyanosis), poor weight gain, and feeling tired.

Residual stress

In materials science and solid mechanics, residual stresses are stresses that remain in a solid material after the original cause of the stresses has been removed. Residual stress may be desirable or undesirable. For example, laser peening imparts deep beneficial compressive residual stresses into metal components such as turbine engine fan blades, and it is used in toughened glass to allow for large, thin, crack- and scratch-resistant glass displays on smartphones.

Ventricular septal defect

A ventricular septal defect (VSD) is a defect in the ventricular septum, the wall dividing the left and right ventricles of the heart. The extent of the opening may vary from pin size to complete absence of the ventricular septum, creating one common ventricle. The ventricular septum consists of an inferior muscular and superior membranous portion and is extensively innervated with conducting cardiomyocytes. The membranous portion, which is close to the atrioventricular node, is most commonly affected in adults and older children in the United States.

Atrioventricular septal defect

Atrioventricular septal defect (AVSD) or atrioventricular canal defect (AVCD), also known as "common atrioventricular canal" or "endocardial cushion defect" (ECD), is characterized by a deficiency of the atrioventricular septum of the heart that creates connections between all four of its chambers. It is a very specific combination of 3 defects: 1) Atrial Septal Defect (ASD), a hole in the wall between the right and left atria; 2) Ventricular Septal Defect (VSD), a hole in the wall between the right and left ventricles; and 3) Abnormalities of the mitral and/or tricuspid valves.

Acyanotic heart defect

An acyanotic heart defect, is a class of congenital heart defects. In these, blood is shunted (flows) from the left side of the heart to the right side of the heart, most often due to a structural defect (hole) in the interventricular septum. People often retain normal levels of oxyhemoglobin saturation in systemic circulation. This term is outdated, because a person with an acyanotic heart defect may show cyanosis (turn blue due to insufficient oxygen in the blood).