MMET 281 FINAL EXAM QUESTIONS
AND ANSWERS ALL CORRECT
What are other sheet lamination processes? - Answer- Ultrasonic additive
manufacturing (for metals)
Sheet lamination of ceramics
What other term is used for ultrasonic additive manufacturing (UAM)? - Answer-
Ultrasonic Consolidation
What is ultrasonic additive manufacturing (UAM) a combination of? - Answer- Ultrasonic
welding and CNC machining
What are the main advantages of ultrasonic additive manufacturing (UAM)? - Answer- It
is able to bond thermally and mechanically dissimilar materials to each other in the solid
state
Able to embed sensitive/functional components between the foil layers and bond the
structure into a dense metal matrix
What was demonstrated about the mechanical properties of materials that underwent
ultrasonic additive manufacturing (UAM)? - Answer- Specimens loaded along the X and
Y directions had lower strength and ductility compared to the wrought alloy
Specimens loaded along the z-axis showed a drastic decrease in strength level and
microscopically brittle fracture
What are the components needed to perform aqueous suspension of sheet lamination
of ceramics? - Answer- Powder (~50% by weight) glass-ceramics
Dispersant: ammonium polyacrylate
Binder: polyvinyl alcohol
Plasticizer: polyethylene glycol
Antifoaming agent: modified fatty and alkoxylated compound
What carrier film is used for the sheet lamination of ceramics? - Answer- Silicone
covered and non-covered polyethylene terephthalate (PET)
How does the sheet lamination of ceramics occur? - Answer- A thin layer of aqueous
binder solution is applied with a painting brush on each tape before stacking the
subsequent tape
,True or False: Significant differences were observed on the green bending strength
depending on the tape orientation during sheet lamination of ceramics. - Answer- False
(No significant differences between orientations)
True or False: After sintering, the 0°/90° laminates presented lower values of sintered
bending strength than the 90°/90° laminates in sheet lamination of ceramics. - Answer-
False
(Higher values of bending strength)
What are processes used for powder bed fusion additive manufacturing? - Answer-
Selective laser melting/sintering (direct metal laser sintering)
Electron beam melting
Describe the selective laser sintering/melting process. - Answer- Laser draws first layer
Powder is spread over completed layer
Process is repeated for subsequent layers
Part is extracted from loose powder bed and post-processed
Name some examples of subtractive shaping. - Answer- Machining
Grinding
Drilling
Define subtractive shaping. - Answer- Shaping a material by subtracting excess material
from the original material
Name some examples of formative shaping. - Answer- Forging
Pressing
Bending
Casting
Define formative shaping. - Answer- Shaping a material by deforming or reflowing the
original material
Define additive shaping. - Answer- Shaping a material by the successive addition of
material
Define 3D Printing. - Answer- An additive manufacturing process based on a traditional
printing operation, such as binder jetting or material jetting
(Recent media exposure have led to this term becoming a general term for the entire
field of additive manufacturing)
What is the additive manufacturing sequence? - Answer- Begin with CAD model
Generate a .STL model
Support Generation
Slice the model (layer thickness)
Final build file (tool path)
, Print
Post processing
Describe the early applications of additive manufacturing from the 1980s to the 2000s. -
Answer- In the late 1980s to early 1990s, it was mostly used for rapid prototyping
In the 1990s and early 2000s, it became popular for producing tooling
In the late 1990s to mid 2000s, it has become all-round rapid manufacturing, capable of
producing end-use parts
Name some of the early examples of products made through additive manufacturing. -
Answer- Cranial and orthodontic implants
Tools for assembly such as jigs and fixtures
Molds and inserts
Turbomachinery applications such as turbine blades, bearings, etc.
Why is additive manufacturing considered "an enabling technology?" - Answer-
Whereas conventional manufacturing methods have a sharp increase in cost when part
complexity rises, additive manufacturing can maintain low costs regardless of the
design's complexity
List the main advantages of additive manufacturing. - Answer- Minimized material
consumption
Individual variation at very little additional cost
Reduced number of components
Reduced number of operations
Automatic process planning based on CAD model
Generic fabrication machine (does not require part-specific fixture/tooling)
Minimal human operation
How is supply chain impacted by additive manufacturing? - Answer- There are simpler
forms of raw materials
There are less manufacturing operations
Less assembly is required
Briefly give examples of the DHL perspective and its use of additive manufacturing. -
Answer- -Ability for consumers to get spare parts on demand (i.e. car repair shop
getting item printed instantly)
-Individualized direct parts manufacturing (prosthetics, etc.)
-End of runway services (printed, packed, ready to fly to destination)
-3D print shops (users upload what they want printed and pick up/USB drive on
location)
-3D printing on the go! (printing in delivery trucks as products are being shipped)
What are the challenges of additive manufacturing? - Answer- It is hard to standardize
everything because there are so many technologies, machine systems, etc.
AND ANSWERS ALL CORRECT
What are other sheet lamination processes? - Answer- Ultrasonic additive
manufacturing (for metals)
Sheet lamination of ceramics
What other term is used for ultrasonic additive manufacturing (UAM)? - Answer-
Ultrasonic Consolidation
What is ultrasonic additive manufacturing (UAM) a combination of? - Answer- Ultrasonic
welding and CNC machining
What are the main advantages of ultrasonic additive manufacturing (UAM)? - Answer- It
is able to bond thermally and mechanically dissimilar materials to each other in the solid
state
Able to embed sensitive/functional components between the foil layers and bond the
structure into a dense metal matrix
What was demonstrated about the mechanical properties of materials that underwent
ultrasonic additive manufacturing (UAM)? - Answer- Specimens loaded along the X and
Y directions had lower strength and ductility compared to the wrought alloy
Specimens loaded along the z-axis showed a drastic decrease in strength level and
microscopically brittle fracture
What are the components needed to perform aqueous suspension of sheet lamination
of ceramics? - Answer- Powder (~50% by weight) glass-ceramics
Dispersant: ammonium polyacrylate
Binder: polyvinyl alcohol
Plasticizer: polyethylene glycol
Antifoaming agent: modified fatty and alkoxylated compound
What carrier film is used for the sheet lamination of ceramics? - Answer- Silicone
covered and non-covered polyethylene terephthalate (PET)
How does the sheet lamination of ceramics occur? - Answer- A thin layer of aqueous
binder solution is applied with a painting brush on each tape before stacking the
subsequent tape
,True or False: Significant differences were observed on the green bending strength
depending on the tape orientation during sheet lamination of ceramics. - Answer- False
(No significant differences between orientations)
True or False: After sintering, the 0°/90° laminates presented lower values of sintered
bending strength than the 90°/90° laminates in sheet lamination of ceramics. - Answer-
False
(Higher values of bending strength)
What are processes used for powder bed fusion additive manufacturing? - Answer-
Selective laser melting/sintering (direct metal laser sintering)
Electron beam melting
Describe the selective laser sintering/melting process. - Answer- Laser draws first layer
Powder is spread over completed layer
Process is repeated for subsequent layers
Part is extracted from loose powder bed and post-processed
Name some examples of subtractive shaping. - Answer- Machining
Grinding
Drilling
Define subtractive shaping. - Answer- Shaping a material by subtracting excess material
from the original material
Name some examples of formative shaping. - Answer- Forging
Pressing
Bending
Casting
Define formative shaping. - Answer- Shaping a material by deforming or reflowing the
original material
Define additive shaping. - Answer- Shaping a material by the successive addition of
material
Define 3D Printing. - Answer- An additive manufacturing process based on a traditional
printing operation, such as binder jetting or material jetting
(Recent media exposure have led to this term becoming a general term for the entire
field of additive manufacturing)
What is the additive manufacturing sequence? - Answer- Begin with CAD model
Generate a .STL model
Support Generation
Slice the model (layer thickness)
Final build file (tool path)
Post processing
Describe the early applications of additive manufacturing from the 1980s to the 2000s. -
Answer- In the late 1980s to early 1990s, it was mostly used for rapid prototyping
In the 1990s and early 2000s, it became popular for producing tooling
In the late 1990s to mid 2000s, it has become all-round rapid manufacturing, capable of
producing end-use parts
Name some of the early examples of products made through additive manufacturing. -
Answer- Cranial and orthodontic implants
Tools for assembly such as jigs and fixtures
Molds and inserts
Turbomachinery applications such as turbine blades, bearings, etc.
Why is additive manufacturing considered "an enabling technology?" - Answer-
Whereas conventional manufacturing methods have a sharp increase in cost when part
complexity rises, additive manufacturing can maintain low costs regardless of the
design's complexity
List the main advantages of additive manufacturing. - Answer- Minimized material
consumption
Individual variation at very little additional cost
Reduced number of components
Reduced number of operations
Automatic process planning based on CAD model
Generic fabrication machine (does not require part-specific fixture/tooling)
Minimal human operation
How is supply chain impacted by additive manufacturing? - Answer- There are simpler
forms of raw materials
There are less manufacturing operations
Less assembly is required
Briefly give examples of the DHL perspective and its use of additive manufacturing. -
Answer- -Ability for consumers to get spare parts on demand (i.e. car repair shop
getting item printed instantly)
-Individualized direct parts manufacturing (prosthetics, etc.)
-End of runway services (printed, packed, ready to fly to destination)
-3D print shops (users upload what they want printed and pick up/USB drive on
location)
-3D printing on the go! (printing in delivery trucks as products are being shipped)
What are the challenges of additive manufacturing? - Answer- It is hard to standardize
everything because there are so many technologies, machine systems, etc.
