Dottorato in INGEGNERIA INDUSTRIALE E GESTIONALE

Titolo della tesi: Holistic approach to SLM technology in industry

This thesis presents a holistic approach through the various aspects related to SLM technology analyzed with different methodologies and objectives according to the various areas of investigation: • Paragraph 1.1 introduces additive manufacturing in general with focus on Selective Laser Melting powder bed technology with special reference to quality control of the SLM process, which has peculiar aspects related to both process and machines. • Chapter 2 introduces a digital manufacturing and circular economy, a peculiar aspect of quality control, that related to cybersecurity, as aspects of industrial systems security affect the entire production chain of AM components. • Chapter 3 emphasizes the inherent defects in manufacturing with SLM technology, using a machine learning approach on micrographs for defect classification. • Chapter 4 addresses surface finishing of parts manufactured with SLM technology, analyzing process parameters in finishing complex SLM parts by tumbling. • Chapter 5 addresses corrosion protection of SLM parts, using nanostructured silica sol-gel coatings to effectively protect various surfaces and materials. • Chapter 6 discusses the methodologies and results of two complex use cases of SLM technology: o Design and fabrication by SLM of a LIDAR reflector unit made of metal matrix composite material o Lightweighting satellite platform using Additive Manufacturing The research methodology employed to achieve the stated objectives is both theoretical and experimental in nature, the former drawing its developmental elements from the geometric study of parts and, through analytical calculations, leading to predictive models dependent on certain process parameters. Numerous experimental observations are employed as an exploratory cognitive and validation tool for the assumptions and results.