Additive Manufacturing (AM) of metals and alloys is a rapidly growing technology used in industries such as aerospace and biomedical where the properties of diverse material systems are critical for the application requirements. However, a limited number of pure metals and alloy systems are commercially available for AM to meet the demanding applications. The adaptation of established alloy systems and development of new alloys for AM has been slow due to challenges related to the AM processing space including complex & moving boundary conditions, solidification rates, compositional effects and inspection challenges which often differ in properties and processing conditions compared with conventional metals processing. The development of old and new alloys for AM still considers basic metallurgical principles such as melting, solidification & thermodynamics but often requires a unique strategy to match the properties of each desired alloy system to an appropriate AM technology to satisfy properties requirements for an application.
Dr. Rock was a process and R&D metallurgist in the industry for 18 years prior to joining the NC State Center for Additive Manufacturing and Logistics in 2016. He has experience in melting, solidification, powder metallurgy, thermomechanical processing and process modeling of a range of alloy systems. In his current role at NC State University, he is active in metals research using powder bed fusion and new alloy development for AM applications.