Supervisor: Industry Associate Professor Colin Hall (UniSA)  

Thesis Title: Additive manufacturing of structural elements via Laser Metal Deposition: Microstructure, Mechanical and Performance characterization 

Thesis synopsis: This study investigated the potential of multi-kilowatt off-axis Laser Metal Deposition (LMD) as a method of 3D printing robust metallic elements. By optimizing processing parameters, including laser power and scan beam settings, the study successfully produced 3D stainless steel structures suitable for industrial applications. These structures exhibited consistent mechanical properties, reduced residual stresses, and superior wear and corrosion resistance compared to conventionally fabricated counterparts. Post-processing heat treatment has further adjusted the mechanical properties of the LMD stainless steel material, making it suitable for repair or modification of industrial gear components. These findings confirm the viability of LMD for remanufacturing industrial parts and highlight the benefits of using high power off-axis LMD techniques in metal Additive Manufacturing.

Andre Hatem is an experienced Mechanical Engineer holding a doctorate in energy and advanced manufacturing. He specializes in materials science and surface engineering at the Future Industries Institute (University of South Australia). Currently, he is engaged in research and consultancy activities, collaborating with industry partners to bolster Australia’s manufacturing sector. In his recent project at the Australian Research Council (ARC) Industrial Transformation Training Centre in Surface Engineering for Advanced Materials (SEAM), Andre focused on applying additive manufacturing and surface modification through laser cladding. The research facilitated the production of structurally sound 3D-printed stainless-steel parts suitable for large-scale industrial use, promoting digitization and competitiveness in Australia’s manufacturing sector.

LinkedIn: https://www.linkedin.com/in/andrehatem/

Google Scholar: https://scholar.google.com/citations?user=E0pJ-84AAAAJ&hl=en&oi=sra

ResearchGate: https://www.researchgate.net/profile/Andre-Hatem

Scopus: https://www.scopus.com/authid/detail.uri?authorId=57194764819