Progress in Additive Manufacturing最新文献

{"title":"The correlation between yttria content and thermal-mechanical properties of GRX-810.","authors":"Yehong Chen, Huan Ding, Selami Emanet, Ehsan Bagheri, Michael M Talachian, Paul R Gradl, Shengmin Guo","doi":"10.1007/s40964-026-01834-1","DOIUrl":"https://doi.org/10.1007/s40964-026-01834-1","url":null,"abstract":"<p><p>In this paper, laser powder bed fusion (L-PBF) prepared GRX-810 samples with different yttria contents (from 0.3 to 1 wt%) were systematically examined. The mechanical properties and thermal properties were measured under as-built and Hot Isostatic Pressing (HIP) heat treated conditions. The results indicate that yttria content significantly affects the thermal properties of as-built L-PBF GRX-810. Higher yttria reduces thermal diffusivity and conductivity by up to 6% in of as-built samples. HIP restores thermal properties to low-yttria levels, indicating that L-PBF-induced microdefects and porosity, rather than composition, primarily cause the thermal degradation. Based on the mechanical testing results, yttria content up to 0.45% provides the most favorable strength-ductility balance in the present dataset. Higher yttria content (from 0.5 to 1%) leads to the reduction of the elongation from 27% to around 4% in the as-built samples. Following HIP, the yield strength decreases from ~ 785 MPa in the as-built state to ~ 685 MPa. The elongation increases from 4% in the as-built state to ~ 42%. HIP samples with yttria content less than 0.45% exhibit a high ductility at approximately 40% maximum elongation, while HIP samples with yttria content higher than 0.5% exhibit a moderate ductility of approximately 18% maximum elongation at failure. These thermal and mechanical performance studies provide valuable guidance for GRX-810 applications and provide a reference for further AM-ODS alloy optimization.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"11 9","pages":"8975-8992"},"PeriodicalIF":5.2,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13631040/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149115988","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Residual Stress Relaxation After Aging Heat Treatment in Laser Powder Bed Fusion CM247LC Superalloy Parts Quantified by Neutron-Diffraction-Validated Full-Field Eigenstrain Tomography.","authors":"Fatih Uzun, Hector Basoalto, Tung Lik Lee, Alexander M Korsunsky","doi":"10.1007/s40964-026-01845-y","DOIUrl":"https://doi.org/10.1007/s40964-026-01845-y","url":null,"abstract":"<p><p>Residual stresses generated during laser powder bed fusion (LPBF) can compromise dimensional stability and in-service performance of nickel-based superalloy components, while the quantitative assessment of stress relaxation during post-build heat treatment remains challenging in three dimensions. This paper quantifies the effects of an aging treatment at 900 °C for 8 h on the residual stress and eigenstrain distributions in an LPBF-fabricated CM247LC component. Eigenstrain tomography is used to reconstruct full-field three-dimensional distributions of eigenstrain, residual elastic strain, and residual stress tensors from synchrotron X-ray diffraction measurements of a single residual elastic strain component acquired from only two orthogonal projections. Reconstruction accuracy is independently validated using neutron diffraction strain measurements. The results show substantial residual-stress relaxation after aging, including a marked reduction in the magnitude of all residual stress tensor components across the volume. Statistical analysis of the raw diffraction data demonstrates a pronounced homogenisation of internal macroscopic strains, accompanied by a corresponding decrease in reconstructed eigenstrain components toward near-zero values. Leveraging a highly streamlined two-projection tomographic protocol, these findings quantitatively reveal the three-dimensional mechanics of macroscopic (Type I) stress relaxation without the need for exhaustive experimental beamtime. The results provide critical volumetric data linking thermal exposure to the elimination of distortion-driving eigenstrain gradients. Ultimately, this work represents a significant advancement in additive manufacturing process evaluation, establishing this efficient tomographic framework as a practical, non-destructive tool for optimizing post-build heat treatments and ensuring dimensional stability in complex additively manufactured superalloys.</p><p><strong>Graphical abstract: </strong></p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"11 9","pages":"9239-9254"},"PeriodicalIF":5.2,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13630886/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149115925","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Embedding of taggants in the vat photo-polymerisation additive manufacturing process for anti-counterfeiting measures.","authors":"Bochuan Liu, Paula F Wilson, Mark A Williams, Gregory J Gibbons","doi":"10.1007/s40964-026-01766-w","DOIUrl":"10.1007/s40964-026-01766-w","url":null,"abstract":"<p><p>The rapid expansion of the additive manufacturing (AM) industry has attracted significant global attention. However, the inherent nature of AM, specifically the direct translation of CAD data into physical components, makes the supply chain highly vulnerable to fraudulent and counterfeit activities. As scanning and reverse-engineering technologies advance, existing authentication methods have become increasingly susceptible to replication, and consequently, unreliable. This article investigates a novel authentication method for the vat photo-polymerisation process (VPP) by introducing a \"double-lock\" system. This system embeds both a physical hash (randomly distributed taggants acting as physically unclonable functions) and a digital hash (derived from X-ray computed tomography scans) into each component. Several digital hashing methods are proposed, including a combination of taggant spatial coordinates, colour codes, and quadrat counts, creating a signature that demonstrates substantial spatial complexity and resistance to physical replication. The chi-square (χ²) value of the distribution can also be utilised as a supplemental digital hash. The study indicates that the embedded physical taggants had no discernible effect on the thermal properties of the parts, and exerted minimal impact on mechanical strength. Specifically, reductions in ultimate tensile strength (UTS) at room temperature were limited to 3.1 ± 0.8 %, 3.9 ± 1.1 %, and 1.0 ± 1.0 % for layer thicknesses of 100, 50, and 25 μm, respectively. While the UTS for all samples decreased with increasing temperature, the presence of taggants did not affect the UTS beyond the standard margin of error across most testing conditions. The exceptions were samples tested at 23 °C and 180 °C, which exhibited UTS variations of 4.0 ± 1.3 % and 17.4 ± 3.8 %, respectively, between samples with and without taggants. Overall, the double-lock system developed in this study maintains a high level of security with minimal sacrifice to the components' thermal and mechanical properties.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"11 8","pages":"7715-7730"},"PeriodicalIF":5.2,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13593714/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149026253","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A finite element approach for modelling the fracture behaviour of unidirectional FFF-printed parts.","authors":"Simon Seibel, Josef Kiendl","doi":"10.1007/s40964-025-01021-8","DOIUrl":"10.1007/s40964-025-01021-8","url":null,"abstract":"<p><p>We present a finite element modelling approach for unidirectional Fused Filament Fabrication (FFF)-printed specimens under tensile loading. In this study, the focus is on the fracture behaviour, the goal is to simulate the mechanical behaviour of specimens with different strand orientations until final failure of the specimens. In particular, the aim is to represent experimentally observed failure modes for different print orientations and the typical dependence of the parts' strength on the print orientation. We investigate several modelling aspects like the choice of a suitable failure criterion, a suitable way to represent fracture in the finite element mesh or the necessary level of detail when modelling the characteristic edges of FFF-printed specimens. As a result, this work provides an approach to model FFF printed specimens in finite element simulations, which can represent the characteristic relation between mesostructural layout and macroscopic fracture behaviour.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 9","pages":"6981-6992"},"PeriodicalIF":5.4,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12287248/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144733703","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Rapid processing window development of Mo-Si-B alloy for electron beam powder bed fusion.","authors":"Yong Chen, Jonas Böhm, Benjamin Wahlmann, Manja Krüger, Carolin Körner","doi":"10.1007/s40964-025-01119-z","DOIUrl":"10.1007/s40964-025-01119-z","url":null,"abstract":"<p><p>The multiphase alloy Mo-9Si-8B (at.%) exhibits high oxidation, creep, and fracture resistance at high temperatures. With a melting point of about 2360 °C, it is a promising material for ultra-high temperature applications in turbine engines. However, Mo-9Si-8B (at.%) is difficult to process by traditional manufacturing methods due to its brittleness. Additive manufacturing offers a solution by enabling the production of complex near-net-shape bulk materials (e.g., turbine blades) in a single step. In this study, electron beam powder bed fusion (PBF-EB), which is characterized by extremely high local processing temperatures and associated high powder bed temperatures (i.e., above the brittle-to-ductile transition temperature of the material), was employed to process this Mo-Si-B alloy. The processing window was rapidly developed for the first time using novel strategies that combine high-throughput thermal modeling to predict the melt pool dimensions with in situ electron-optical imaging. High-density bulk Mo-9Si-8B (at.%) samples were successfully fabricated according to the established processing window, and the typical microstructure and phase composition of the as-built samples were analyzed. This novel approach significantly reduces the effort required to generate processing windows, making it highly viable for developing stable processing conditions for new materials in PBF-EB.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 10","pages":"8311-8320"},"PeriodicalIF":5.4,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12479609/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145207970","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"4D fabrication of shape-changing systems for tissue engineering: state of the art and perspectives.","authors":"Lorenzo Bonetti, Giulia Scalet","doi":"10.1007/s40964-024-00743-5","DOIUrl":"10.1007/s40964-024-00743-5","url":null,"abstract":"<p><p>In recent years, four-dimensional (4D) fabrication has emerged as a powerful technology capable of revolutionizing the field of tissue engineering. This technology represents a shift in perspective from traditional tissue engineering approaches, which generally rely on static-or passive-structures (e.g., scaffolds, constructs) unable of adapting to changes in biological environments. In contrast, 4D fabrication offers the unprecedented possibility of fabricating complex designs with spatiotemporal control over structure and function in response to environment stimuli, thus mimicking biological processes. In this review, an overview of the state of the art of 4D fabrication technology for the obtainment of cellularized constructs is presented, with a focus on shape-changing soft materials. First, the approaches to obtain cellularized constructs are introduced, also describing conventional and non-conventional fabrication techniques with their relative advantages and limitations. Next, the main families of shape-changing soft materials, namely shape-memory polymers and shape-memory hydrogels are discussed and their use in 4D fabrication in the field of tissue engineering is described. Ultimately, current challenges and proposed solutions are outlined, and valuable insights into future research directions of 4D fabrication for tissue engineering are provided to disclose its full potential.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 4","pages":"1913-1943"},"PeriodicalIF":5.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11926060/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143693766","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Application of strain tomography and contour method to residual stress analysis in additively manufactured CM247LC superalloy parts.","authors":"Fatih Uzun, Mohamed Fares Slim, Hector Basoalto, Konstantinos Liogas, Zifan Ivan Wang, Alexander M Korsunsky","doi":"10.1007/s40964-025-01116-2","DOIUrl":"10.1007/s40964-025-01116-2","url":null,"abstract":"<p><p>Residual stresses are recognized as a critical factor influencing the mechanical performance and structural integrity of additively manufactured parts, particularly in nickel-based superalloys. Although the contour method and strain tomography have been applied independently for residual stress evaluation of such materials, a direct comparison of their reconstructions in laser powder bed fusion fabricated specimens has not been reported. In this study, both techniques were employed on identically produced specimens of CM247LC superalloy, and a strong qualitative agreement in residual elastic strain distributions was observed. Using the contour method, tensile residual stresses up to +1300 MPa were identified near the specimen edges, while compressive stresses approaching - 600 MPa were found in the central regions. Strain tomography, based on synchrotron X-ray diffraction, was used to non-destructively reconstruct internal residual elastic strain fields, revealing consistent trends and capturing localized variations aligned with the contour method. Through this integrated approach, a complete validation of stress reconstruction was achieved, and new insights into the stress evolution of laser powder bed fusion manufactured CM247LC were provided. The findings demonstrate how the complementary strengths of these techniques can be leveraged for improved residual stress characterization in high-performance superalloy parts.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 10","pages":"8279-8291"},"PeriodicalIF":5.4,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12479594/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145207949","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multimodal defect analysis and application of virtual machining for solid-state manufactured aluminium structure.","authors":"Vladislav Yakubov, Halsey Ostergaard, Shishira Bhagavath, Chu Lun Alex Leung, James Hughes, Evren Yasa, Mani Khezri, Sandra K Löschke, Qing Li, Anna M Paradowska","doi":"10.1007/s40964-024-00904-6","DOIUrl":"10.1007/s40964-024-00904-6","url":null,"abstract":"<p><p>Additive friction stir deposition (AFSD) is an emerging solid-state non-fusion additive manufacturing (AM) technology, which produces parts with wrought-like material properties, high deposition rates, and low residual stresses. However, impact of process interruption on defect formation and mechanical properties has not yet been well addressed in the literature. In this study, Al6061 aluminium structure with two final heights and deposition interruption is successfully manufactured via AFSD and characterised. Defect analysis conducted via optical microscopy, electron microscopy, and X-ray computed tomography reveals > 99% relative density with minimal defects in centre of the parts. However, tunnel defects at interface between substrate and deposit as well as kissing bonds are present. Edge of deposit contains tunnel defects due to preference for greater material deposition on advancing side of rotating tool. Virtual machining highlights the ability to remove defects via post-processing, avoiding mechanical performance impact of stress concentrating pores. Electron backscatter diffraction revealed regions with localised shear bands that contain 1-5 µm equivalent circular diameter grains. Kissing bonds are exhibited in areas separated by large grain size difference. Meanwhile, Vickers hardness testing reveals hardness variation with deposit height. This work advances the understanding of complex microstructure development, material flow, and mechanical behaviour of AFSD Al6061 alloy.</p><p><strong>Supplementary information: </strong>The online version contains supplementary material available at 10.1007/s40964-024-00904-6.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 8","pages":"5281-5297"},"PeriodicalIF":4.4,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12267324/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144676044","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The effect of inter- and intra-layer delay time on TPU parts fabricated by laser powder bed fusion.","authors":"Samuel Connor, Ruth Goodridge, Ian Maskery","doi":"10.1007/s40964-024-00933-1","DOIUrl":"10.1007/s40964-024-00933-1","url":null,"abstract":"<p><p>In polymer laser powder bed fusion (PBF-LB-P) techniques, such as laser sintering, the time between scanning a given point in one layer and the same <i>x-y</i> point in the next layer is known as the 'inter-layer delay time'. Multiple parts are normally fabricated in a PBF-LB-P build for efficiency; however, this leads to variation in the inter-layer delay time for individual parts; in this study, we present a specific investigation using a commercially available thermoplastic polyurethane (TPU). Multiple part layouts were used and the resulting parts were subject to tensile testing and fracture surface analysis. The results demonstrate that an increase in inter-layer delay time can lead to a significant reduction in mechanical properties. Fabricating specimens in groups of 5 led to a 10% reduction in ultimate tensile strength, 30% reduction in extension at break, and 15 <math><mo>%</mo></math> reduction in Young's modulus compared to specimens fabricated individually. Fractography suggests this is due to decreased inter-layer bonding and an increase in defects. This has significant implications for the production of multiple parts in a build where consistent mechanical properties are critical. Based on our understanding of this detrimental effect, we put forward a novel build packing approach for PBF-LB-P, based on scanning area equivalence rather than the conventional time minimisation, to mitigate against it.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 8","pages":"5661-5674"},"PeriodicalIF":4.4,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12267361/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144676045","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Physics-aware feedforward dwell time adjustment for mitigating distortion in additively manufactured cantilevers.","authors":"Barış Kavas, Lars Witte, Efe C Balta, Michael R Tucker, Mohamadreza Afrasiabi, Markus Bambach","doi":"10.1007/s40964-025-01270-7","DOIUrl":"10.1007/s40964-025-01270-7","url":null,"abstract":"<p><p>Heterogeneous temperature distributions in additively manufactured metallic parts, particularly in laser powder bed fusion (PBF-LB/M), pose a major challenge to achieving high-quality components due to thermal distortions, microstructural inconsistencies, and shifts in the process window. This study introduces a physics-aware feedforward approach for regulating dwell time that effectively mitigates distortion in 3D-printed cantilevers by reducing thermal variations along the build direction. A fast, 1D finite volume method thermal simulation is employed to estimate the temperature profile throughout the build. The interlayer dwell time is dynamically adjusted based on a predefined thermal difference threshold between layers to minimize residual stresses and part deformation. Experimental validation on a cantilever beam geometry confirms that the adaptive dwell time strategy significantly reduces distortion compared to a constant dwell time approach. The proposed method enhances thermal stability while maintaining processing times, offering an efficient solution for distortion control in PBF-LB/M. These findings contribute to advancing process optimization strategies by integrating physics-based thermal modeling with feedforward control.</p>","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"10 12","pages":"10961-10977"},"PeriodicalIF":5.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12630239/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145589246","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}