3D Printing and Additive Manufacturing最新文献

{"title":"Intelligent Optimization Method of Piezoelectric Ejection System Design Based on Finite Element Simulation and Neural Network.","authors":"Xin Li, Yongsheng Zhao","doi":"10.1089/3dp.2022.0286","DOIUrl":"10.1089/3dp.2022.0286","url":null,"abstract":"<p><p>This study describes an intelligent method for modeling and optimization of piezoelectric ejection system design for additive manufacturing. It is a combination of neural network (NN) techniques and finite element simulation (FES) that allows designing each parameter of a piezoelectric ejection system faster and more reliably than conventional methods. Using experimental and literature data, a FE model of the droplet ejection process was developed and validated to predict two indexes of droplet ejection behavior (DEB): jetting velocity and droplet diameter. Two artificial neural network (ANN) models based on feed-forward back propagation were developed and optimized by genetic algorithm (GA). A database was established by FE calculations, and the models were trained to establish the relationship between the piezoelectric ejection system design input parameters and each DEB indicator. The results show that both NN models can independently predict the droplet jetting velocity and droplet diameter values from the training and testing data with high accuracy to determine the optimal piezoelectric ejection system design. Finally, the accuracy of the prediction results of the FES and ANN-GA models was verified experimentally. It was found that the errors between the predicted and experimental results were 4.48% and 3.18% for the jetting velocity and droplet diameter, respectively, verifying that the optimization method is reliable and robust for piezoelectric ejection system design optimization.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442184/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46403879","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Scalable Hierarchically Structured Materials from a Multiscale Particle System Enabled by Microscaffolds.","authors":"Jiawei Ren, Shu Jian Chen, Yiping Qiao, Wei Wang","doi":"10.1089/3dp.2022.0313","DOIUrl":"10.1089/3dp.2022.0313","url":null,"abstract":"<p><p>Structural hierarchy is the key to manufacturing multiscale particle-based composite materials. A novel manufacturing method was developed to generate scalable hierarchical structures in concrete. The new method used 3D-printed microscaffolds to interact with the multiscale particle packing in concrete, resulting in a structured lightweight composite material. The size of internal members can vary by more than two orders of magnitude, to adapt to different applications. Based on compression tests and microstructural investigation by optical microscope and quantitative nanomechanical mapping, we found that the new material is 63.93% more efficient in energy absorption capacity compared with traditional lightweight concrete. Our experimental trials also showed that introducing structural hierarchy can reduce the consumption of cementitious material in the system by up to 14% and significantly reduce the use of scaffolds. The method could be applied to a board spectrum of multiscale particle-based materials, such as dental cement and bone implant materials, to improve material performance and efficiency in medical and construction applications.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442189/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48927232","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of Pulse Interval on Forming Process in Wire Arc Metal Additive Manufacturing Using Pulsed Arc Plasma.","authors":"Xiaoming Duan, Jin Zhuang, Xiaodong Yang","doi":"10.1089/3dp.2022.0339","DOIUrl":"10.1089/3dp.2022.0339","url":null,"abstract":"<p><p>To overcome the material processing challenges induced by high levels of heat input in wire arc additive manufacturing (WAAM), an innovative WAAM method using pulsed arc plasma (PAP-WAAM), was developed by the authors in the previous study. In this method, the PAP generated by the pulsed voltage was used as the heat source. The pulse interval can be defined as the time interval between adjacent pulse voltages, which determines the ignition time and frequency of the arc plasma, thus influencing the forming process. However, the effect of pulse interval on the forming process has not yet been revealed. Here, the effects of pulse interval on forming process during the PAP-WAAM of Ti6Al4V, including thermal behavior, arc plasma characteristics, and metal transfer process, were investigated by experiments and simulation. The results exhibited that the interpass temperature and maximum peak temperature decrease with increasing pulse interval at the same arc plasma power, indicating an alleviation of heat accumulation along the building direction. As the pulse interval increased, the ignition mode of the arc plasma changed from ignition between the tungsten electrode and the previously deposited layer to ignition between the tungsten electrode and filler wire, which increased the proportion of discharge energy allocated to the filler wire, thus reducing the overall heat input required for material deposition. When the pulse interval was 300 and 400 ms, only the uninterrupted bridging transfer mode was observed during the deposition process. The uninterrupted bridging transfer is considered to contribute to forming a smooth and consistent layer appearance. In addition, longer pulse intervals resulted in less surface oxidation, narrower wall thickness, and better macrostructure, attributed to reduced heat input and improved effective heat dissipation. This research reveals the effect of pulse interval on forming process during PAP-WAAM, which benefits the fabrication of desirable metal parts.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442374/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42069961","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Synergistic Strengthening Mechanisms of Dual-Phase (TiN+AlN) Reinforced Aluminum Matrix Composites Prepared by Laser Powder Bed Fusion.","authors":"Ruiqi Wang, Lixia Xi, Lili Feng, Baran Sarac, Konda Gokuldoss Prashanth, Jürgen Eckert, Dongdong Gu","doi":"10.1089/3dp.2023.0004","DOIUrl":"10.1089/3dp.2023.0004","url":null,"abstract":"<p><p>Dual-phase reinforcing approach provides a novel and efficient strategy for the fabrication of advanced aluminum matrix composites (AMCs). The devisable and desirable performance could be achieved by tuning dual-phase reinforcing system. However, it is still challenging to design a dual-phase reinforcing system with synergistic strengthening effect, especially for the laser powder bed fusion (LPBF) characterized by nonequilibrium metallurgical process. In this work, we designed and fabricated dual-phase (TiN+AlN) particles (20 wt.%) reinforced pure Al by LPBF. The TiN and AlN can form a metastable ternary Ti_1-xAl_xN solid solution in the whole range of composition, which is a promising reinforcing phase for AMCs. We observed novel microstructure in laser-fabricated composites under the action of dual-phase (TiN+AlN) ceramic particles and laser melting process. A gradient layer is formed on the surface of TiN particles. This interfacial structure can act as an anchor for ceramic particles in the Al matrix, which is beneficial to achieve a strong interface bonding and good load transfer. Besides this gradient layer, uniformly dispersed Ti_1-xAl_xN nanoparticles were observed to precipitate, which can effectively hinder dislocation movement and refine grains. Furthermore, the pure Al and TiN/Al, AlN/Al composites were fabricated to compare and reveal the contributions of dual-phase (TiN+AlN) reinforcements. The tensile strength of the (TiN+AlN)/Al composite reach ∼254 MPa, improved by ∼75% and ∼81% compared with those of the TiN/Al and the AlN/Al composites, respectively. This novel microstructure about gradient layer and precipitated nanoparticles contributes to the high strengthening efficiency of the (TiN+AlN)/Al composite.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442376/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42793521","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D Printing Process Research and Performance Tests on Sodium Alginate-Xanthan Gum-Hydroxyapatite Hybridcartilage Regenerative Scaffolds.","authors":"Honghao Chen, Youping Gong, Junlin He, Zizhou Qiao, Bo Hong, Wenxin Li, Chuanping Zhou, Rougang Zhou, Huifeng Shao","doi":"10.1089/3dp.2022.0272","DOIUrl":"10.1089/3dp.2022.0272","url":null,"abstract":"<p><p>Cartilage injury is a common occurrence in the modern world. Compared with traditional treatment methods, bio-3D printing technology features better utility in the field of cartilage repair and regeneration, but still faces great challenges. For example, there is currently no means to generate blood vessels inside the scaffolds, and there remains the question of how to improve the biocompatibility of the generated scaffolds, all of which limit the application of bio-3D printing technology in this area. The main objective of this article was to prepare sodium alginate-xanthan gum-hydroxyapatite (SA-XG-HA) porous cartilage scaffolds that can naturally degrade in the human body and be used to promote cartilage damage repair by 3D printing technology. First, the viscosities of SA and XG were analyzed, and their optimal ratio was determined. Second, a mathematical model of the hybrid slurry was established based on the power-law fluid model, in which the printing pressure, needle movement speed, and fiber spacing were established as important parameters affecting the printing performance of the composite. Third, by performing a finite element simulation of the printing process and combining it with the actual printing process, suitable printing parameters were determined (air pressure of 1 bar, moving speed of 9 mm/s, line spacing of 1.6 mm, and adjacent layers of 0-90°). Fourth, composite scaffolds were prepared and tested for their compressive properties, degradation properties, cytotoxicity, and biocompatibility. The results showed that the novel composite scaffolds prepared in this study possessed good mechanical and biological properties. Young's modulus of the composite scaffolds reached 130 KPa and was able to maintain a low degradation rate in simulated body fluid solution for >1 month. The activity of the C5.18 chondrocytes in the scaffold leach solution exceeded 120%. The cells were also able to proliferate densely on the scaffold surface.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442156/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44627554","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Nondestructive Testing of 3D Printed Fiber-Reinforced Polymeric Composites: An Experimental Critical Comparison.","authors":"Henrique V Silva, Nuno P Catapirra, Marta S Carvalho, Telmo G Santos, Miguel A Machado","doi":"10.1089/3dp.2022.0291","DOIUrl":"10.1089/3dp.2022.0291","url":null,"abstract":"<p><p>Polymer matrix composite (PMC) materials produced by additive manufacturing are a promising solution with several applications in industry. The presence of defects due to fabrication could undermine the performance of the component structure. PMC performance has been extensively studied using destructive tests, but reliable nondestructive testing (NDT) techniques are essential. In this study, PMC with unidirectional fibers were 3D printed with an adapted conventional fused filament fabrication printer. The matrix material was polylactic acid, and three different reinforcement fibers were used: Kevlar^®, carbon, and glass fibers. The samples were 3D printed with artificial defects, to simulate delamination's 0.5 mm thick. Four NDT techniques were explored, benchmarking the inspection of PMC envisaging an automated noncontact imaging inspection for easier result interpretation. Active pulse thermography, air-coupled ultrasounds, continuous wave terahertz, and digital X-ray were the techniques chosen, and a critical comparison is presented, evaluating the performance of each technique in the detection of defects. NDT technique diversity, complementarity, and redundancy improve inspection reliability, as there is not a single inspection technique that can cover all material defects or characteristics.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442158/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44903915","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Recycling of Acrylonitrile Butadiene Styrene from Electronic Waste for the Production of Eco-Friendly Filaments for 3D Printing.","authors":"Rafaela de Oliveira, Milena Heloísa Araújo Silva, Pankaj Agrawal, Gustavo de Figueiredo Brito, Carlos Thiago Candido Cunha, Tomás Jeferson Alves de Mélo","doi":"10.1089/3dp.2022.0211","DOIUrl":"10.1089/3dp.2022.0211","url":null,"abstract":"<p><p>In this work, acrylonitrile butadiene styrene (ABS) copolymer from electronic waste (e-waste) was used to produce filaments for application in 3D printing. Recycled ABS (rABS) from e-waste was blended with virgin ABS (vABS) in different concentrations. By differential scanning calorimetry, it was observed that the values of the glass transition temperatures for vABS/rABS blends ranged between the values of vABS and rABS. Torque rheometry analysis showed that the processability of vABS was not compromised with the addition of rABS. Rheological measurements showed that the viscosity of vABS was higher than that of rABS at low frequencies and indicated that vABS and rABS are immiscible. Impact strength (IS) tests of the 3D printed samples showed an increase in the IS with an increase in the rABS content up to 50 wt%. Blending vABS with rABS from e-waste is promising and proved to be feasible, making it possible to recycle a considerable amount of plastics from e-waste and, thus, contributing to the preservation of the environment.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442160/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47223918","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A Comparable Study on Laser Welding Behaviors of Selective Laser Melted 304 Stainless Steel, Inconel 718 Superalloy and Ti-6Al-4V Alloy.","authors":"Jingjing Yang, Yun Wang, Tongbo Wei, Zemin Wang","doi":"10.1089/3dp.2022.0302","DOIUrl":"10.1089/3dp.2022.0302","url":null,"abstract":"<p><p>The hybrid selective laser melting (SLM) technology by laser welding can capture the superiorities of both processes to produce large-scale, high-quality, high-resolution, and complicated-shaped metallic parts. In this work, the SLMed 304 stainless steel, Inconel 718 superalloy, and Ti-6Al-4V alloy sheets were joined by laser welding under various building directions. And then, the microstructure, microhardness, tensile properties, and corrosion resistance of the laser-welded SLMed 304 stainless steel, Inconel 718 superalloy, and Ti-6Al-4V alloy were compared to explore the effect of SLMed microstructural anisotropy and crystal structure. The results showed that phase constitutions were the same between the SLMed and laser-welded joints for the three alloys. But the grain size and dendrite arm spacings in the joints were coarser than those in the SLMed samples. The SLMed microstructural anisotropy resulted in differences in the thermal gradient, grain size, dendrite arm spacing, and tensile properties in the joints under various welding types. Compared with the SLMed counterparts, the laser-welded 304 stainless steel and Inconel 718 joints showed lower microhardness and tensile properties but better corrosion resistance. In contrast, the laser-welded Ti-6Al-4V joints possess a higher microhardness, tensile properties, and corrosion resistance. Therefore, it is feasible to join SLMed parts to manufacture large-scale parts by laser welding.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442360/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49651531","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterizing the Effect of Filament Moisture on Tensile Properties and Morphology of Fused Deposition Modeled Polylactic Acid/Polybutylene Succinate Parts.","authors":"Raihan Quader, Evan Dramko, David Grewell, Jed Randall, Lokesh Karthik Narayanan","doi":"10.1089/3dp.2022.0222","DOIUrl":"10.1089/3dp.2022.0222","url":null,"abstract":"<p><p>Moisture absorption into hygroscopic/hydrophilic materials used in fused deposition modeling (FDM) can diminish desired mechanical properties. Sensitivity to moisture is dependent on material properties and environmental factors and needs characterization. In this article, moisture sensitivity of four grades of polylactic acid (PLA) filaments and four different ratios of PLA/polybutylene succinate (PBS) blended filaments were characterized through FDM printed American society for testing and materials (ASTM-D638) test samples after conditioning the filaments at different relative humidity levels. The tensile testing and scanning electron microscopy (SEM) of the samples' fracture surfaces revealed that PLA 4043D was the most moisture-sensitive among the chosen grades of PLA filaments. Through filament tension test and melt flow index (MFI) testing it was observed that moisture had a significant detrimental effect (20% reduction in tensile strength and 50% increase in MFI) on PLA 4043D filaments. Samples from moisture-conditioned PLA/PBS 75/25 blended filaments displayed a significant reduction (10%) in tensile strength. Moreover, the MFI of 75/25 filaments was increased with subsequent increases in moisture level. Investigation of tensile properties of ASTM samples made from four grades of PLA filaments exposed to room temperature and humidity conditions for 3 months showed an even more significant decrease in strength (ranging from 24% to 36%).</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442157/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"60697395","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Finite Difference Modeling and Experimental Investigation of Cyclic Thermal Heating in the Fused Filament Fabrication Process.","authors":"Luca Luberto, Volker Böß, Kristin M de Payrebrune","doi":"10.1089/3dp.2022.0282","DOIUrl":"10.1089/3dp.2022.0282","url":null,"abstract":"<p><p>Fused filament fabrication (FFF) is one of the most popular additive manufacturing (AM) processes due to its simplicity and low initial and maintenance costs. However, good printing results such as high dimensionality, avoidance of cooling cracks, and warping are directly related to heat control in the process and require precise settings of printing parameters. Therefore, accurate prediction and understanding of temperature peaks and cooling behavior in a local area and in a larger part are important in FFF, as in other AM processes. To analyze the temperature peaks and cooling behavior, we simulated the heat distribution, including convective heat transfer, in a cuboid sample. The model uses the finite difference method (FDM), which is advantageous for parallel computing on graphics processing units and makes temperature simulations also of larger parts feasible. After the verification process, we validate the simulation with an <i>in situ</i> measurement during FFF printing. We conclude the process simulation with a parameter study in which we vary the function of the heat transfer coefficient and part size. For smaller parts, we found that the print bed temperature is crucial for the temperature gradient. The approximations of the heat transfer process play only a secondary role. For larger components, the opposite effect can be observed. The description of heat transfer plays a decisive role for the heat distribution in the component, whereas the bed temperature determines the temperature distribution only in the immediate vicinity of the bed. The developed FFF process model thus provides a good basis for further investigations and can be easily extended by additional effects or transferred to other AM processes.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442153/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42309122","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}