3D Printing and Additive Manufacturing最新文献

{"title":"Iodine-Based Sensitization of Copper Alloys to Enable Self-Terminating Etching for Support Removal and Surface Improvements of Additively Manufactured Components.","authors":"Sanaz Yazdanparast, Subbarao Raikar, Meredith Heilig, Owen J Hildreth","doi":"10.1089/3dp.2021.0242","DOIUrl":"10.1089/3dp.2021.0242","url":null,"abstract":"<p><p>Advances in selective laser melting (SLM) of metals in the past two decades have made metals additive manufacturing more accessible for industrial adoption. Despite printing process improvements, post-processing of SLM components has not improved much, resulting in considerable costs, delay, and design limitations. Building upon recent advances in sensitization-based self-terminating etching processes, this work details a new set iodine-based sensitization and etching chemistries that simplify the post-processing of copper (Cu) alloy components fabricated using SLM. This work demonstrates that iodine can be used to \"sensitize\" the surface of copper alloy components to form soluble copper iodide salt that can be then dissolved in common solvents, such as acetonitrile. This process removes a predefined amount of material from all interior and exterior surfaces in a self-terminating manner, enabling facile removal of internal and external supports, removal of any trapped powder, and the smoothing of interior and exterior surfaces. We demonstrate this process on GRCop (Cu-chromium-niobium) alloys due to their widespread use by the rocket propulsion industry along with a demonstration in copper (110) for applications in heat exchangers and electromagnetic transmitters/receivers. Our results provide the first systematic study on the effect of iodization temperature and duration on the thickness of the iodide region in GRCop-84 components. Additionally, the surface roughness before and after each iodization-dissolution was also quantified for GRCop-84 and showed 70% reduction in R_a roughness from a high of 10 μm as-printed to a low of 3 μm after four iodization-dissolution cycles.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"619-630"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440683/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10052245","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":"Direct Ink Writing of Carbon-Doped Polymeric Composite Ink: A Review on Its Requirements and Applications.","authors":"Ratnesh Raj, Amit Rai Dixit","doi":"10.1089/3dp.2021.0209","DOIUrl":"10.1089/3dp.2021.0209","url":null,"abstract":"<p><p>Direct Ink Writing (DIW) opens new possibilities in three-dimensional (3D) printing of carbon-based polymeric ink. This is due to its ability in design flexibility, structural complexity, and environmental sustainability. This area requires exhaustive study because of its wide application in different manufacturing sectors. The present article is related to the variant emerging 3D printing techniques and DIW of carbonaceous materials. Carbon-based materials, extensively used for various applications in 3D printing, possess impressive chemical stability, strength, and flexible nanostructure. Fine printable inks consist predominantly of uniform solutions of carbon materials, such as graphene, graphene oxide (GO), carbon fibers (CFs), carbon nanotubes (CNTs), and solvents. It also contains compatible polymers and suitable additives. This review article elaborately discusses the fundamental requirements of DIW in structuring carbon-doped polymeric inks viz. ink formulation, required ink rheology, extrusion parameters, print fidelity prediction, layer bonding examination, substrate selection, and curing method to achieve fine functional composites. A detailed description of its application in the fields of electronics, medical, and mechanical segments have also been focused in this study.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"828-854"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440670/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10059367","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":"Selective Laser Sintering Parameter Optimization of Prosopis Chilensis/Polyethersulfone Composite Fabricated by AFS-360 SLS.","authors":"Aboubaker I B Idriss, Jian Li, Yanling Guo, Tong Shuhui, Yangwei Wang, Elkhawad A Elfaki, Gafer A Ahmed","doi":"10.1089/3dp.2021.0118","DOIUrl":"10.1089/3dp.2021.0118","url":null,"abstract":"<p><p>The current available selective laser sintering (SLS) materials are often high in cost and limited in variety; the mechanical properties of wood-composite SLS parts are low quality, which restricts the development of SLS technology. This article aims to optimize the SLS processing parameters to enhance the mechanical properties of the Prosopis chilensis powder (PCP)/polyethersulfone (PES) composite (PCPC) part fabricated via SLS. The PCP and PES powder were proposed as the feedstock of the PCPC powder bed for SLS. First, the thermal decomposition and glass transition temperatures (Tg) of PCP and PES powder were estimated to reduce the produced PCPC parts from warping and deformation during SLS. An orthogonal experimental methodology with five factors and four levels was used to optimize the SLS parameters for the PCPC SLS test. The scanning speed, preheating temperature, and laser power are selected as the main affecting factors on this study. The influence of these factors on dimension accuracies, bending and tensile strengths, and surface roughness quality of the produced PCPC parts was studied. The PCPC particle distribution and microstructure were inspected via scanning electron microscopy. Furthermore, the synthesis weighted scoring methods were utilized to determine the optimal SLS processing parameters of the produced PCPC parts. The combined results of tests showed that the optimal SLS parameters were as follows: the scanning speed is 1.8 m/s, preheating temperature is 80°C, and the laser power is 12 W. Thus, the quality of PCPC SLS parts was significantly enhanced when the optimal parameters were utilized in the SLS process. This article provided the main reference values of SLS parameters of the PCPC. To further enhance the surface roughness quality and mechanical strengths, the postprocessing infiltration with wax was introduced; after wax infiltration, the surface roughness and mechanical strengths were significantly improved.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"697-710"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440679/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10433422","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":"Optimization of Surface Roughness and Density of Overhang Structures Fabricated by Laser Powder Bed Fusion.","authors":"Hong-You Lin, Hong-Chuong Tran, Yu-Lung Lo, Trong-Nhan Le, Kuo-Chi Chiu, Yuan-Yao Hsu","doi":"10.1089/3dp.2021.0180","DOIUrl":"10.1089/3dp.2021.0180","url":null,"abstract":"<p><p>Laser powder bed fusion (LPBF) provides a rapid and versatile approach for producing parts with complex geometries. However, many parts with intricate geometries have overhang structures, which are not easily fabricated by using LPBF and are often downgraded by staircase effects, warpage, cracks, and dross formation. Thus, the present study proposes a combined numerical and experimental approach for determining the optimal settings of the laser power and scanning speed that minimize the surface roughness and maximize the density of Inconel 718 LPBF overhang structures. In the proposed approach, the heat transfer simulations are employed to determine the melt pool depth, the melt pool length, and the solid cooling rate within the feasible input space of laser power and scanning speed combinations. Notably, the simulations take account of both the difference in the material properties of the solid and powder materials, respectively, and the variation of the laser absorptivity in the depth direction of the powder layer. The simulation results are then used to train artificial neural networks for predicting the melt pool depth for 3600 combinations of the laser power and scanning speed within the input space. The resulting processing maps are screened in accordance with three quality criteria (namely the melt pool depth, the melt pool length, and the solid cooling rate) to determine the optimal processing region, which improves the surface roughness. The feasibility of the proposed approach is demonstrated by fabricating 10 × 10 and 20 × 20 mm² horizontal overhang structures using parameter settings chosen from the optimal processing map. It shows that the optimal processing conditions result in a low surface roughness and a maximum density of 99.78%.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"732-748"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440661/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10052246","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":"Fabrication of Temperature- and Humidity-Independent Silver Nanoparticle's Carbon Composite-Based Strain Sensor Through Additive Manufacturing Process.","authors":"Iqbal Nadeem, Sajid Memoon, Rahman Khalid, Amin Qausaria Tahseen, Muhammad Shakeel, Ahmad Salman, Amin Mohsin","doi":"10.1089/3dp.2021.0032","DOIUrl":"10.1089/3dp.2021.0032","url":null,"abstract":"<p><p>A highly sensitive low-cost strain sensor was fabricated in this research study based on microdispensing direct write (MDDW) technique. MDDW is an additive manufacturing approach that involves direct deposition of functional material to the substrate. The devices were printed directly onto a polymeric substrate by optimizing the fabrication parameters. A composite of silver and carbon was used as active sensor material where both materials in the composite have opposite resistance temperature coefficients. The ratio of materials in the composite was selected so that the effect of temperature on the resistance of overall composite was canceled out. This resulted in achieving temperature compensation or inherent independence of the strain sensor resistance on temperature without requiring any additional sensors and components. The sensor was further encapsulated by electrospray deposition, which is also an additive manufacturing approach, to eliminate the effect of humidity as well. Electrical and morphological characterizations were performed to investigate the output response of the sensors and their physical and structural properties. An analog signal conditioning circuit was developed for seamless interfacing of the sensor with any electronic system. The sensor had an excellent gauge factor of 45 and a strain sensitivity of 45 Ω/μɛ that is higher than most of the conventional strain sensors. The sensor's response showed excellent temperature and humidity compensation reducing the relative effect of temperature on the resistance by ∼99.5% and humidity by ∼99.8%.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"674-683"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440668/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10059366","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":"The Facile Three-Dimensional Printing of the Composite of Copper Nanosized Powder and Micron Powder with Enhanced Properties.","authors":"Youzhi Zhou, Huijun He, Jingjie Xu, Minghui Liang, Limin Wang, Ligen Wang, Xu Pan, Qiang Hu, Jingguo Zhang","doi":"10.1089/3dp.2021.0122","DOIUrl":"10.1089/3dp.2021.0122","url":null,"abstract":"<p><p>Three-dimensional (3D) printing of Cu items is a new way to build up the structured Cu materials, but 3D printing of Cu items is usually a challenge because of the high melting point, high thermal conductivity, and high light reflection rate of Cu material. In this study, the composite of Cu microspheres powder and Cu nanoparticles (micro/nano Cu powder) is used to realize the 3D printing of Cu items with the selective laser melting technology. The sintering temperature and the thermal conductivity of micro/nano Cu powder are evidently decreased due to Cu nanoparticles' addition in the micron Cu powder. The results reveal that the 3D printing of 50%/50% micro/nano Cu powder needs laser power range of 100-240 W, which is in contrast to 200-340 W for 3D printing of 100% Cu microspheres powder. Furthermore, the conductivity, mechanical strength, and density of 3D-printed Cu items are improved with the addition of Cu nanoparticles into the micron Cu powder. The increasement of 34% on electrical conductivity and 17% on tensile strength are reached by the addition of 50% Cu nanoparticles with the laser power of 240 W.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"631-639"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440659/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10433425","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":"Optimizing Process Parameters of Direct Ink Writing for Dimensional Accuracy of Printed Layers.","authors":"Yongqiang Tu, Javier A Arrieta-Escobar, Alaa Hassan, Uzair Khaleeq Uz Zaman, Ali Siadat, Gongliu Yang","doi":"10.1089/3dp.2021.0208","DOIUrl":"10.1089/3dp.2021.0208","url":null,"abstract":"<p><p>Direct ink writing (DIW) belongs to extrusion-based three-dimensional (3D) printing techniques. The success of DIW process depends on well-printable ink and optimized process parameters. After ink preparation, DIW process parameters considerably affect the parts' dimensional accuracy, and process parameters optimization for dimensional accuracy of printed layers is necessary for quality control of parts in DIW. In this study, DIW process parameters were identified and divided into two categories as the parameters for printing a line and the parameter from lines to a layer. Then, a two-step method was proposed for optimizing process parameters. Step 1 was to optimize process parameters for printing a line. In Step 1, continuity and uniformity of extruded filaments and printed rectangular objects were observed in screening experiments to determine printability windows for each process parameter. Then, interaction effect tests were conducted and degree of freedom for experiments was calculated followed by orthogonal array selection for the Taguchi design. Next, main experiments of line printing based on the Taguchi method were conducted. Signal-to-noise ratio calculations and analysis of variance were performed to find the optimal combination and evaluate the significance, respectively. Step 2 was to optimize the parameter from lines to a layer. In Step 2, the average width of the printed line under optimal condition was first measured. Then, single-factor tests of rectangular object printing were conducted to find the optimal parameter from lines to a layer. After these two steps, confirmation results were conducted to verify the reliability of the proposed method and the method robustness on other shapes and other materials; parameter adaptability in 3D parts printing from printed layers' analyses for the proposed method; and parameter adaptability in constructs fabricated as 100% infill or with porosities.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"816-827"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440672/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10059368","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":"Influence of Auxiliary Process on Microstructure and Mechanical Properties of Wire Arc Additive Manufacturing of Thick Wall Depositions.","authors":"Wei Wu, Wei Xu, Jiaxiang Xue, Ping Yao","doi":"10.1089/3dp.2021.0142","DOIUrl":"10.1089/3dp.2021.0142","url":null,"abstract":"<p><p>Serious heat accumulation causes poor properties and anisotropy of products in wire and arc additive manufacturing, which restricts the further efficiency in application, especially in double-wire and double-arc depositions. Consequently, this study applied an auxiliary gas process in double-arc additive manufacturing and then compared two 50-layer depositions in morphology, microstructure, and properties to research the influence of the auxiliary process on the forming and performance. The results showed that the auxiliary gas process could improve the deposition morphology, and the efficiency was increased by 24%; moreover, the surface roughness was reduced. As the cooling and stirring effect of the auxiliary gas process, the deposition with the auxiliary gas process mainly presented short axis columnar crystal and less defects on cross-section, which was finally increasing the hardness, tensile strength, and impact toughness and bending force and decreasing the tensile strength anisotropy obviously.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"776-784"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440653/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10052244","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":"Multipart Build Effects on Temperature and Residual Stress by Laser Beam Powder Bed Fusion Additive Manufacturing.","authors":"Wenyou Zhang, Mingming Tong, Noel M Harrison","doi":"10.1089/3dp.2021.0143","DOIUrl":"10.1089/3dp.2021.0143","url":null,"abstract":"<p><p>Laser beam powder bed fusion (PBF-LB) is a leading technique among metal additive manufacturing (AM), and it has a wide range of applications in aerospace and medical devices. Most of the existing PBF-LB process modeling is mainly based on the fabrication of a single part on a large build plate, which is not reflective of the practical multipart PBF-LB manufacturing. The effects of batch size on the thermal and mechanical behavior of additively manufactured parts have not been investigated. In this work, the multipart PBF-LB thermomechanical modeling framework was proposed for the first time. The effects of sample numbers (1, 2, and 4) on temperature and residual stress (RS) of part-scale components were computationally investigated. It is found that RS within the parts decreased with increasing number of components per build. Parts located at the central areas of the build plate had larger RS than at the border. These findings can be beneficial for informing AM designers and operators of the optimum printing setup to minimize RS of metal parts in PBF-LB.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"749-761"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440682/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10059364","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":"Selective Laser Sintering of Polydimethylsiloxane Composites.","authors":"Jinzhi Wang, Shaojie Sun, Xue Li, Guoxia Fei, Zhanhua Wang, Hesheng Xia","doi":"10.1089/3dp.2021.0105","DOIUrl":"10.1089/3dp.2021.0105","url":null,"abstract":"<p><p>Conductive silicone elastomer carbon nanotubes (CNTs) composites possess potential applications in a variety of fields, including electronic skin, wearable electronics, and human motion detection. Based on a novel self-made covalent adaptable network (CANs) of polydimethylsiloxane (PDMS) containg dynamic steric-hindrance pyrazole urea bond (PDMS-CANs), CNTs wrapped PDMS-CANs (CNTs@PDMS-CANs) powders were prepared by a liquid phase adsorption and deposition, and were successfully used for selective laser sintering (SLS) three-dimensional printing. SLS-printed PDMS-CANs/CNTs nanocomposites possess high electrical conductivity and low percolation threshold as SLS is one kind of quasi-static processing, which leads to the formation of conductive segregated CNTs network by using the PDMS powders with special CNTs wrapped structure. The introduction of dynamic pyrazole urea bond endows the materials self-healing capability under electrothermal and photothermal stimulus. In addition, due to the resistance difference of the damaged and intact areas, crack diagnosing can be realized by infrared thermograph under electricity. In an application demonstration in strain sensor, the composite exhibits a regular cyclic electrical resistance change at cyclic compression and bending, indicating a relative high reliability.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 4","pages":"684-696"},"PeriodicalIF":2.3,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440645/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10061431","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}