Additive manufacturing最新文献

{"title":"Formation mechanisms and control strategies of geometric errors induced by edge bumping during laser powder bed fusion","authors":"Haolin Liu,&nbsp;Huiliang Wei,&nbsp;Qingyuan Yin,&nbsp;Jiashun Yue,&nbsp;Tingting Liu,&nbsp;Wenhe Liao","doi":"10.1016/j.addma.2025.104970","DOIUrl":"10.1016/j.addma.2025.104970","url":null,"abstract":"<div><div>Edge bumping, a typical abnormal surface feature during the laser powder bed fusion (LPBF) process, can significantly affect the geometric accuracy of the final product. In a representative case, edge bumping induced severe geometric errors in lattice structures, including both strut necking and out-of-tolerance deviations. Despite the critical influences, the formation mechanisms and control strategies of edge bumping remain unclear. This study comprehensively investigated the characteristics of edge bumping for both standard octagonal specimens and general samples (such as topological features and overhang structures) with various geometries and dimensions, utilizing in-situ monitoring, ex-situ characterization and numerical modelling approaches. The results showed that edge bumping manifested as edge protrusions on the part top surface, exacerbated by higher laser power, slower scanning speeds, and increased laser rotations at edges. The formation mechanisms of edge bumping were revealed for the first time in this work, which comprised spatter knockdown by the laser, extra powder entrainment into the molten pool, and molten material flow and solidification at the rear of the molten pool. To mitigate the geometric errors, control strategies of edge bumping considering LPBF energy densities and inter-track cooling intervals were developed. Efficient suppressions were achieved, with edge bumping height reduced to 0.04 mm for the standard octagonal specimens, and the dimensional accuracy of lattice structures increased significantly from 68.0 % to over 96.9 %. The novel findings provide valuable insights for understanding the complexity of the transient processes, and improving the LPBF quality of engineering structures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104970"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155961","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Room-temperature laser crystallization of oxygen vacancy-engineered zirconia for additive manufacturing","authors":"Jaime A. Benavides-Guerrero ,&nbsp;Luis F. Gerlein ,&nbsp;Astrid C. Angel-Ospina ,&nbsp;Paul Fourmont ,&nbsp;Abhiroop Bhattacharya ,&nbsp;Abbas Zirakjou ,&nbsp;Fabrice Vaussenat ,&nbsp;Caroline A. Ross ,&nbsp;Sylvain G. Cloutier","doi":"10.1016/j.addma.2025.104969","DOIUrl":"10.1016/j.addma.2025.104969","url":null,"abstract":"<div><div>We demonstrate how strategically engineered oxygen vacancies enable room-temperature laser crystallization of zirconia (ZrO₂) in ambient air. Our sol-gel chelation synthesis creates amorphous ZrO₂ nanoparticles with a high concentration of oxygen vacancies that fundamentally alter the material's energy landscape. These defects create sub-bandgap states that facilitate visible light absorption and dramatically reduce the energy barrier for crystallization. Under low-energy laser irradiation (405–532 nm), oxygen vacancies mediate a rapid phase transformation mechanism where atmospheric oxygen interacts with vacancy sites, triggering ionic rearrangement and crystallization without conventional high-temperature processing. For comparison purposes, this study also explores the thermal crystallization of black zirconia in an oxidative atmosphere, a process typically performed under vacuum or inert conditions. Through comprehensive characterization (FTIR, EPR, XPS, XRD, Raman), we establish that vacancy-mediated crystallization produces monoclinic ZrO₂ with preserved defect structures, yielding a distinctive black phase with 25.6 % oxygen vacancy concentration, significantly higher than thermally processed counterparts (9.2 %). This vacancy-enabled crystallization circumvents the need for extreme temperatures (&gt;1170°C) typically required for ZrO₂ processing, making it compatible with additive manufacturing. Using a modified 3D printer with a 405 nm laser, we demonstrate patterned crystallization of complex architectures, opening new possibilities for fabricating advanced ZrO₂-based devices for photocatalysis, fuel cells, and energy applications. This work provides fundamental insights into defect-mediated phase transformations and establishes a new paradigm for room-temperature ceramic processing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104969"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107675","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Stress-induced martensitic transformation mechanism in the crack behaviour of compressed additively manufactured Ti-5553 alloy: A variant selection approach","authors":"Carlos Samuel Alves da Silva ,&nbsp;Hugo Magalhães de Azevedo ,&nbsp;Matheus Valentim ,&nbsp;Gilberto Vicente Prandi ,&nbsp;João Felipe Queiroz Rodrigues ,&nbsp;Kaio Niitsu Campo ,&nbsp;Hamilton Ferreira Gomes de Abreu ,&nbsp;Rubens Caram","doi":"10.1016/j.addma.2025.104954","DOIUrl":"10.1016/j.addma.2025.104954","url":null,"abstract":"<div><div>This investigation aims to explore the unresolved crack formation mechanism in compression, based on the influence of the crystallographic nature in the Ti-5553 alloy, which is susceptible to Laser Powder Bed Fusion (PBF-LB) defects as well as stress-induced martensitic transformations (SIMT). The cylindrical samples were obtained and subsequently subjected to a compressive load to investigate the BCC/orthorhombic transformation in the failure behaviour. Here, the variant selection approach based on the Schmid factor (SF) criteria was employed to elucidate the martensitic phase transformations and their role in the crack path. It was demonstrated that the accumulation of plastic strain at discontinuities that result from the processing route initiate the martensitic transformation. Additionally, a stacking fault in the orthorhombic phase will assist the α’’/α’ (Orthorhombic/Hexagonal closed packed - HCP) transformation. The analysis showed that the SIMT mechanism follows the <span><math><msub><mrow><mo>{</mo><mn>101</mn><mo>}</mo></mrow><mrow><mi>β</mi></mrow></msub></math></span>//<span><math><msub><mrow><mo>{</mo><mn>001</mn><mo>}</mo></mrow><mrow><mi>α</mi><mo>′</mo><mo>′</mo></mrow></msub></math></span>//<span><math><msub><mrow><mo>{</mo><mn>0001</mn><mo>}</mo></mrow><mrow><mi>α</mi><mo>′</mo></mrow></msub></math></span> and <span><math><msub><mrow><mo>&lt;</mo><mn>111</mn><mo>&gt;</mo></mrow><mrow><mi>β</mi></mrow></msub></math></span>//<span><math><msub><mrow><mo>&lt;</mo><mn>110</mn><mo>&gt;</mo></mrow><mrow><mi>α</mi><mo>′</mo><mo>′</mo></mrow></msub></math></span>//<span><math><msub><mrow><mo>&lt;</mo><mn>11</mn><mover><mrow><mn>2</mn></mrow><mo>̅</mo></mover><mn>0</mn><mo>&gt;</mo></mrow><mrow><mi>α</mi><mo>′</mo></mrow></msub></math></span> orientation relationship and that the failure on the transverse direction follows a direction close to <span><math><msub><mrow><mo>&lt;</mo><mn>212</mn><mo>&gt;</mo></mrow><mrow><mi>β</mi></mrow></msub></math></span> // <span><math><msub><mrow><mo>&lt;</mo><mn>211</mn><mo>&gt;</mo></mrow><mrow><mi>α</mi><mo>′</mo><mo>′</mo></mrow></msub></math></span>//TD.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104954"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155962","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Ceramic insert enabled build plate thermal isolation for enhanced microstructure and residual stress mitigation in laser-based powder bed fusion of metals","authors":"Soung Yeoul Ahn ,&nbsp;Sang Guk Jeong ,&nbsp;Gitaek Lee ,&nbsp;Hobyung Chae ,&nbsp;Wanchuck Woo ,&nbsp;Eun Seong Kim ,&nbsp;Muhammad Raihan Hashmi ,&nbsp;Levin Sebastian Cahyaputra ,&nbsp;Renhao Wu ,&nbsp;Sun Ig Hong ,&nbsp;Soon-Jik Hong ,&nbsp;Hyoung Seop Kim","doi":"10.1016/j.addma.2025.104967","DOIUrl":"10.1016/j.addma.2025.104967","url":null,"abstract":"<div><div>Mitigating thermally induced residual stresses remains a critical challenge in components made by laser-based powder bed fusion of metals (PBF-LB/M). This study proposes a novel passive thermal isolation strategy utilizing a ceramic base plate to control thermal gradients during fabrication, which in turn reduces residual stress and simultaneously inducing distinct microstructural differences in PBF-LB/M processed stainless steel 316 L alloys. A combined approach using finite element method (FEM) simulations, neutron diffraction, microstructure analysis, and mechanical testing, was employed to systematically evaluate the thermal, structural, and mechanical responses. The ceramic base plate elevates the temperatures of the part during fabrication while reducing thermal gradients, and effect that corresponded with neutron diffraction measurements showing reduced tensile and compressive residual stresses across the build. Importantly, distinct microstructure differences were identified, characterized by grain coarsening, reduced local misorientation, a lower twin fractions, and diminished defects. Collectively, these features promoted greater microstructural uniformity and effectively suppressed thermal induced plasticity. The enhanced microstructural homogeneity across different locations also contributed to more uniform mechanical properties throughout the specimen. Unlike conventional strategies requiring additional energy input or system modifications, the proposed approach offers a scalable, energy-efficient, and easily implementable solution that does not interfere with existing machine control systems. It can be integrated with other stress-relief methods such as preheating, and/or other active systems to provide synergistic effects. Moreover, the reduced thermal deformation enhances dimensional accuracy and manufacturing reliability, without compromising mechanical performance, addressing critical requirements in aerospace, biomedical, and energy applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104967"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145119971","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Revealing the interplay between element mixing, intermetallics, and microcracks in multi-material laser additive manufacturing","authors":"Jingyu Xu ,&nbsp;Dongxu Cheng ,&nbsp;Xuxiao Li ,&nbsp;Heng Gu ,&nbsp;Wei Li ,&nbsp;Chenxi Lu ,&nbsp;Xiao Yang ,&nbsp;Lin Li ,&nbsp;Chao Wei","doi":"10.1016/j.addma.2025.104971","DOIUrl":"10.1016/j.addma.2025.104971","url":null,"abstract":"<div><div>Additive manufacturing (AM) of multiple metallic materials suffers from microcracks at the dissimilar material interface due to brittle intermetallic compounds (IMCs). While avoiding IMCs through specialized composition design is a conventional approach, the interdependence between molten pool material mixing, IMC characteristics, and microcracks are not well understood. In this work, we compared typical process conditions for laser powder bed fusion of aluminum alloy substrate and Inconel particles. We revealed that the insufficient dissimilar material mixing under the lower energy density condition can exacerbate element clustering, IMC concentration, and cracking. High-speed synchrotron X-ray imaging shows that Ni-rich clusters can abruptly plunge into the molten pool to cause localization of IMCs and microcracks. In the high energy density case, the keyhole oscillation can disperse the Ni-rich clusters and suppress cracks but lead to keyhole porosities. Microstructural characterization and multiphysics simulations support the X-ray imaging observations. We propose that control of molten pool flow to enhance mixing while preventing porosities is the key to crack-free AM of metallurgically incompatible dual alloys.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104971"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155960","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure characteristics of LPBF&HIP fabricated graded composite transition joint between ferritic steel and austenitic stainless steel","authors":"Yuying Wen ,&nbsp;Shanshan Hu ,&nbsp;Youyuan Zhang ,&nbsp;Ting Sun ,&nbsp;Luke Wadle ,&nbsp;Lanh Trinh ,&nbsp;Xingru Tan ,&nbsp;Susheng Tan ,&nbsp;Wei Zhang ,&nbsp;Haiyang Qian ,&nbsp;Bai Cui ,&nbsp;Yanli Wang ,&nbsp;Zhili Feng ,&nbsp;Xingbo Liu","doi":"10.1016/j.addma.2025.104961","DOIUrl":"10.1016/j.addma.2025.104961","url":null,"abstract":"<div><div>Graded composite transition joints (GCTJs) offer a promising alternative to conventional dissimilar metal welds (DMWs) by enabling smooth compositional and microstructural transitions. However, GCTJs fabricated solely through additive manufacturing (AM) face challenges such as heat accumulation, complex parameter control, and elemental segregation. In this study, we propose a novel approach that relies on AM to design a spatially graded structure in one alloy and then employs hot isostatic pressing (HIP) as a diffusion bonding method to join it with a second alloy. This method combines the flexibility of AM with the powder net-shaping advantage of HIP. Specifically, a series of closely packed austenitic stainless steel 304 conical structures were printed using laser powder bed fusion (LPBF) and then combined with ferritic steel P91 powder via HIP. By using electron backscatter diffraction (EBSD), electron probe microanalysis (EPMA), and transmission electron microscopy (TEM) techniques, the microstructure characteristics of the GCTJ of 304&amp;P91, especially the interdiffusion zone (IDZ), have been systematically investigated. The microstructure at the interface transitions from austenite-ferrite (A+F) to austenite-martensite-ferrite (A+M+F), and finally to martensite-ferrite (M+F) due to diffusion. Additionally, the diffusion width between 304 and P91 increases with the volume fraction of P91. This unique design also ensures a gradual transition in both hardness and thermal expansion coefficient from 304 to P91, thereby enabling a smooth gradient in functional properties. Overall, this study proposes a novel approach for fabricating GCTJs and contributes to advancing design concepts in the field of dissimilar metal joining.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104961"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145027572","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microscale additively manufactured 3D metal-ceramic nanocomposites with improved strength and thermal stability","authors":"Nadia Rohbeck ,&nbsp;Maria Watroba ,&nbsp;Christopher Gunderson ,&nbsp;Alexander Groetsch ,&nbsp;Manish Jain ,&nbsp;Janne-Petteri Niemelä ,&nbsp;Aurelio Borzi ,&nbsp;Ivo Utke ,&nbsp;Xavier Maeder ,&nbsp;Antonia Neels ,&nbsp;Johann Michler ,&nbsp;Jakob Schwiedrzik","doi":"10.1016/j.addma.2025.104957","DOIUrl":"10.1016/j.addma.2025.104957","url":null,"abstract":"<div><div>Nanocomposites hold great promise for enhancing material properties beyond those of conventional materials. Here, we present a novel method integrating template-assisted electrodeposition of nanocrystalline gold (nc Au) and atomic layer deposition (ALD) of alumina to fabricate three-dimensional nanostructured metal matrix composites (MMCs) with enhanced mechanical strength, reduced density, and improved thermal stability. Microcompression experiments demonstrate that Au-alumina MMC achieves a yield strength of 838 MPa, outperforming pure nc Au (792 MPa) and Au hollow microlattices (250 MPa). The strength advantage increases at elevated temperatures: the MMC exhibits a 5 % improvement in yield strength at room temperature while retaining only 80 % of the weight, rising to a 42 % improvement at 100 °C. To enable design and optimization of such nanocomposites, we performed a systematic thermomechanical study on pure nc Au. Compression tests across a range of temperatures (23 °C to 100 °C) and strain rates (0.0004 s⁻¹ to 216 s⁻¹) revealed a transition in deformation behavior around 1 s⁻¹ . In the quasistatic regime, strain rate sensitivity increased from 0.025 to 0.063 with temperature, while remaining low (0.013) and temperature-independent at higher strain rates. The increase in activation volume (10 b³ to 24 b³) and activation energy (49–83 kJ/mol) with strain rate suggests a change in the rate-controlling mechanism. These results provide essential input for finite element modeling (FEM) of MMC, enabling identification of architectural parameters that can be tuned to optimize strength before fabrication. This work demonstrates the potential of microscale additive manufacturing and hybrid fabrication strategies to produce nanocomposites with tunable thermomechanical properties for demanding structural applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104957"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047677","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Solvent- and binder-free additive manufacturing of polymer-derived ceramics: Rheological tuning and structural performance","authors":"Laxmi Sai Viswanadha ,&nbsp;Jeremy Watts ,&nbsp;Mohammad Naraghi","doi":"10.1016/j.addma.2025.104962","DOIUrl":"10.1016/j.addma.2025.104962","url":null,"abstract":"<div><div>Silicon carbide (SiC) ceramic matrix composites are widely used in aerospace applications due to their high strength, heat resistance, and corrosion resistance. However, traditional machining methods make it challenging to fabricate complex shapes. This study presents a solvent-free and binder-free direct ink writing (DIW) method for producing SiC/SiOC composites using polycarbosilane SMP-10, a preceramic polymer that acts as both the ceramic precursor and the liquid phase, thereby eliminating the need for volatile solvents and sacrificial binders. By adjusting the SiC content, printable ink formulations were developed, and their flow properties were analyzed. The influence of geometric factors, such as inter-wall spacing and base layer width, on structural stability was also examined. Wider base layers provided greater support, increasing the maximum printable height before failure, while structures with larger inter-wall spacing were more prone to collapse due to reduced lateral support. These findings highlight the importance of structural design in achieving stable and precise prints. The printed lattice structures exhibited compressive strength of 5.62 ± 1.75 MPa – 9.62 ± 1.10 MPa and density of 2.05 – 2.34 g/cm³, alongside exceptional thermal insulation and stability. This approach offers an easy and efficient method for fabricating complex ceramic structures with excellent mechanical and thermal performance, making it highly relevant for advanced aerospace and high-temperature applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104962"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A skeletal line-based printing path planning method for continuous fiber reinforced composite structures","authors":"Yamin Li ,&nbsp;Xiaobao Zhi ,&nbsp;Xin Yan ,&nbsp;Jiancheng Hao ,&nbsp;Shangqin Yuan ,&nbsp;Tong Gao ,&nbsp;Jihong Zhu ,&nbsp;Weihong Zhang","doi":"10.1016/j.addma.2025.104960","DOIUrl":"10.1016/j.addma.2025.104960","url":null,"abstract":"<div><div>Continuous fiber-reinforced composite (CFRC) 3D printing integrates the benefits of additive manufacturing and advanced composites, enabling the fabrication of complex geometries with enhanced mechanical performance. However, CFRC printing faces significant path planning challenges. Conventional path generation methods frequently introduce printing defects such as voids and fiber misalignment, which substantially compromise the structural integrity of printed components. This paper proposes a novel skeletal line-based continuous path planning methodology that optimizes both manufacturability and mechanical strength, which is especially suitable for beam-like structures. The approach begins with extraction of the part's medial axis skeleton, followed by strategic decomposition into simplified sub-curves through skeleton node disconnection. Each sub-curve undergoes offset-based sub-path planning, after which the generated sub-paths are intelligently reconnected to form continuous loops. The process culminates in global path continuity through systematic loop interconnection. Experimental validation was performed to evaluate the efficacy of the proposed methodology. Comparative analysis demonstrates that our approach significantly reduces printing-induced defects while improving mechanical performance relative to conventional path planning techniques, including the Connected Fermat Spiral (CFS) method.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104960"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145027573","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Machine learning-assisted multiscale optimization for continuous fiber reinforced composites","authors":"Shengya Li ,&nbsp;Huanlong Chen ,&nbsp;Zheyi Zhang ,&nbsp;Wenyang Liu ,&nbsp;Yiqi Mao ,&nbsp;Shujuan Hou ,&nbsp;Xu Han","doi":"10.1016/j.addma.2025.104968","DOIUrl":"10.1016/j.addma.2025.104968","url":null,"abstract":"<div><div>Continuous fiber reinforced composites (CFRCs) are key material systems in fields such as automotive and aerospace. Recently, additive manufacturing technology has provided a new methods for the controlled preparation of CFRCs. However, the material anisotropy and nonlinear properties caused by the non-uniform spatial distribution of fiber orientation and microstructural features pose significant challenges in multiscale modeling and concurrent optimization. In this paper, a neural network-assisted multiscale concurrent optimization (NNMCO) algorithm for the continuous fiber orientation and macrostructure topology of anisotropic composites is proposed. In order to do this, firstly, a mapping relationship between the micro fiber orientation and effective material properties of representative volume element (RVE) is constructed using fully-connected neural network (FCNN). Then, at the macroscale, the density-based Solid Isotropic Material with Penalization (SIMP) method is used to optimize the macrostructure topology by penalizing the stiffness of intermediate-density elements. Meanwhile, at the microscale, the fiber orientation is optimized during the iteration process according to the principal strain alignment (PSA) method to maximize local stiffness. The Gaussian filtering smoothing technique was used to smooth the local fiber distribution and avoid getting trapped in local optima, and the streamline algorithms were employed to generate smooth, continuous fiber paths. Finally, the efficiency and applicability of the developed method are further confirmed via 2D/3D numerical examples, 3D printing preparation, load-displacement experiment, and digital image correlation (DIC) testing. A concurrent multiscale optimization strategy is introduced for CFRCs fabricated via 3D printing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104968"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107674","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}