Additive manufacturing最新文献

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Multiphysics modelling of 3D concrete printing: From material model to process simulation and optimisation 3D混凝土打印的多物理场建模:从材料模型到过程模拟和优化
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-26 DOI: 10.1016/j.addma.2025.104847
Maxime Pierre , Siavash Ghabezloo , Patrick Dangla , Romain Mesnil , Matthieu Vandamme , Jean-François Caron
{"title":"Multiphysics modelling of 3D concrete printing: From material model to process simulation and optimisation","authors":"Maxime Pierre ,&nbsp;Siavash Ghabezloo ,&nbsp;Patrick Dangla ,&nbsp;Romain Mesnil ,&nbsp;Matthieu Vandamme ,&nbsp;Jean-François Caron","doi":"10.1016/j.addma.2025.104847","DOIUrl":"10.1016/j.addma.2025.104847","url":null,"abstract":"<div><div>Predictive simulation of 3D concrete printing is important to warrant printability and durability of print pieces and to optimise printing parameters, yet tedious due to the complexity of the material behaviour and printing process. From a constitutive model allowing a continuous description of the coupled chemo-thermo-poro-mechanical behaviour of cement-based materials from the early-age to the hardened state, a comprehensive finite element simulation framework is designed. It aims at modelling extrusion-based 3D printing processes, taking into account the sequential deposition of material. Study of the onset of plastic collapse on specific geometries at different printing speeds show the complexity of collapse prediction as well as the importance of process-related effects. An optimisation scheme is proposed to determine optimal printing speed modulations from numerical simulations with the perspective of increasing productivity in 3D concrete printing. The model shows good predicting capabilities when compared with experimental printing failures, and is able to extrapolate to other accelerator dosages without model re-calibration.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104847"},"PeriodicalIF":10.3,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518602","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}
引用次数: 0
Scalable path planning and reduced order modeling for temperature optimization in Direct Energy Deposition 直接能量沉积中温度优化的可扩展路径规划和降阶建模
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-25 DOI: 10.1016/j.addma.2025.104831
Iason Sideris , Yiyang Yan , Stephen Duncan , Mohamadreza Afrasiabi , Markus Bambach
{"title":"Scalable path planning and reduced order modeling for temperature optimization in Direct Energy Deposition","authors":"Iason Sideris ,&nbsp;Yiyang Yan ,&nbsp;Stephen Duncan ,&nbsp;Mohamadreza Afrasiabi ,&nbsp;Markus Bambach","doi":"10.1016/j.addma.2025.104831","DOIUrl":"10.1016/j.addma.2025.104831","url":null,"abstract":"<div><div>Direct energy deposition (DED) processes, including laser DED and wire-arc additive manufacturing, provide high throughput and geometric flexibility, yet dimensional inaccuracies and heterogeneous properties frequently arise when sub-optimal tool paths create uneven temperature fields. Thermally aware path optimization is therefore essential but remains computationally prohibitive for complex geometries, forming the principal bottleneck in current algorithms. This study introduces an efficient planning framework that constructs a reduced order thermal model with GPyro, a machine-learning subspace technique that predicts temperature profiles only on the deposition layer. This allows swift layer-wise reductions, thereby extending the applicability of reduced-order models to arbitrary three-dimensional geometries. Additionally, the algorithm leverages the fast Fourier transform to evaluate temperature evolution efficiently, significantly reducing computational time while preserving accuracy. Compared to existing methods, the proposed approach achieves up to a 10<span><math><msup><mrow></mrow><mrow><mn>9</mn></mrow></msup></math></span>-fold reduction in pre-computing time and a 10<span><math><msup><mrow></mrow><mrow><mn>2</mn></mrow></msup></math></span>-fold acceleration in evaluating process temperature fields. Experimental validation on components with high overhang angles confirms the effectiveness of the algorithm, consistently producing high-quality, defect-free parts and demonstrating that coupling GPyro with iterative optimizers enables the optimization of deposition strategies, even for complex geometries.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104831"},"PeriodicalIF":10.3,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144511032","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}
引用次数: 0
Concurrent optimization of building direction and structural topology for multi-axis additive manufacturing of rotary parts considering anisotropic strength 考虑各向异性强度的旋转零件多轴增材制造制造方向与结构拓扑并行优化
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-25 DOI: 10.1016/j.addma.2025.104851
Cheng Yan , Haowei Guo , Ben Pei , He Liu , Yun Chen , Cunfu Wang , Zeyong Yin
{"title":"Concurrent optimization of building direction and structural topology for multi-axis additive manufacturing of rotary parts considering anisotropic strength","authors":"Cheng Yan ,&nbsp;Haowei Guo ,&nbsp;Ben Pei ,&nbsp;He Liu ,&nbsp;Yun Chen ,&nbsp;Cunfu Wang ,&nbsp;Zeyong Yin","doi":"10.1016/j.addma.2025.104851","DOIUrl":"10.1016/j.addma.2025.104851","url":null,"abstract":"<div><div>The additional printing degrees of freedom in multi-axis additive manufacturing (AM) based on the BC table machine facilitate control of the building direction (BD), the formation of complex curved surfaces, and the fabrication of rotary parts. This provides significant advantages in controlling material anisotropy and structural layouts. In topology optimization (TO), concurrent optimization of BD and topological layouts can fully take advantage of the process-induced anisotropy. However, most of the previous studies were limited to three-axis AM systems and failed to fully exploit the manufacturing potential of multi-axis AM machines. Therefore, this study develops a TO method tailored for multi-axis AM based on the BC table machine. Firstly, an innovative constitutive model is developed for printing rotary parts based on the BC table machine. This model describes the constitutive characteristics of anisotropic rotary parts formed by <span><math><mi>C</mi></math></span>-axis rotation after adjusting the print platform based on the <span><math><mi>B</mi></math></span>-axis to a non-horizontal plane, providing a theoretical foundation for material property interpolation and BD optimization. Secondly, the Tsai–Hill failure criterion for multi-axis AM of rotary parts is derived, which can predict the anisotropic strength distribution under different BDs. Next, a TO model is developed to concurrently optimize BD and topological layouts considering anisotropic strength and structural stiffness in multi-axis AM, and the sensitivities of the objective function and constraints are derived. Finally, optimization examples of hook supports and compressor disks are presented to validate the importance and effectiveness of BD optimization and anisotropic strength constraints, while an optimization example of turbine rear cooling plates demonstrates the method’s engineering applicability. The results show that this method can concurrently optimize the BD and structural layout of multi-axis AM of rotary parts, fully utilizing anisotropy in AM and improving overall structural performance.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104851"},"PeriodicalIF":10.3,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502538","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}
引用次数: 0
Fabrication of ophthalmic lenses by Fluidic Shaping 流体成形技术制备眼晶状体
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-25 DOI: 10.1016/j.addma.2025.104871
Mor Elgarisi , Omer Luria , Yotam Katzman , Daniel Widerker , Valeri Frumkin , Moran Bercovici
{"title":"Fabrication of ophthalmic lenses by Fluidic Shaping","authors":"Mor Elgarisi ,&nbsp;Omer Luria ,&nbsp;Yotam Katzman ,&nbsp;Daniel Widerker ,&nbsp;Valeri Frumkin ,&nbsp;Moran Bercovici","doi":"10.1016/j.addma.2025.104871","DOIUrl":"10.1016/j.addma.2025.104871","url":null,"abstract":"<div><div>Limited access to corrective eyewear remains a significant medical, societal, and economic challenge in developing countries, with more than 1 billion people suffering from uncorrected vision impairment. Philanthropy has failed to meet the demand, and local manufacturing using standard technologies remains beyond reach due to inadequate resources. We present a fluidic approach, leveraging the surface tension of liquid polymers, with which high-quality solid lenses, with any prescription, can be created without machining, polishing or any post-processing steps. We provide an experimentally-validated analytical model relating the geometrical degrees of freedom to the desired prescription. Using a compact low-power device, we demonstrate that the fluidic approach allows the fabrication of industry-standard eyeglasses in several minutes, opening the door to advanced manufacturing in low-resource settings.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104871"},"PeriodicalIF":10.3,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518518","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}
引用次数: 0
Fabrication of robust high-aspect-ratio Ti-6Al-4V ultra-thin-walled structures using powder bed fusion with in-situ focused infrared heating 原位聚焦红外加热粉末床熔合制备高宽高比Ti-6Al-4V超薄壁结构
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-24 DOI: 10.1016/j.addma.2025.104867
Arif Hussain , Junghoon Lee , Rae Eon Kim , Hyoung Seop Kim , Jeonghong Ha , Young Sam Kwon , Dongsik Kim
{"title":"Fabrication of robust high-aspect-ratio Ti-6Al-4V ultra-thin-walled structures using powder bed fusion with in-situ focused infrared heating","authors":"Arif Hussain ,&nbsp;Junghoon Lee ,&nbsp;Rae Eon Kim ,&nbsp;Hyoung Seop Kim ,&nbsp;Jeonghong Ha ,&nbsp;Young Sam Kwon ,&nbsp;Dongsik Kim","doi":"10.1016/j.addma.2025.104867","DOIUrl":"10.1016/j.addma.2025.104867","url":null,"abstract":"<div><div>Thin-walled structures (thin walls) fabricated via laser-based powder bed fusion (PBF-LB/M) are prone to buckling at critical heights at which buckling of thin-walled structures begins (2.3 mm for ∼75 µm thin wall) due to excessive thermal residual stresses. The susceptibility of thin-wall buckling under thermal load is directly related to their high aspect ratio (height/thickness) and residual stress. When fabricating a part with a positive minimum feature size, minimizing the residual stress is crucial to achieving the designated part shape and height. Here, we demonstrate the printing of mechanically robust (high-strength) ultra-thin freeform Ti-6Al-4V thin walls at previously unprintable heights via a modified PBF-LB/M process. This was made possible by employing an in-situ focused infrared (IR) heating technique. Two focused IR heaters were employed to heat the powder bed and mitigate the thermal stresses. Residual stress measurements were conducted via X-ray diffraction (XRD), and the effect of IR heating temperature on residual stress was studied via thermomechanical simulations. Thin walls buckled at 2.3 mm build height without IR heating. When IR heating was employed with insufficient intensity (IR supply voltages &lt;50 V), the maximum printable thin-wall height increased slightly; however, with optimized IR heating (50 V), the thin wall successfully reached its designated build height of 20 mm. This improvement was attributed to a maximum reduction of approximately 95 % in equivalent stress along the build height of the 20 mm tall thin wall. No major deviation in the wall thickness through the thin wall height was observed as a result of the IR heating. The ability to print tall sub-100 µm thin walls enabled us to analyze the tensile properties of these thin-walled samples for the first time. The ultimate tensile strength (UTS) values recorded for IR supply voltages of 40 V, 45 V, and 50 V were 1114 MPa, 1234 MPa, and 1184 MPa, respectively. Correspondingly, the maximum elongation values improved with increasing IR heating voltage, measured as 2.16 %, 2.28 %, and 2.45 % for 40 V, 45 V, and 50 V, respectively. The major finding from the testing indicated consistent material strength for thin walls below and above 100 µm thickness. However, the reduction in sample thickness led to a significant reduction in elongation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104867"},"PeriodicalIF":10.3,"publicationDate":"2025-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502584","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}
引用次数: 0
4D insight into the defect evolution of additively manufactured ceramics during debinding and sintering 增材制造陶瓷在脱粘和烧结过程中缺陷演变的4D洞察
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-24 DOI: 10.1016/j.addma.2025.104873
Qiaoyu Meng , Rongqi Zhu , Zhichao Gong , Juncheng Pu , Keqiang Zhang , Rujie He , Zhaoliang Qu , Daining Fang
{"title":"4D insight into the defect evolution of additively manufactured ceramics during debinding and sintering","authors":"Qiaoyu Meng ,&nbsp;Rongqi Zhu ,&nbsp;Zhichao Gong ,&nbsp;Juncheng Pu ,&nbsp;Keqiang Zhang ,&nbsp;Rujie He ,&nbsp;Zhaoliang Qu ,&nbsp;Daining Fang","doi":"10.1016/j.addma.2025.104873","DOIUrl":"10.1016/j.addma.2025.104873","url":null,"abstract":"<div><div>Defects emerging in the additive manufacturing process can substantially influence the mechanical properties of ceramics. The actual evolution of these defects during manufacturing has not been in-situ observed, making precise control over them a considerable challenge. This study marks the first observation of defect emergence and evolution during the debinding and sintering of vat photopolymerization (VP) additively manufactured ceramics, facilitated by a specially developed high-temperature in-situ computed tomography (CT) technique. Defects at various temperatures were visualized and underwent quantitative analysis. Their temperature-dependent characteristics, spatial distributions, and evolutionary dynamics of defects among the ceramic, were discussed in detail. This work offers a 4D insight into the defect evolution of VP additively manufactured Al<sub>2</sub>O<sub>3</sub> ceramics during their debinding and sintering processes for the first time, which is expected to provide ideas for the precise control of defects and enhances the mechanical properties in the future.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104873"},"PeriodicalIF":10.3,"publicationDate":"2025-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144481073","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}
引用次数: 0
Cu-25Cr composites processed by in situ alloying in electron beam powder bed fusion 电子束粉末床熔合原位合金化Cu-25Cr复合材料
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-23 DOI: 10.1016/j.addma.2025.104869
Lucas Varoto , Elodie Courtois , Mélanie Prost , Pierre Lhuissier , Jean-Jacques Blandin , Sophie Roure , Anthony Papillon , Mélissa Chosson , Guilhem Martin
{"title":"Cu-25Cr composites processed by in situ alloying in electron beam powder bed fusion","authors":"Lucas Varoto ,&nbsp;Elodie Courtois ,&nbsp;Mélanie Prost ,&nbsp;Pierre Lhuissier ,&nbsp;Jean-Jacques Blandin ,&nbsp;Sophie Roure ,&nbsp;Anthony Papillon ,&nbsp;Mélissa Chosson ,&nbsp;Guilhem Martin","doi":"10.1016/j.addma.2025.104869","DOIUrl":"10.1016/j.addma.2025.104869","url":null,"abstract":"<div><div>Due to their high thermal and electrical conductivity and high resistance to arc erosion, Cu-Cr alloys (Cr &gt;10 wt%) are used as electrical contacts in medium voltage vacuum circuit breakers. Such electrical contacts are industrially processed using solid-state sintering (SSS) from pure Cu and Cr powders or vacuum arc remelting (VAR). In this work, we confirm the possibility of fabricating dense Cu-25Cr samples with a refined and relatively homogeneous microstructure by electron beam powder bed fusion (EB-PBF) using elemental powder blending. The as-printed microstructure is characterized using SEM imaging and EBSD analysis while the mechanical, electrical, and thermal are probed to establish the microstructure-property relationships of the EB-PBF Cu-25Cr composite. The properties of the EB-PBF composite are systematically compared to their VAR counterparts. The as-printed microstructure results from the presence of a metastable miscibility gap that refines the microstructure (micron-sized Cr particles) by an order of magnitude compared to the VAR. The fine EB-PBF microstructure shows superior mechanical properties (hardness, yield strength and ultimate tensile strength), enhanced electrical conductivity, and equivalent thermal conductivity with respect to its VAR counterpart. The microstructure-property relationships are discussed in light of the mechanisms affecting the mechanical, electrical, and thermal properties of metal matrix composites. This work demonstrates the interest in producing Cu-Cr electrical contacts by additive manufacturing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104869"},"PeriodicalIF":10.3,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144517427","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}
引用次数: 0
Highly HFOM three-dimensional anti-tetrachiral negative Poisson's ratio BaTiO3 ceramics prepared via vat photopolymerization 用还原光聚合法制备了高HFOM三维抗四手性负泊松比BaTiO3陶瓷
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-23 DOI: 10.1016/j.addma.2025.104872
Xin Zhao , Yinghong Sun , Jimin Chen , Yong Zeng
{"title":"Highly HFOM three-dimensional anti-tetrachiral negative Poisson's ratio BaTiO3 ceramics prepared via vat photopolymerization","authors":"Xin Zhao ,&nbsp;Yinghong Sun ,&nbsp;Jimin Chen ,&nbsp;Yong Zeng","doi":"10.1016/j.addma.2025.104872","DOIUrl":"10.1016/j.addma.2025.104872","url":null,"abstract":"<div><div>As lead-free piezoelectric ceramics with high electromechanical conversion performance, Barium Titanate (BaTiO<sub>3</sub>) has been widely used in fields such as hydrophones and energy collection. Negative Poisson's ratio (NPR) structures can resist compression in the vertical direction when subjected to compressive force and exhibit an auxetic effect in the horizontal direction. This feature provides new degrees of freedom for material design, especially in high-performance application scenarios that require specific mechanical responses. In this paper, the optimal preparation process of BaTiO<sub>3</sub> ceramics was established by studying the influence of the mass ratio of submicron/micron BaTiO<sub>3</sub> particles on the rheological properties and curing properties of the slurry, as well as the mechanical and electrical properties of ceramics under different sintering processes. The prepared bulk BaTiO<sub>3</sub> had a relative density of 97.9 %, a compressive strength of 300.2 MPa, a piezoelectric strain coefficient <em>d</em><sub><em>33</em></sub> of 275 pC/N, and a hydrostatic figure of merit (<em>HFOM</em>) of 0.0812 × 10<sup>−12</sup> Pa<sup>−1</sup>. Two types of BaTiO<sub>3</sub> ceramics with Positive Poisson's ratio (PPR) structure, Body-centered Cubic (BCC) and Simple Grid Cubic (SGC) were designed and prepared, and their performance was compared with that of BaTiO<sub>3</sub> ceramics with NPR structure at the same porosity, proving the performance improvement effect of NPR structure on BaTiO<sub>3</sub> ceramics. In this paper, we started from the two aspects of process parameter optimization and NPR structural configuration parameter design and used vat photopolymerization (VPP) 3D printing technology to prepare Three-dimensional NPR structural BaTiO<sub>3</sub> ceramics with high hydrostatic piezoelectric strain coefficient <em>d</em><sub><em>h</em></sub> (520 pC/N) and <em>HFOM</em> (88.26 × 10<sup>−12</sup> Pa<sup>−1</sup>), 1085 times higher than that of the bulk BaTiO<sub>3</sub>. The results of this work guided the design and preparation of piezoelectric ceramics and also showed the great potential of VPP 3D printing technology in developing structural piezoelectric ceramics with high electromechanical response.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104872"},"PeriodicalIF":10.3,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144471401","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}
引用次数: 0
Achieving high strength Al-Li alloy with minimized element evaporation by wire-arc directed energy deposition 采用线弧定向能沉积法制备高强度铝锂合金,使元素蒸发最小化
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-23 DOI: 10.1016/j.addma.2025.104870
Jiannan Yang, Xuewei Fang, Yao Zhang, Xiangzhe Zhao, Chuanghong Huang, Hao Zhang, Ziyou Zheng, Shuchang Zhang, Jiarong Guo, Ke Huang, Bingheng Lu
{"title":"Achieving high strength Al-Li alloy with minimized element evaporation by wire-arc directed energy deposition","authors":"Jiannan Yang,&nbsp;Xuewei Fang,&nbsp;Yao Zhang,&nbsp;Xiangzhe Zhao,&nbsp;Chuanghong Huang,&nbsp;Hao Zhang,&nbsp;Ziyou Zheng,&nbsp;Shuchang Zhang,&nbsp;Jiarong Guo,&nbsp;Ke Huang,&nbsp;Bingheng Lu","doi":"10.1016/j.addma.2025.104870","DOIUrl":"10.1016/j.addma.2025.104870","url":null,"abstract":"<div><div>Porosity defects and lithium evaporation remain critical challenges in the wire-arc directed energy deposition (WA-DED) of Al-Li alloys. This study develops and validates a dual-surface Gaussian heat source model specifically tailored to the gas tungsten arc-based DED (GTA-DED) process, enabling accurate thermal field simulations. By coupling these simulations with Gaussian process regression (GPR), we systematically investigate the influence of key processing parameters on the deposition quality of AA2195 Al-Li alloy. A novel feature parameter system is introduced to quantitatively evaluate lithium loss—measured at a minimized rate of 1.6 %—and predict dimensional accuracy, which guides the identification of an optimized process window with enhanced formability. Subsequent T8 heat treatment, chosen for its effectiveness in promoting precipitate strengthening, drives microstructural evolution marked by the dissolution of intergranular Cu/Mg-rich phases and the precipitation of dense nano-scale T<sub>1</sub>(Al<sub>2</sub>CuLi) phases. This transformation leads to a significant increase in yield strength, reaching 554.5 MPa. Despite these improvements, residual defects such as hydrogen-induced pores and shrinkage cavities act as stress concentrators, limiting elongation to 2.2 %. The interplay between strength and ductility is further elucidated through detailed analysis of pore nucleation mechanisms and microtexture evolution. These findings provide critical theoretical insights and empirical data to advance the industrial application of WA-DED processing for Al-Li alloys.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104870"},"PeriodicalIF":10.3,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144471402","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}
引用次数: 0
A novel three-dimensional profile prediction method integrated with particle acceleration simulation and layer stacking in cold spray additive manufacturing 冷喷涂增材制造中粒子加速模拟与层叠加相结合的三维轮廓预测方法
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-23 DOI: 10.1016/j.addma.2025.104866
Cihao Xing, Wenya Li, Yaxin Xu, Chunjie Huang
{"title":"A novel three-dimensional profile prediction method integrated with particle acceleration simulation and layer stacking in cold spray additive manufacturing","authors":"Cihao Xing,&nbsp;Wenya Li,&nbsp;Yaxin Xu,&nbsp;Chunjie Huang","doi":"10.1016/j.addma.2025.104866","DOIUrl":"10.1016/j.addma.2025.104866","url":null,"abstract":"<div><div>In cold spray additive manufacturing (CSAM), predicting the deposit profile is a critical prerequisite for subsequent path planning. Unlike other additive manufacturing (AM) technologies, which achieve high single-track resolution through precise energy input, CSAM still faces challenges in shape control. While some previous models can predict thin coatings, they are unsuitable for complete CSAM workpieces or cold spray (CS) repairing of irregular damaged zones. Therefore, we proposed a new combined 3D method based on the particle acceleration simulation and the layer stacking principle, taking critical velocity (<em>v</em><sub>cr</sub>) as the regulation of deposition efficiency (DE) into consideration. The predicted profile is deduced by the integral equation containing various process parameters, namely particle distribution, particle height, nozzle traversing speed and the number of stacking layers. The effects of different influencing factors on deposit profile during CSAM were investigated, including nozzle cross-section shape, spray angle, standoff distance, nozzle traversing speed and scanning step. Results show that this new method overcomes the limitations of spatially symmetric particle distribution and adds up the critical velocity criterion (CVC) to ground the simulation ‌in virtue of solid physical principle. It provides real-time profile prediction feedback for nozzle path planning within a short time, offering a visual reference for complex spraying scenarios without requiring pre-experiments.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104866"},"PeriodicalIF":10.3,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144490387","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}
引用次数: 0
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