Additive manufacturing最新文献

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Multi-modal contrastive causal consistency fusion for anomaly detection in additive manufacturing 多模态对比因果一致性融合在增材制造异常检测中的应用
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-28 DOI: 10.1016/j.addma.2025.104816
Junwei Gu , Yu Wang , Jianing Chen , Mingquan Zhang , Zenghui Wang , Jiahao Chen
{"title":"Multi-modal contrastive causal consistency fusion for anomaly detection in additive manufacturing","authors":"Junwei Gu ,&nbsp;Yu Wang ,&nbsp;Jianing Chen ,&nbsp;Mingquan Zhang ,&nbsp;Zenghui Wang ,&nbsp;Jiahao Chen","doi":"10.1016/j.addma.2025.104816","DOIUrl":"10.1016/j.addma.2025.104816","url":null,"abstract":"<div><div>With the increasing demand for intelligent and efficient process monitoring in additive manufacturing (AM), multi-sensor data fusion has shown superior anomaly detection accuracy over single-modality sensor systems. However, cross-modal data exhibit substantial differences in feature distributions, presenting challenges for their fusion. To tackle these challenges, this paper proposes an anomaly detection method using multiple sensor modalities, integrating their data via a causal approach. First, a contrastive feature extraction method is introduced to identify anomaly-sensitive features within each sensor modality. Second, causal consistency alignment is utilized to exploit the causal relationships among cross-modal data, thereby facilitating collaborative learning across multi-sensor data during the AM process. Third, a collaborative fusion strategy based on global attention mechanisms using transformers is proposed to adaptively fuse multi-modal features for anomaly detection tasks. Finally, the real fused deposition modeling (FDM) dataset, sourced from an AM dataset platform with multiple sensor modalities, is utilized to validate the effectiveness of the proposed method. The experimental results demonstrate that the proposed method significantly enhances early anomaly detection and the identification of anomalous regions in comparison to existing methods.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104816"},"PeriodicalIF":10.3,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167689","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
Mechanistic study of fiber damage evolution in 3D printing of two-matrix continuous carbon fiber-reinforced composites based on electrical conductivity changes 基于电导率变化的双基连续碳纤维增强复合材料3D打印过程中纤维损伤演化机理研究
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-25 DOI: 10.1016/j.addma.2025.104826
Jiale Yi , Ben Deng , Fangyu Peng , Xiaopeng Xie , Aodi Yan , Zhijie Li , Rong Yan , Jinguo Shen
{"title":"Mechanistic study of fiber damage evolution in 3D printing of two-matrix continuous carbon fiber-reinforced composites based on electrical conductivity changes","authors":"Jiale Yi ,&nbsp;Ben Deng ,&nbsp;Fangyu Peng ,&nbsp;Xiaopeng Xie ,&nbsp;Aodi Yan ,&nbsp;Zhijie Li ,&nbsp;Rong Yan ,&nbsp;Jinguo Shen","doi":"10.1016/j.addma.2025.104826","DOIUrl":"10.1016/j.addma.2025.104826","url":null,"abstract":"<div><div>This study addresses the critical issue of fiber breakage defects that significantly affect the mechanical performance of 3D printed two-matrix continuous carbon fiber-reinforced composites. A conductivity-based method is proposed to characterize the extent of fiber fracture during the printing process. The entire process is segmented into five stages, from the raw two-matrix prepreg filament (<em>Stage</em> 1) to the final printed part (<em>Stage</em> 5). The relationship between fiber breakage and electrical conductivity at different stages is systematically investigated, verifying the effectiveness of electrical conductivity as an indicator for assessing fiber continuity and damage severity. Experimental analysis under varying processing parameters further reveals that the electrical conductivity of printed part is highly sensitive to both printing speed and temperature. These findings indicate that conductivity monitoring can effectively capture the degradation in mechanical performance caused by microscale defects, offering valuable guidance for process parameters optimization. Within the given process and parameter range in this paper, the optimal process parameter combination is a printing temperature of 210°C and a printing speed coefficient of 3. Finally, by integrating thermal property analysis and microstructural characterization, the study elucidates a damage evolution mechanism dominated by epoxy softening-induced interfacial failure and thermo-temporal stress accumulation. This mechanism collectively drives the fracture of continuous carbon fibers during printing, laying the groundwork for future multiscale modeling of damage evolution in two-matrix continuous carbon fiber-reinforced composites.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104826"},"PeriodicalIF":10.3,"publicationDate":"2025-05-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144178738","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
Effects of laser powder bed fusion parameters on the delta-ferrite to austenite phase transformation in duplex stainless steels 激光粉末床熔合参数对双相不锈钢δ -铁素体向奥氏体相变的影响
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-23 DOI: 10.1016/j.addma.2025.104825
X.Y. He , V.V. Rielli , Q. Liu , X.P. Li , V. Luzin , N. Haghdadi , S. Primig
{"title":"Effects of laser powder bed fusion parameters on the delta-ferrite to austenite phase transformation in duplex stainless steels","authors":"X.Y. He ,&nbsp;V.V. Rielli ,&nbsp;Q. Liu ,&nbsp;X.P. Li ,&nbsp;V. Luzin ,&nbsp;N. Haghdadi ,&nbsp;S. Primig","doi":"10.1016/j.addma.2025.104825","DOIUrl":"10.1016/j.addma.2025.104825","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) of 2205 duplex stainless steels is attractive for making complex shaped engineering parts for applications requiring unique combinations of strength-toughness-corrosion properties. However, as-built parts possess highly non-equilibrium microstructures (&gt;98 % δ-ferrite). The desirable balanced austenite/δ-ferrite microstructure can be recovered after a brief heat treatment, potentially achieving much finer duplex microstructures than in wrought counterparts. However, systematic understanding of how LPBF parameters control the microstructural characteristics of the parent δ-ferrite and, hence, the transformed austenite product, is currently missing. We aim to close this gap by establishing the process-microstructure-property relationship using multi-scale characterization and nano-indentation. We compare as-built and heat-treated conditions fabricated with eight different combinations of laser power and scan speed. We show how variations in residual stress, texture, and characteristics of dislocations and inclusions in the parent δ-ferrite control the phase fraction, morphology, grain size, texture, and variant selection of the daughter austenite. A higher dislocation density in δ-ferrite is found to be associated with lower laser power and/or higher scan speed, contributing to higher hardness in as-built δ-ferrite and smaller intragranular austenite grain sizes in heat-treated conditions. Higher residual stress and/or stronger δ-ferrite texture contribute to higher austenite phase fractions. Intragranular austenite variant selection is revealed to be related to the complexity of δ-ferrite dislocation structures, and results in significant hardness increments in the heat-treated conditions. These findings highlight the capability of microstructural engineering via adjusting LPBF parameters and controlling materials performance through manipulating solid-state phase transformations.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104825"},"PeriodicalIF":10.3,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167687","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
Closed loop recycling approach for aged polyamide 12 feedstocks for powder bed fusion by precipitation from a moderate solvent combined with solvolysis 中等溶剂沉淀与溶剂分解相结合的粉末床熔融用老化聚酰胺12原料的闭环回收方法
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-22 DOI: 10.1016/j.addma.2025.104822
Florentin Tischer , Simon Cholewa , Björn Düsenberg , Dietmar Drummer , Andreas Bück , Wolfgang Peukert , Jochen Schmidt
{"title":"Closed loop recycling approach for aged polyamide 12 feedstocks for powder bed fusion by precipitation from a moderate solvent combined with solvolysis","authors":"Florentin Tischer ,&nbsp;Simon Cholewa ,&nbsp;Björn Düsenberg ,&nbsp;Dietmar Drummer ,&nbsp;Andreas Bück ,&nbsp;Wolfgang Peukert ,&nbsp;Jochen Schmidt","doi":"10.1016/j.addma.2025.104822","DOIUrl":"10.1016/j.addma.2025.104822","url":null,"abstract":"<div><div>A major challenge in the powder bed fusion (PBF) process with polyamides, which are the most commonly used powders, is the handling of already used powder (aged powder). During PBF, polyamide powders undergo chemical ageing, resulting in altered thermal and rheological properties of the feedstock material. Components made from aged powder are of inferior quality. Therefore, aged powder is usually refreshed with new (virgin) powder. Although, a substantial amount of aged powder accumulates over the course of processing. These excess quantities are either employed in other plastic manufacturing processes (downcycling) or, more frequently, disposed. A combined process of solvolysis with subsequent thermally induced liquid-liquid phase separation and polymer crystallisation (TIPS+S) is used to restore the thermal properties and rheological properties of aged polyamide 12 (PA12) and thus to make the powders suitable for PBF again. The degree of solvolysis of the aged PA12 is tuned by reaction temperature or reaction time. A kinetic model allows to determine suitable process parameters for TIPS+S depending on the ageing condition of the feed to match the thermal properties of the recycled PA12 powders to those of PA12 virgin powder. The optimised recycled PA12 powder shows comparable zero shear viscosity, particle size distribution, particle shape and flowability to the virgin material. Specimen built from equally mixed recycled and aged PA12 powder achieved the same mechanical properties like those obtain by PBF of equally mixed virgin and aged powder. Therefore, a closed loop recycling approach is feasible, in which aged PA12 powders from the PBF process are recycled by the proposed TIPS+S process.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104822"},"PeriodicalIF":10.3,"publicationDate":"2025-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167688","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
Deep learning based optical image super-resolution via generative diffusion models for layerwise in-situ LPBF monitoring 基于生成扩散模型的深度学习光学图像超分辨率分层原位LPBF监测
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-21 DOI: 10.1016/j.addma.2025.104790
Francis Ogoke , Sumesh Kalambettu Suresh , Jesse Adamczyk , Dan Bolintineanu , Anthony Garland , Michael Heiden , Amir Barati Farimani
{"title":"Deep learning based optical image super-resolution via generative diffusion models for layerwise in-situ LPBF monitoring","authors":"Francis Ogoke ,&nbsp;Sumesh Kalambettu Suresh ,&nbsp;Jesse Adamczyk ,&nbsp;Dan Bolintineanu ,&nbsp;Anthony Garland ,&nbsp;Michael Heiden ,&nbsp;Amir Barati Farimani","doi":"10.1016/j.addma.2025.104790","DOIUrl":"10.1016/j.addma.2025.104790","url":null,"abstract":"<div><div>The stochastic formation of defects during Laser Powder Bed Fusion (L-PBF) negatively impacts its adoption for high-precision use cases. Optical monitoring techniques can be used to identify defects based on layer-wise imaging, but these methods are difficult to scale to high resolutions due to cost and memory constraints. Therefore, we implement generative deep learning models to link low-cost, low-resolution images of the build plate to detailed high-resolution optical images of the build plate, enabling cost-efficient process monitoring. To do so, a conditional latent probabilistic diffusion model is trained to produce realistic high-resolution images of the build plate from low-resolution webcam images, recovering the distribution of small-scale features and surface roughness. We first evaluate the performance of the model by analyzing the reconstruction quality of the generated images using peak-signal-to-noise-ratio (PSNR), structural similarity index measure (SSIM) and wavelet covariance metrics that describe the preservation of high-frequency information. Additionally, we design a framework based upon the Segment Anything foundation model to recreate the 3D morphology of the printed part and analyze the surface roughness of the reconstructed samples. Finally, we explore the zero-shot generalization capabilities of the implemented framework to other part geometries by creating synthetic low-resolution data.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104790"},"PeriodicalIF":10.3,"publicationDate":"2025-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144167690","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
Feasibility of 3D-printed polymeric covers for electrode wires in electropolishing of additively manufactured parts with internal channels 具有内通道的增材制造零件电抛光中3d打印电极丝聚合物护套的可行性
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-20 DOI: 10.1016/j.addma.2025.104824
Manyou Sun, Ali Mohammadnejad, Ehsan Toyserkani
{"title":"Feasibility of 3D-printed polymeric covers for electrode wires in electropolishing of additively manufactured parts with internal channels","authors":"Manyou Sun,&nbsp;Ali Mohammadnejad,&nbsp;Ehsan Toyserkani","doi":"10.1016/j.addma.2025.104824","DOIUrl":"10.1016/j.addma.2025.104824","url":null,"abstract":"<div><div>This work discloses the preliminary results of a feasibility study of a novel setup and procedure for electropolishing internal channels of additively manufactured components. A specially designed and printed polymeric cover was assembled with a flexible stainless steel 316 wire to facilitate electropolishing of internal channels with various curvatures. A numerical simulation was conducted for optimization of wire cover designs, and the performance of three designs were analyzed and compared. Following that, experimental studies were conducted to assess the feasibility of the process. The presence of curvatures was found to influence the formation and removal of conductive solid reaction products, thus affecting the electropolishing performance accordingly. A maximum surface roughness <em>Sa</em> reduction from 10.86 ± 0.50 μm to 1.44 ± 0.46 μm was obtained for straight channels after electropolishing for 20 min, while less efficient surface smoothening performance was observed on curved channels. While challenges need to be solved for improving the electropolishing performance and reducing the limit of the channel size that can be electropolished, the methods show significant potential on electropolishing curved internal channels, which can be further used in industrial-scale applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104824"},"PeriodicalIF":10.3,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144107027","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
The effect of thermal history on elemental diffusion, phase evolution, and mechanical properties of laser powder bed fusion fabricated Ti6Al4V/AlMgScZr multi-material components 热历史对激光粉末床熔合Ti6Al4V/AlMgScZr多材料构件元素扩散、相演化及力学性能的影响
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-19 DOI: 10.1016/j.addma.2025.104821
Guangjing Huang, Dongdong Gu, Hong Liu, Kaijie Lin, Jie Wang, He Sun, Ziqi Guo
{"title":"The effect of thermal history on elemental diffusion, phase evolution, and mechanical properties of laser powder bed fusion fabricated Ti6Al4V/AlMgScZr multi-material components","authors":"Guangjing Huang,&nbsp;Dongdong Gu,&nbsp;Hong Liu,&nbsp;Kaijie Lin,&nbsp;Jie Wang,&nbsp;He Sun,&nbsp;Ziqi Guo","doi":"10.1016/j.addma.2025.104821","DOIUrl":"10.1016/j.addma.2025.104821","url":null,"abstract":"<div><div>Ti/Al multi-material components integrate the high specific strength of titanium with the lightweight characteristics of aluminum, demonstrating significant potential for applications in extreme environments. However, challenges such as weak interfacial bonding, elemental diffusion mismatch, and residual stress accumulation hinder broader application. In this study, Ti6Al4V/AlMgScZr multi-material components were fabricated using laser powder bed fusion (LPBF), with thermal history control to optimize residual stress and mechanical properties. The effects of thermal history on Ti/Al multi-material interface were analyzed, encompassing elemental diffusion, phase interface, and mechanical performance. Results showed that heat treatment significantly enhanced elemental interdiffusion, with the diffusion layer thickness increasing from 3.74 µm in the as-built state to 26.86 µm after 425°C× 4 h heat treatment. The L1<sub>2</sub>-Al<sub>3</sub>Ti phases formed a coherent interface with the aluminum matrix, alleviating lattice mismatch, enhancing stress transfer, and promoting partial ordered phases under high-temperature heat treatment. Simulations revealed that residual stress in the AlMgScZr region decreased from 282 MPa in the as-built sample to 81.2 MPa after heat treatment at 325°C× 4 h, effectively mitigating thermal mismatch-induced deformation and ensuring uniform stress distribution. This study provides new insights into the interfacial phase evolution and residual stress optimization in LPBF-fabricated multi-material systems. The synergistic effect of grain refinement and residual stress reduction led to a notable improvement in mechanical performance, with the tensile strength reaching 313.1 MPa after 325°C× 4 h heat treatment, representing a 50.3 % increase over the as-built sample. These findings offer valuable guidance for the design and processing of high-performance Ti/Al multi-material components for aerospace applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104821"},"PeriodicalIF":10.3,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144114984","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
Vacuum additive manufacturing of polyether ether ketone: Prediction of mechanical properties and forming mechanism 聚醚醚酮的真空增材制造:力学性能预测及形成机理
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-19 DOI: 10.1016/j.addma.2025.104820
Jingxuan wang , Yiwei Chen , Zhongde Shan , Congze Fan , Wenzhe Song , Jinghua Zheng , Fan Lu
{"title":"Vacuum additive manufacturing of polyether ether ketone: Prediction of mechanical properties and forming mechanism","authors":"Jingxuan wang ,&nbsp;Yiwei Chen ,&nbsp;Zhongde Shan ,&nbsp;Congze Fan ,&nbsp;Wenzhe Song ,&nbsp;Jinghua Zheng ,&nbsp;Fan Lu","doi":"10.1016/j.addma.2025.104820","DOIUrl":"10.1016/j.addma.2025.104820","url":null,"abstract":"<div><div>Polyether ether ketone (PEEK) 3D printing technology has enormous potential uses in space exploration and engineering because of the exceptional qualities of material and ability to withstand the harsh conditions of the space environment. Considering the significant influence of the vacuum environment on the thermal history and resin rheology of the 3D printing process, this study establishes a predictive model using response surface methodology (RSM) to correlate axial tensile strength with critical process parameters under 10 Pa vacuum environment (VAC) and standard atmospheric pressure (ATM). Moreover, the relationship between tensile strength and process parameters across different environmental pressures is analyzed using analysis of variance (ANOVA) and univariate analysis. To further understand the intricate behaviors of PEEK during 3D printing, cooling and non-isothermal crystallization models, the neck growth model, and the pore growth model were developed for both VAC and ATM conditions. These models were validated through crystallinity assessments, microstructural cross-section analysis, and monofilament extrusion tests. Experimental results reveal that the theoretical model provides an accurate depiction of heat and mass transfer processes in VAC and ATM conditions. The results calculated using the theoretical model systematically elucidate the influence mechanisms of the vacuum environment on heat and mass transfer, resin rheological behavior, and defect formation. The study explains the different effects of process parameters on the tensile properties under VAC and ATM pressure conditions and proposes a defect formation mechanism for vacuum-printed samples, attributed to the expansion of initial pores within the filament driven by the pressure difference between the internal and external environments.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104820"},"PeriodicalIF":10.3,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144107025","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
Mechanical properties and deformation mechanisms of metastable β Ti-12Mo alloy fabricated by in-situ alloying-based additive manufacturing 原位合金化增材制造亚稳β Ti-12Mo合金的力学性能及变形机理
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-17 DOI: 10.1016/j.addma.2025.104819
Ranxi Duan , Dingshan Liang , Fuzeng Ren , Dominik Daisenberger , Oxana V. Magdysyuk , Junhua Luan , Zengbao Jiao , Moataz M. Attallah , Biao Cai
{"title":"Mechanical properties and deformation mechanisms of metastable β Ti-12Mo alloy fabricated by in-situ alloying-based additive manufacturing","authors":"Ranxi Duan ,&nbsp;Dingshan Liang ,&nbsp;Fuzeng Ren ,&nbsp;Dominik Daisenberger ,&nbsp;Oxana V. Magdysyuk ,&nbsp;Junhua Luan ,&nbsp;Zengbao Jiao ,&nbsp;Moataz M. Attallah ,&nbsp;Biao Cai","doi":"10.1016/j.addma.2025.104819","DOIUrl":"10.1016/j.addma.2025.104819","url":null,"abstract":"<div><div>The strength-ductility trade-off in additively manufactured (AM) β Ti alloys remains a significant challenge. In this study, we employed a cost-effective in-situ alloying laser powder bed fusion approach with optimized processing parameters to fabricate a nearly fully dense, chemically homogeneous β Ti-12Mo alloy. We then examined how solution-treatment duration influences the tensile behavior of the AM Ti-12Mo alloy. The optimally solution-treated alloys exhibited high tensile yield strength (725–741 MPa) and commendable ductility (22–36 %) along both the 0° and 90° orientations relative to the build direction. Focusing on the underlying deformation mechanisms perpendicular to the build direction, we report a uniform elongation of 17.9 % and a pronounced strain hardening rate (∼2300 MPa at 4 %), which we elucidate via in-situ high-energy synchrotron X-ray diffraction and microstructural characterization. The high yield strength is primarily attributed to the presence of Mo-lean embryonic athermal ω nanoparticles. During plastic deformation, both twinning and phase transformation contribute to the high strain hardening rate. At the early stage (strain &lt; 1.9 %), deformation is dominated by {332}&lt; 113 &gt;<sub>β</sub> twinning, whereas at later stages, the deformation-induced α'' phase becomes significant. The volume fraction of α'' phase increases with strain, supporting the continuous hardening. Notably, irrational {112}&lt; 751 &gt;<sub>β</sub>, secondary {112}&lt; 111 &gt;<sub>β</sub>, and {130}&lt; 310 &gt;<sub>α</sub><sub>''</sub> nano-twins confine the primary structures to nanograins and sustain strain hardening. This study sheds light on designing high-performance β Ti-12Mo alloy via AM followed by heat treatment.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104819"},"PeriodicalIF":10.3,"publicationDate":"2025-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144107026","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
Numerical analysis of powder-induced gas porosity in directed energy deposition: Formation, evolution, and mitigation 定向能沉积中粉末诱导气体孔隙度的数值分析:形成、演化和缓解
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-16 DOI: 10.1016/j.addma.2025.104815
Haodong Chen , Yajing Sun , Shuhao Wang , Miao Yu , Hao Lu , Xin Lin , Lida Zhu
{"title":"Numerical analysis of powder-induced gas porosity in directed energy deposition: Formation, evolution, and mitigation","authors":"Haodong Chen ,&nbsp;Yajing Sun ,&nbsp;Shuhao Wang ,&nbsp;Miao Yu ,&nbsp;Hao Lu ,&nbsp;Xin Lin ,&nbsp;Lida Zhu","doi":"10.1016/j.addma.2025.104815","DOIUrl":"10.1016/j.addma.2025.104815","url":null,"abstract":"<div><div>Directed energy deposition (DED) is an important branch of metal additive manufacturing and holds significant potential for the manufacturing and in-situ repairing of complex parts. However, the gas porosity defect is inevitably introduced in the DEDed parts, which severely affects the fatigue performance of the parts. This paper innovatively combines the discrete element method (DEM) and computational fluid dynamics (CFD) model to trace the transformation from powder dynamics to bubble evolution in the molten pool and finally to pore entrapment in solidified tracks. The results show that the fluid drag force play the dominate role on bubble evolution in the molten pool. Specifically, in the straight flow region, small bubbles escape directly from the molten pool, while in the vortex region, their satellite-like rotational motions promote coalescence and entrapment, leading to higher porosity density at the top and bottom of the track. Finally, two methods, namely powder stream size tailoring and laser beam shaping are proposed to mitigate gas porosity. This work can further enhance the understanding of coupled physical phenomena and gas porosity formation in DED.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"107 ","pages":"Article 104815"},"PeriodicalIF":10.3,"publicationDate":"2025-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144089709","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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