Additive manufacturing最新文献

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Electron beam powder bed fusion process monitoring by in-melt electron analysis 电子束粉末床熔合过程的熔体内电子分析监测
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-18 DOI: 10.1016/j.addma.2025.104858
Jinghao Xu , Prithwish Tarafder , Anton Wiberg , Huotian Zhang , Johan Moverare
{"title":"Electron beam powder bed fusion process monitoring by in-melt electron analysis","authors":"Jinghao Xu ,&nbsp;Prithwish Tarafder ,&nbsp;Anton Wiberg ,&nbsp;Huotian Zhang ,&nbsp;Johan Moverare","doi":"10.1016/j.addma.2025.104858","DOIUrl":"10.1016/j.addma.2025.104858","url":null,"abstract":"<div><div>Effective process monitoring is crucial for ensuring high print quality in electron beam powder bed fusion (PBF-EB), an advanced additive manufacturing technique. The interaction of electrons and matter provides a wealth of in-melt information during repeated local melting. To utilize the emitted electron signal efficiently, this study develops an in-melt electron analysis (IMEA) approach by analyzing and interpreting emissions, primarily composed of backscattered, secondary, and thermionic electrons. Owing to the high correlation of thermionic electrons to the temperature and area of the hottest spot, the melt pool characteristics can be monitored from the signal of emitted electrons. Two types of melting were conducted: (1) single tracks on a bare plate without powder and (2) printing on a powder bed. We demonstrate that the intensity of measured in-melt electrons correlated with the melt pool width on bare plate of 316 L stainless steel. In addition, we also demonstrate the applications of IMEA approach to detect the melt pool dynamics such as melt pool surface depression during a real print of 80 layers on 316 L stainless steel powder bed. This approach provides reliable monitoring of melt pool characteristics and surface depression, offering a promising tool for process control in PBF-EB.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104858"},"PeriodicalIF":10.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330497","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
Additive manufacturing of multicomponent glasses with enhanced optical properties via sol-gel 溶胶-凝胶法增材制造光学性能增强的多组分玻璃
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-18 DOI: 10.1016/j.addma.2025.104864
Alice Zanini , Giada Bombardelli , Giulio Giometti , Anna De Marzi , Johannes Erler , Dennis Nissen , Giorgia Franchin , Paolo Colombo
{"title":"Additive manufacturing of multicomponent glasses with enhanced optical properties via sol-gel","authors":"Alice Zanini ,&nbsp;Giada Bombardelli ,&nbsp;Giulio Giometti ,&nbsp;Anna De Marzi ,&nbsp;Johannes Erler ,&nbsp;Dennis Nissen ,&nbsp;Giorgia Franchin ,&nbsp;Paolo Colombo","doi":"10.1016/j.addma.2025.104864","DOIUrl":"10.1016/j.addma.2025.104864","url":null,"abstract":"<div><div>Glass is the cornerstone material for various applications in modern society and industry owing to its fascinating and unique properties. Herein, a versatile sol-gel protocol is proposed for the manufacturing of multicomponent complex-shaped glass structures with enhanced optical properties via photopolymerization-based processes, specifically UV-assisted Direct Ink Writing (UV-DIW) and Digital Light Processing (DLP). The photocurable, all-liquid inks comprise tetraethyl orthosilicate, triethoxymethylsilane, zirconium butoxide and/or titanium isopropoxide for the formation of an inorganic backbone tethered to the organic photopolymerization-derived network through 3-(trimethoxysilyl)propyl methacrylate, which serves both as photocurable monomer and silica source. The flexibility of our sol-gel system offers access to various multicomponent compositions, including the use of bulk coloring pigments. Such formulations enable the fabrication of components with remarkable refractive index (1.548–1.572) and the highest Abbe number v<sub>d</sub> hitherto reported for 3D-printed parts (64.85). In addition, sintering temperatures are decreased to 1000°C, far below those typically required in conventional particle-based approaches (&gt;1400°C). This work provides novel fabrication frameworks and technological enhancements, expanding the potential of glass additive manufacturing techniques for scaled-up and rapid production.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104864"},"PeriodicalIF":10.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330506","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
Stimulating multi-scale gradient heterostructure in laser direct energy deposited and hybrid additive manufactured AA7075 alloy via double-aging heat treatment to realize strength-ductility synergy 通过双时效热处理,激发激光直接能量沉积和混合添加剂制备的AA7075合金的多尺度梯度异质结构,实现强度-塑性协同
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-18 DOI: 10.1016/j.addma.2025.104861
Jiming Lv, Haifei Lu, Yuchen Liang, Kaiyu Luo, Jinzhong Lu
{"title":"Stimulating multi-scale gradient heterostructure in laser direct energy deposited and hybrid additive manufactured AA7075 alloy via double-aging heat treatment to realize strength-ductility synergy","authors":"Jiming Lv,&nbsp;Haifei Lu,&nbsp;Yuchen Liang,&nbsp;Kaiyu Luo,&nbsp;Jinzhong Lu","doi":"10.1016/j.addma.2025.104861","DOIUrl":"10.1016/j.addma.2025.104861","url":null,"abstract":"<div><div>The inverse relationship between strength and ductility has long been a major challenge in the field of metal research. Recently, the design and fabrication of non-uniform heterostructures, which involve the spatial distribution of different constituents via external thermal or mechanical means, have proven to be effective strategies for simultaneously enhancing strength and ductility. In this work, double-aging heat treatment (HT) was employed to activate the alternating columnar-equiaxial and cross-scale coarse-fine gradient heterostructures in laser direct energy deposited (LDED) and hybrid additive manufactured (HAM) AA7075 aluminum alloy. This approach led to a synchronous improvement in strength and ductility. Specifically, the ultimate tensile strength (UTS) and elongation (EL) of the LDED-HT samples were enhanced by approximately 20.1 % and 58.8 %, respectively. Meanwhile, the HAM-HT samples exhibited an UTS of ∼ 591.5 MPa and an EL of ∼ 15.1 %, which are superior to those of commercial wrought plates. Compared with the standalone LDED samples, The HAM ones with interlayer friction stir processing (IFSP) demonstrated completely pore elimination, significantly refined grains, and homogeneously fragmented inherent coarse precipitates. Following the double-aging HT, the width of columnar grains in LDED samples increased slightly, whereas the HAM samples exhibited abnormal grain growth (AGG) in the inter-track (IT) zones and normal grain growth (NGG) in the interlayer (IL) zones. Additionally, double-aging HT induced a much higher density of precipitations, such as η/η' phases, in the HAM samples compared to the LDED ones. The width of the precipitate-free zone (PFZ) in the HAM-HT samples was also significantly narrower than that in the LDED-HT ones. This work provides a novel approach for preparing multi-scale spatially heterostructures in thermally sensitive aluminum alloys, thereby breaking the inverse relationship between strength and ductility.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104861"},"PeriodicalIF":10.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330501","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
External field induced high speed sintering of dynamically cross-linked polydimethylsiloxane: Mechanical properties and electromagnetic wave absorption 动态交联聚二甲基硅氧烷外场诱导高速烧结:力学性能和电磁波吸收
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-17 DOI: 10.1016/j.addma.2025.104860
Tianci Liang , Yifan Cai , Lingyao Zhou , Tongzhi Zang , Liangyou Wu , Guoxia Fei , Ludwig Cardon , Hesheng Xia
{"title":"External field induced high speed sintering of dynamically cross-linked polydimethylsiloxane: Mechanical properties and electromagnetic wave absorption","authors":"Tianci Liang ,&nbsp;Yifan Cai ,&nbsp;Lingyao Zhou ,&nbsp;Tongzhi Zang ,&nbsp;Liangyou Wu ,&nbsp;Guoxia Fei ,&nbsp;Ludwig Cardon ,&nbsp;Hesheng Xia","doi":"10.1016/j.addma.2025.104860","DOIUrl":"10.1016/j.addma.2025.104860","url":null,"abstract":"<div><div>External field induced high speed sintering (HSS), is one kind of powder bed fusion 3D printing technology, which significantly enhances the printing rate using infrared light area-scanning instead of laser point-scanning and fusion. HSS printing needs to develop new materials with rapid melting-solidification kinetics to adapt to its rapid sintering process. Here, the polydimethylsiloxane (PDMS) covalent adaptable networks (CANs) with dynamic imidazolium bonds were synthesized and further pulverized to make the elastomer powders for HSS 3D printing. The high-quality PDMS elastomer parts with good dimension accuracy and mechanical strength can be HSS-printed through the optimization of printing processing parameters. A post-treatment process with vacuum impregnation and heating can further improve the surface appearance and mechanical strength. The printed PDMS parts exhibit a tensile strength of 4.24 MPa and can be healed multiple times with an efficiency of nearly 100 %. A surprising finding is that the HSS printed parts have a good ultra-broadband electromagnetic wave (EMW) absorption function, which also can be tuned by altering the printing parameters. The sub-microscopic layered structures of the inkjet-printed carbon black particles used as infrared absorbers of HSS printing were formed during the printing process, which can induce the multiple reflections and refractions of EMWs, significantly attenuating their intensity. At a specimen thickness of 28.3 mm, an effective absorption bandwidth (EAB) of 14 GHz (4–18 GHz) can be achieved. The simulation results indicate that polarization loss, conduction loss, and quarter-wavelength interference are responsible for the electromagnetic waves' energy dissipation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104860"},"PeriodicalIF":10.3,"publicationDate":"2025-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313396","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
Screw extrusion-plasticizing friction stir deposition of pure aluminum: A novel solid-state additive manufacturing approach with particulate feedstock 纯铝的螺杆挤出-搅拌摩擦塑化沉积:一种新型颗粒原料固态增材制造方法
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-16 DOI: 10.1016/j.addma.2025.104855
Licheng Sun , Jiaxun Li , Yidi Wu , Zexi Wu , Huihong Liu , Yongbing Li
{"title":"Screw extrusion-plasticizing friction stir deposition of pure aluminum: A novel solid-state additive manufacturing approach with particulate feedstock","authors":"Licheng Sun ,&nbsp;Jiaxun Li ,&nbsp;Yidi Wu ,&nbsp;Zexi Wu ,&nbsp;Huihong Liu ,&nbsp;Yongbing Li","doi":"10.1016/j.addma.2025.104855","DOIUrl":"10.1016/j.addma.2025.104855","url":null,"abstract":"<div><div>Discrete feedstock-based (powders, particles, chips) solid-state additive manufacturing (AM) processes show significant application prospects in future due to their ability to efficiently and cost-effectively produce dense and uniform equiaxed microstructures, as well as customizable feedstock compositions. However, current processes face serious challenges, such as significant flash characteristics and porosity, low geometric flexibility and spatial freedom due to mold constraints, and difficulties in achieving continuous feeding and forming. This study proposes a novel solid-state AM process called “Screw Extrusion-plasticizing Friction Stir Deposition (SEFSD)” that enables the extrusion plasticization process of pure aluminum particulate feedstock through a three-stage tapered screw tool, potentially alleviating these above issues. Based on the feeding and forming principles of SEFSD, a gradient process parameter optimization method was employed to establish the matching relationship among the parameters that ensures the sound formation of deposition layers. A deposition wall with a refined equiaxed microstructure and uniform mechanical properties in different directions was successfully fabricated through continuous, layer-by-layer reciprocating deposition. The influence of rotational speed on the microstructure and its evolution of the single-layer as well as wall depositions were revealed through EBSD analysis. Finally, the heat generation mechanism, extrusion plasticization process mechanism, and material flow behavior during SEFSD were elucidated, providing a theoretical foundation for the AM of aluminum alloys or other customized materials in future studies.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104855"},"PeriodicalIF":10.3,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144308147","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
Automated desktop wiring of micromodular electronic systems with submicron electrohydrodynamic jet printed interconnects 采用亚微米电流体动力喷射打印互连的微模块电子系统的自动化桌面布线
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-16 DOI: 10.1016/j.addma.2025.104830
Kaifan Yue , Rebecca K. Banner , Siddharth Kurup , Hubert N. Elly , Eric M. Vogel , Michael A. Filler , Kira Barton
{"title":"Automated desktop wiring of micromodular electronic systems with submicron electrohydrodynamic jet printed interconnects","authors":"Kaifan Yue ,&nbsp;Rebecca K. Banner ,&nbsp;Siddharth Kurup ,&nbsp;Hubert N. Elly ,&nbsp;Eric M. Vogel ,&nbsp;Michael A. Filler ,&nbsp;Kira Barton","doi":"10.1016/j.addma.2025.104830","DOIUrl":"10.1016/j.addma.2025.104830","url":null,"abstract":"<div><div>Wiring microscale modular electrical components into functional circuits presents significant challenges in fabricating high-resolution interconnects through contactless, maskless processes and aligning them reliably with imprecisely placed components. This work introduces an integrated, desktop-scale process flow for assembling high-performance micromodular electronic systems, by synergistically combining: (1) modularized components for seamless electrical interconnection under ambient conditions, (2) vision-assisted adaptive routing to compensate for irregular placement and orientation, and (3) electrohydrodynamic jet printing for submicron-resolution interconnect fabrication. Physical interface requirements (e.g., approach angle, overlay count, continuation length, and deviation tolerance) and process constraints (e.g., nozzle idle time, crosstalk spacing, and stage acceleration limits) are embedded directly into routing algorithms to ensure reliable, high-quality interconnect formation. Statistical evaluation demonstrates high routing feasibility and runtime efficiency across varying circuit complexities and layout conditions. Experimental validation using micromodular n-MOSFETs as building blocks successfully assembled transistor test structures and depletion-load nMOS inverters, achieving 650<!--> <!-->nm interconnect resolution, 82% device-level yield, and excellent transistor characteristics including sub-1<!--> <!-->V threshold voltages and electron mobilities exceeding 600 cm<span><math><msup><mrow></mrow><mrow><mn>2</mn></mrow></msup></math></span>/(V<span><math><mi>⋅</mi></math></span>s). This adaptive, process-aware routing framework advances the integration of additive manufacturing and modular microelectronics, paving the way for scalable, robust, and highly customizable electronic systems.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104830"},"PeriodicalIF":10.3,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322774","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 reduced-order modelling procedure for estimating residual stress and distortion in fusion-based metal AM parts 一种用于估计熔合金属增材制造零件残余应力和变形的降阶建模方法
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-16 DOI: 10.1016/j.addma.2025.104856
Zetao Jin , Pingsha Dong
{"title":"A reduced-order modelling procedure for estimating residual stress and distortion in fusion-based metal AM parts","authors":"Zetao Jin ,&nbsp;Pingsha Dong","doi":"10.1016/j.addma.2025.104856","DOIUrl":"10.1016/j.addma.2025.104856","url":null,"abstract":"<div><div>There has been a growing interest in understanding and estimating residual stress and distortion in fusion-based metal additive manufacturing (AM) to support process qualification and part certification. This paper presents a reduced-order modeling procedure that provides deeper insights into the residual stress development process and improves computational efficiency by identifying two key parameters that have controlling effects on both the final residual stress state and resulting distortion. One is the plastic zone consisting of both the deposition fusion zone and a region around it and the other is the limit elastic strain state within the plastic zone. A set of closed-form solutions is derived for estimating both the plastic zone boundary and the elastic strain limit. With both parameters being determined, a novel shrinkage strain method is presented for performing simplified finite element simulations of some typical metal AM pass depositions and 3D build scenarios. Validations are then performed by comparing the results obtained from the proposed reduced-order modeling procedure and those from detailed time-history-based thermoplasticity simulations and experimental measurements, demonstrating the effectiveness and computational efficiency of the proposed procedure. This approach provides a practical tool for rapid residual stress estimation and a more comprehensive understanding of residual stress evolution in AM processes.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104856"},"PeriodicalIF":10.3,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330505","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
Multiphysics modelling of pulsed-wave laser powder bed fusion 脉冲波激光粉末床熔合的多物理场建模
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-16 DOI: 10.1016/j.addma.2025.104833
Xueyu Bai , Chao Tang , Shubo Gao , Van-Thai Tran , Kun Zhou , Hejun Du
{"title":"Multiphysics modelling of pulsed-wave laser powder bed fusion","authors":"Xueyu Bai ,&nbsp;Chao Tang ,&nbsp;Shubo Gao ,&nbsp;Van-Thai Tran ,&nbsp;Kun Zhou ,&nbsp;Hejun Du","doi":"10.1016/j.addma.2025.104833","DOIUrl":"10.1016/j.addma.2025.104833","url":null,"abstract":"<div><div>A fundamental understanding of process–structure–property correlations is crucial for improving the performances of metallic materials produced by additive manufacturing. In the laser-based powder bed fusion (PBF-LB) process, compared to the conventional continuous-wave mode, the implementation of pulsed-wave mode has advantages such as less heat accumulation, fast cooling rates, and improved mechanical properties. However, the correlations between process parameters and as-built quality remain underexplored for pulsed-wave PBF-LB. In this study, we fill this gap by developing a computational fluid dynamics (CFD) model coupled with a cellular automaton (CA) model to investigate the influence of pulsed-wave laser on heat transfer and microstructure evolution in the melt pool. Several parameter sets, including varying frequencies and scanning speeds, were arranged to conduct numerical simulations and to print both single-track and cubic stainless steel 316L samples for experimental validation. The predicted surface roughness, melt pool depth, print defects, cellular structures, and grain structures show good agreement with experimental measurements, with a maximum relative error of 17 %. In our demonstration cases, the application of a pulsed-wave laser increases the cooling rate by at least 9 %. The cooling rate increases at an approximate rate of 0.5 K/s·Hz with decreasing laser frequency, leading to the formation of finer cellular and grain structures. This research offers new insights into the role of pulsed-wave PBF-LB in reducing process defects, controlling microstructures, and enhancing material properties.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104833"},"PeriodicalIF":10.3,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330507","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
Modeling of the high-viscosity fluid transient flow for material deposition in direct ink writing 直墨书写中材料沉积的高粘度流体瞬态流动建模
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-16 DOI: 10.1016/j.addma.2025.104836
James Lorenz , Matthew Hildner , William van den Bogert , Bizhong Zhu , Stanley Yee , Nima Fazeli , Albert J. Shih
{"title":"Modeling of the high-viscosity fluid transient flow for material deposition in direct ink writing","authors":"James Lorenz ,&nbsp;Matthew Hildner ,&nbsp;William van den Bogert ,&nbsp;Bizhong Zhu ,&nbsp;Stanley Yee ,&nbsp;Nima Fazeli ,&nbsp;Albert J. Shih","doi":"10.1016/j.addma.2025.104836","DOIUrl":"10.1016/j.addma.2025.104836","url":null,"abstract":"<div><div>A transient flow model is developed to predict the flow of high-viscosity fluid dispensing for precision direct ink writing (DIW) in additive manufacturing. Models for pump deformation and fluid friction to accurately predict flow of a high-viscosity non-Newtonian fluid through a progressive cavity pump, static mixer, and a tapered nozzle are created. Inside the progressive cavity pump, the effect of elastic deformation on modeling high-viscosity fluid transient flow is included. Based on the Characteristic Method (CM) and boundary conditions for DIW, the continuity and momentum equations are numerically solved. Using deformation modeling and CM, the transient response of the DIW system to the input volumetric flow rate is modeled for both a pipe and static mixer. The transient response of the DIW output volumetric flow rate is recorded using flow and pressure sensors and found to match the flow model. The deformation and CM models are applied to predict the swelling of a 90° corner DIW tool path from trapezoidal motion planning with accelerations from 100 to 2000 mm/s<sup>2</sup>. Predicted corner swelling is matched with the actual corner swelling via image processing of the 90° corner. The corner swelling is significant, ranging from 0.76 to 0.37 mm for a line width of 0.25 mm and a height of 0.15 mm, and represents the model’s ability to quantify print errors. This study demonstrates that the flow model can accurately predict the transient response of the DIW volumetric flow rate, which is foundational to high-fidelity flow control and compensation in precision DIW.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104836"},"PeriodicalIF":10.3,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322771","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
Influence of remelting sequence on defect generation and high-temperature mechanical properties in laser powder bed fusion of IN718 alloys 重熔顺序对IN718合金激光粉末床熔焊缺陷产生及高温力学性能的影响
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-06-14 DOI: 10.1016/j.addma.2025.104854
Fuzhong Chu , Shun Wu , Haopeng Shen , Hongyu Yan , Yaping Wu , Xianfa Xu , Hao Zhang , Aijun Huang , Ruiping Zou , Xinhua Wu , Zongyan Zhou
{"title":"Influence of remelting sequence on defect generation and high-temperature mechanical properties in laser powder bed fusion of IN718 alloys","authors":"Fuzhong Chu ,&nbsp;Shun Wu ,&nbsp;Haopeng Shen ,&nbsp;Hongyu Yan ,&nbsp;Yaping Wu ,&nbsp;Xianfa Xu ,&nbsp;Hao Zhang ,&nbsp;Aijun Huang ,&nbsp;Ruiping Zou ,&nbsp;Xinhua Wu ,&nbsp;Zongyan Zhou","doi":"10.1016/j.addma.2025.104854","DOIUrl":"10.1016/j.addma.2025.104854","url":null,"abstract":"<div><div>The laser multiple melting strategy is commonly employed in the laser powder bed fusion (LPBF) process to reduce porosity levels and optimize mechanical properties. However, the influence of the temporal sequences of energy input has received limited attention, despite their potential to control defect generation and microstructure evolution. Therefore, in this work, two specific remelting sequences were investigated, referred to here as the preheating strategy (a low-energy first scan followed by a high-energy second scan) and the remelting (a high-energy first scan followed by a low-energy second scan) strategy. The findings indicated that defect generation and surface roughness are highly sensitive to variations in the remelting sequences, demonstrating that samples subjected to the remelting strategy exhibit significantly lower porosity levels. The simulations revealed that the defects in the preheating strategy originate from insufficient melting between layers and rough top surfaces caused by inadequate melt pool flow. Additionally, the samples subjected to the remelting strategy exhibited superior high-temperature mechanical properties, with an ultimate tensile strength of 959.7 MPa, yield strength of 792.0 MPa, and outstanding elongation of 23.1 % along the building direction after heat treatment. This enhancement was attributed to the increased geometrically necessary dislocation density induced by fine carbides measuring 0.9 μm. This study offers valuable insights into the laser multiple melting process, providing a foundation for future research aimed at optimizing mechanical properties in the LPBF process.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104854"},"PeriodicalIF":10.3,"publicationDate":"2025-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144308148","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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