Additive manufacturing最新文献

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Online thermal profile prediction for large format additive manufacturing: A hybrid CNN-LSTM based approach 大型增材制造热剖面在线预测:一种基于CNN-LSTM的混合方法
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-18 DOI: 10.1016/j.addma.2025.104882
Lu Liu , Feng Ju , Seokpum Kim
{"title":"Online thermal profile prediction for large format additive manufacturing: A hybrid CNN-LSTM based approach","authors":"Lu Liu ,&nbsp;Feng Ju ,&nbsp;Seokpum Kim","doi":"10.1016/j.addma.2025.104882","DOIUrl":"10.1016/j.addma.2025.104882","url":null,"abstract":"<div><div>Large format additive manufacturing (LFAM) is an advanced 3D printing technique that efficiently fabricates large-scale components through a layer-by-layer extrusion and deposition process. Accurate surface layer temperature monitoring is essential to prevent manufacturing failures and ensure final product quality. Traditional physics-based offline approaches for simulating thermal behavior are often inefficient and complex, posing challenges on real-time, in-situ monitoring. To address this, we propose a data-driven hybrid CNN-LSTM model to predict sequential thermal images of arbitrary length using real-time infrared thermal imaging. In this approach, a Convolutional Neural Networks (CNN) is trained offline to capture spatial features, reduce dimensional complexity, and enhance time efficiency, while a stacked Long Short-Term Memory (LSTM) is applied online to capture temporal information for improved prediction of future thermal behavior in subsequent printing layers. Model performance is evaluated using MSE, SSIM, and PSNR metrics and is benchmarked against stacked LSTM and convolutional LSTM models, demonstrating superior accuracy and applicability. Additionally, to mitigate noise from moving extruders and gantry backgrounds in thermal images, a fine-tuned semantic segmentation model is impletemented offline to extract printing geometry, enabling precise temperature tracking along the tool path for further thermal analysis. The frameworks developed in this study significantly advance temperature monitoring, thermal analysis, and in-situ manufacturing control for LFAM, bridging the gap between theoretical modeling and practical application.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104882"},"PeriodicalIF":10.3,"publicationDate":"2025-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711462","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
Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites 激光增材制造金属基金刚石复合材料中相变诱导膨胀的残余应力消除
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104883
Yuan Gao , Wei Zhang , Yingbo Peng , Qingyuan Ma , Yuxuan Chen , Jiarong Chen , Xiaohan Du , Yongjian Fang , Yali Zhang , Yong Liu , Shoufeng Yang
{"title":"Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites","authors":"Yuan Gao ,&nbsp;Wei Zhang ,&nbsp;Yingbo Peng ,&nbsp;Qingyuan Ma ,&nbsp;Yuxuan Chen ,&nbsp;Jiarong Chen ,&nbsp;Xiaohan Du ,&nbsp;Yongjian Fang ,&nbsp;Yali Zhang ,&nbsp;Yong Liu ,&nbsp;Shoufeng Yang","doi":"10.1016/j.addma.2025.104883","DOIUrl":"10.1016/j.addma.2025.104883","url":null,"abstract":"<div><div>While laser powder bed fusion (LPBF) has emerged as a transformative approach for fabricating geometrically intricate metal matrix-diamond composites, the interfacial integrity of these components is critically undermined by residual stress originating from rapid thermal cycling and severe thermal expansion mismatch between diamond reinforcements and metallic binders. Existing mitigation strategies—including process parameter optimization, ductile phase incorporation, and graded CTE transition layers—fail to eliminate interfacial microcracks due to inherent limitations in thermal strain compensation. Herein, we propose a phase-transformation-driven stress-relief strategy by engineering a W/Co bilayer coating on diamond particles within a CuSn10 matrix. The tungsten interlayer ensures interfacial integrity through carbide bonding and thermal buffering, while the cobalt overlayer exploits HCP→FCC phase transformation during LPBF thermal cycling to generate compensatory volumetric expansion, effectively counteracting thermal contraction-induced residual stress. The W-Co coated diamond/CuSn10 composite achieved a bending strength of 159 MPa (90 % higher than Ti-Cu coated counterparts) and a friction coefficient of 0.25, with complete suppression of interfacial cracking under cyclic wear. Multiscale characterization revealed that Co-induced twinning and dynamic recrystallization synergistically enhanced interfacial toughness, while molecular dynamics simulations quantitatively validated the stress-neutralization mechanism through lattice mismatch analysis. This work establishes a transformative \"expansion-compensation\" paradigm for residual stress regulation in MMCs, advancing the design of crack-resistant diamond composites for high-stress additive manufacturing applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104883"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144595416","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 test artifact for rapid evaluation of material ductility variation in laser powder bed fusion 一种用于快速评估激光粉末床熔合过程中材料延展性变化的测试伪仪
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104878
Dinh Son Nguyen, Shane Garner, Albert C. To
{"title":"A test artifact for rapid evaluation of material ductility variation in laser powder bed fusion","authors":"Dinh Son Nguyen,&nbsp;Shane Garner,&nbsp;Albert C. To","doi":"10.1016/j.addma.2025.104878","DOIUrl":"10.1016/j.addma.2025.104878","url":null,"abstract":"<div><div>This work proposes a test artifact design to evaluate the ductility variation of laser powder bed fusion (LPBF) processed materials by measuring the length of cracking specifically designed to occur along a plane in the artifact in the presence of residual stress. The test artifact consists of an inverted L-shaped cantilever structure whose fixed end is anchored to the build plate and the free overhanging beam end is attached to a support structure. By designing the beam/support interface to have a half-V notch, the residual stress generated in the LPBF process can be concentrated to cause cracking to occur along the interface. It is found that the crack lengths measured in test artifacts printed in Inconel 718 using different process parameters have a decaying exponential relationship with elongations measured in tensile testing of notched tensile specimens, having an R-squared value of 0.9365 in the regression. This strong correlation indicates that an increase in crack length in a test artifact means smaller notch ductility in the printed material. To demonstrate its application, the test artifact is used to evaluate the impact of moisture in feedstock powders on the ductility of the printed materials. Our experimental result shows that the test artifacts printed using dry powders consistently have shorter cracks and hence higher ductility than those printed using powders with 70 % humidity for a wide range of process parameters. This work demonstrates the potential of using the proposed test artifact to evaluate the print quality of an LPBF build in an efficient and cost-effective way.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104878"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144564040","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 mechanistic study on environment gas in laser powder bed fusion 激光粉末床熔合中环境气体的机理研究
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104886
Zhongshu Ren , Samuel J. Clark , Lin Gao , Kamel Fezzaa , Tao Sun
{"title":"A mechanistic study on environment gas in laser powder bed fusion","authors":"Zhongshu Ren ,&nbsp;Samuel J. Clark ,&nbsp;Lin Gao ,&nbsp;Kamel Fezzaa ,&nbsp;Tao Sun","doi":"10.1016/j.addma.2025.104886","DOIUrl":"10.1016/j.addma.2025.104886","url":null,"abstract":"<div><div>A variety of protective or reactive environmental gases have recently gained growing attention in laser-based metal additive manufacturing (AM) technologies due to their unique thermophysical properties and the potential improvements they can bring to the build processes. However, much remains unclear regarding the effects of different gas environments on critical phenomena in laser AM, such as rapid cooling, energy coupling, and defect generation. Through simultaneous high-speed synchrotron x-ray imaging and thermal imaging, we identify distinct effects of two environmental gases in laser AM and gained a deeper understanding of the underlying mechanisms. Compared to the commonly used protective gas, argon, it is found that helium has a negligible effect on cooling the part. However, helium can suppress unstable keyholes by decreasing effective energy absorption, thus mitigating keyhole porosity generation and reducing pore size under certain processing conditions. These observations provide guidelines for the strategic use of environmental gases in laser AM to produce parts with improved quality.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104886"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654354","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
Effect of relative humidity on powder flowability and powder bed formation in additive manufacturing 增材制造中相对湿度对粉末流动性和粉末床形成的影响
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104862
Rafael Kleba-Ehrhardt , Ben Jastram , Christoph Heinze , Anzhelika Gordei , Aleksander Gurlo , David Karl
{"title":"Effect of relative humidity on powder flowability and powder bed formation in additive manufacturing","authors":"Rafael Kleba-Ehrhardt ,&nbsp;Ben Jastram ,&nbsp;Christoph Heinze ,&nbsp;Anzhelika Gordei ,&nbsp;Aleksander Gurlo ,&nbsp;David Karl","doi":"10.1016/j.addma.2025.104862","DOIUrl":"10.1016/j.addma.2025.104862","url":null,"abstract":"<div><div>Powder flowability is essential for powder-based additive manufacturing processes such as powder bed fusion, binder jetting, or directed energy deposition. Powder flow is the prerequisite for uniform powder distribution and delivery, which decisively influences the product's final material behavior and mechanical properties. Despite considerable advances in the field of additive manufacturing (AM), the identification of reliable methods for characterizing powder flow behavior that correlates with the powder spreading conditions in an AM machine remains an ongoing challenge. In this study, five conventional AM powders (H282, IN738, WC17, H13 and TiAl) were examined using standard and advanced flowability measurements under various storage conditions. The flowability results were correlated with powder spreadability using a self-built powder distribution machine and a process monitoring system for evaluating the powder bed. Given that moisture is a significant factor in the deterioration of flowability and that permanent control of humidity during storage can only be achieved at considerable expense and effort and is not feasible for all laboratories, this study also investigates the influence of humid storage conditions on flowability measurements and powder distribution. The findings of this study demonstrate that the powders exhibit disparate performance outcomes when subjected to the selected flowability testing methodologies. In general, the H282, WC17 and H13 powders demonstrate noticeably better flowability compared to the IN738 and TiAl in the majority of the evaluated measurements. Nevertheless, the distribution of powder in a manner that produces homogeneous powder layers with high packing density is achievable with all powders in the dry state, while the impact of elevated moisture storage conditions can be considerable and might result in agglomeration, which can markedly disrupt the distribution process. For the TiAl powder, with its specific low density, a significant influence of moisture on the powder flow can be reported.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104862"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703829","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
JEMA-SINDYc: End-to-end Control using Joint Embedding Multimodal Alignment in Directed Energy Deposition JEMA-SINDYc:在定向能沉积中使用关节嵌入多模态对准的端到端控制
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104888
João Sousa , Benedikt Brandau , Rico Hemschik , Roya Darabi , Armando Sousa , Luís Paulo Reis , Frank Brueckner , Ana Reis
{"title":"JEMA-SINDYc: End-to-end Control using Joint Embedding Multimodal Alignment in Directed Energy Deposition","authors":"João Sousa ,&nbsp;Benedikt Brandau ,&nbsp;Rico Hemschik ,&nbsp;Roya Darabi ,&nbsp;Armando Sousa ,&nbsp;Luís Paulo Reis ,&nbsp;Frank Brueckner ,&nbsp;Ana Reis","doi":"10.1016/j.addma.2025.104888","DOIUrl":"10.1016/j.addma.2025.104888","url":null,"abstract":"<div><div>Bringing AI models from digital to real-world applications presents significant challenges due to the complexity and variability of physical environments, often leading to unexpected model behaviors. We propose a framework that learns to translate images into control actions by modeling multimodal real-time data and system dynamics. This end-to-end controller offers enhanced explainability and robustness, making it well suited for complex manufacturing processes. This end-to-end framework differs from traditional approaches that rely on manually engineered features by learning complex relationships directly from raw data. Labels are only required during training to define the observable feature to be optimized. This adaptability significantly reduces development time and enhances scalability across varying conditions. This approach was tested in the Directed Energy Deposition (L-DED) process, a laser-based metal additive manufacturing technique that produces near-net-shape parts with exceptional energy efficiency and flexibility in both geometry and material selection. L-DED is inherently complex, involving multiphysics interactions, multiscale phenomena, and dynamic behaviors, which make modeling and optimization difficult. Effective control is crucial to ensure part quality in this dynamic environment. To address these challenges, we introduce Joint Embedding Multimodal Alignment with Sparse Identification of Nonlinear Dynamics for control (JEMA-SINDYc). It combines an image-based JEMA monitoring model, which predicts the melt pool size using only the on-axis sensor with labels provided by the off-axis camera, and dynamic modeling using SINDYc, which acts as a World Model by capturing system dynamics within the embedding space. Together, these components enable the development of an advanced controller trained via Behavioral Cloning. This approach improves part quality by minimizing porosity and reducing deformation. Thin-walled cylindrical parts were produced to validate and compare this approach with other control strategies, including both open-loop and JEMA-PID. This framework improves the reliability of AI-driven manufacturing and enhances control of complex industrial processes, potentially enabling wider adoption of the process.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104888"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711463","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
Non-uniform deformation response of Ti6Al4V/TiC functionally graded material under different composition gradient designs by direct energy deposition 不同成分梯度设计下Ti6Al4V/TiC功能梯度材料的非均匀变形响应
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104885
Jiahao Zhang , Leilei Wang , Kai Zhao , Chaoqi Qi , Yunbo Hao , Yanxiao Zhang , Longxiang Sun , Xiaohong Zhan
{"title":"Non-uniform deformation response of Ti6Al4V/TiC functionally graded material under different composition gradient designs by direct energy deposition","authors":"Jiahao Zhang ,&nbsp;Leilei Wang ,&nbsp;Kai Zhao ,&nbsp;Chaoqi Qi ,&nbsp;Yunbo Hao ,&nbsp;Yanxiao Zhang ,&nbsp;Longxiang Sun ,&nbsp;Xiaohong Zhan","doi":"10.1016/j.addma.2025.104885","DOIUrl":"10.1016/j.addma.2025.104885","url":null,"abstract":"<div><div>Metal/ceramic functionally graded materials (FGMs) have garnered considerable attention due to their capability to improve heat resistance while maintaining excellent mechanical strength. However, the non-uniform spatial gradient distribution of ceramic particles makes the deformation and fracture behavior of FGMs very complicated during static loading. Optimizing the composition gradient designs to enhance mechanical properties and fracture toughness while maintaining heat resistance has been a longstanding puzzle. Herein, three ceramic composition gradient transition methods including convex function mode, linear mode and concave function mode were designed, and Ti6Al4V/TiC FGMs were fabricated by laser direct energy deposition (LDED), with TiC mass fraction gradually changing from 0 % to 30 %. To reveal the non-uniform deformation response and fracture mechanism under different composition gradient modes, comprehensive analyses of microstructure characterization, in-situ DIC tensile measurement and fracture morphology of as-deposition Ti6Al4V/TiC FGMs were conducted. As a result, the strain along the central axis exhibits a wavy non-uniform gradient distribution during the longitudinal tensile process, while low-gradient layers with good plastic deformation capability alleviate the stress concentration of high-gradient layers through localization bands. Compared with the convex function mode, the tensile strength of concave function transition mode along with the Z-direction exhibits a distinct increase of 201 MPa, while the elongation improves by 1.11 %, which reflects the synergistic improvement in strength and ductility. This is due to the increased occurrence of plastic deformation in more areas, resulting in a stronger gradient synergistic strengthening effect. Meanwhile, the stress intensity factor of the crack tip under different gradient transition modes was obtained through integral transformation and dual integral equation solving, further verifying the above conclusion theoretically. The fractures tend to occur in high-gradient ceramic regions, primarily due to the fracture of unmelted particles leading to premature failure. This work emphasizes the importance of nonlinear composition design strategies in the development of metal/ceramic functionally graded materials.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104885"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654355","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
On the mitigation of the fiber breakage in material extrusion based additive manufacturing of carbon fiber reinforced polymer composites 基于增材制造的碳纤维增强聚合物复合材料挤压过程中纤维断裂的缓解研究
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104896
Pengyue Guo , Jiang Wu , Xizhong An , Zongyan Zhou , Dongmin Yang , Hao Zhang
{"title":"On the mitigation of the fiber breakage in material extrusion based additive manufacturing of carbon fiber reinforced polymer composites","authors":"Pengyue Guo ,&nbsp;Jiang Wu ,&nbsp;Xizhong An ,&nbsp;Zongyan Zhou ,&nbsp;Dongmin Yang ,&nbsp;Hao Zhang","doi":"10.1016/j.addma.2025.104896","DOIUrl":"10.1016/j.addma.2025.104896","url":null,"abstract":"<div><div>A coupled computational fluid dynamics and discrete element method (CFD-DEM) model has been developed to characterize multiphase flow interactions between non-Newtonian fluid and flexible fiber in material extrusion additive manufacturing (MEX AM). The breakage mechanisms of carbon fibers in conventional MEX AM process are revealed through systematic investigation of the multiphase flow dynamics between carbon fibers and molten polymer during extrusion deposition. The results demonstrate that the stable fiber structure with high contact density arising from constraints of boundary wall and confined space serves as a critical factor inducing substantial mechanical forces that leads to fiber deformation or even breakage. Two optimization cases for the deposition of long carbon fiber reinforced composites have been developed, i.e., enlarging raster height and adjusting nozzle feeding angles (<em>NFA</em>) to mitigate substantial mechanical forces on fibers. The optimization efficacy has also been quantitatively evaluated through critical performance parameters including fiber deformation magnitude, fiber breakage content and fiber orientation distribution. It is found that adjusting <em>NFA</em> yield excellent performance in concomitantly mitigating fiber breakage while improving the fiber orientation. Finally, experimental observations confirm the effectiveness of the adjusting <em>NFA</em>. This study establishes numerical framework for the development and optimization of MEX AM systems for printing long discontinuous carbon fiber reinforced polymer composites, providing insights for mitigating fiber breakage while maintaining uniformity of the fiber orientation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104896"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144679997","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
Development and characterization of Ti-6Al-4V/C103 functionally graded material using LP-DED 利用LP-DED技术制备Ti-6Al-4V/C103功能梯度材料
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104895
D.A. Ariza , K.I. Watanabe , E. Arrieta , M. Madigan , L.E. Murr , B. McWilliams , S. Tin , F. Medina
{"title":"Development and characterization of Ti-6Al-4V/C103 functionally graded material using LP-DED","authors":"D.A. Ariza ,&nbsp;K.I. Watanabe ,&nbsp;E. Arrieta ,&nbsp;M. Madigan ,&nbsp;L.E. Murr ,&nbsp;B. McWilliams ,&nbsp;S. Tin ,&nbsp;F. Medina","doi":"10.1016/j.addma.2025.104895","DOIUrl":"10.1016/j.addma.2025.104895","url":null,"abstract":"<div><div>This paper explores the fabrication and characterization of functionally graded Ti-6Al-4V–C103 thin wall specimens produced using Laser Powder Directed Energy Deposition (LP-DED). Thin walls were successfully manufactured with three distinct transition steps: 100 wt%, 50 wt%, and 25 wt%. Geometrical analysis demonstrated printing fidelity and consistent build quality across experimental setups. EDS validated the compositional gradients along the build direction, while discrepancies between expected and measured compositions were attributed to the presence of unmelted C103 particles. Quantitative analysis revealed that the area fraction of unmelted particles increased with higher C103 content. SEM and EBSD analyses revealed microstructural evolution from coarse columnar to finer equiaxed grains with increasing C103. Dendritic width analysis further revealed that increasing C103 content led to the refinement of Ti-rich regions and the coarsening of Nb-rich regions within the graded deposition zones. Microhardness measurements exhibited a nonlinear trend with composition, peaking at 425 HV for 25 wt% C103 potentially due to possible presence of ω-phase in this graded region, while further addition of C103 lead to a decrease on the overall microhardness.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104895"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144687560","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
AI for AM in zirconia ceramic vat photopolymerization: A machine learning approach to stabilising slurry suspension and maximizing dimensional accuracy of the 3D print process 用于氧化锆陶瓷缸光聚合增材制造的人工智能:一种稳定浆液悬浮液和最大化3D打印过程尺寸精度的机器学习方法
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-07-05 DOI: 10.1016/j.addma.2025.104893
Fatih Tarak , Leah Okoruwa , Basar Ozkan , Farzaneh Sameni , Gerald Schaefer , Ehsan Sabet
{"title":"AI for AM in zirconia ceramic vat photopolymerization: A machine learning approach to stabilising slurry suspension and maximizing dimensional accuracy of the 3D print process","authors":"Fatih Tarak ,&nbsp;Leah Okoruwa ,&nbsp;Basar Ozkan ,&nbsp;Farzaneh Sameni ,&nbsp;Gerald Schaefer ,&nbsp;Ehsan Sabet","doi":"10.1016/j.addma.2025.104893","DOIUrl":"10.1016/j.addma.2025.104893","url":null,"abstract":"<div><div>The stability of ceramic suspensions and the dimensional accuracy of green bodies are critical factors influencing both printing process and the quality of the final component. Therefore, assessing dispersant agents and stability is essential during the suspension development stage. A novel power-law-based stability assessment approach was developed and employed for evaluating dispersant performance. The conventional stability testing method is based on visual monitoring and requires prolonged durations, whereas the newly introduced technique demonstrated significantly greater accuracy within a much shorter timeframe, which is in complete accordance with the conventional stability testing methods. Consequently, among six dispersants examined, DisperBYK-145 was selected based on the results of both evaluation methods. Additionally, the dimensional errors of green-body zirconia ceramics were analysed considering printing parameters and slurry additives. Optimal parameters were determined as 5.5 mW/cm² light intensity, 0.1 wt% photoinitiator, and 4 wt% white pigment (TiO<sub>2</sub>) to minimise geometric errors. Given its significance, supervised machine learning algorithms were employed to predict dimensional errors based on the selected parameters. An artificial neural network model with 12 hidden nodes exhibited the best performance, aside from averaging-based ensembles. This study introduces a stability assessment method and machine learning models to predict the dimensional accuracy of zirconia ceramic suspensions in vat-photopolymerisation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104893"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144679961","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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