Additive manufacturing最新文献

{"title":"Exploring the tempering behaviour of additively manufactured high-alloy tool steel using synchrotron X-ray and neutron techniques","authors":"Huayue Zhang ,&nbsp;Xuan Zhang ,&nbsp;Diego Alba Venero ,&nbsp;Jun-Sang Park ,&nbsp;Andrew Chihpin Chuang ,&nbsp;Gareth Douglas ,&nbsp;Xuezhen Cao ,&nbsp;Alexander Carruthers ,&nbsp;Ed Pickering ,&nbsp;Bo Chen","doi":"10.1016/j.addma.2026.105219","DOIUrl":"10.1016/j.addma.2026.105219","url":null,"abstract":"<div><div>Post-processing heat treatment provides a critical pathway toward the commercialisation of additively manufactured (AM) S390 high-speed steel, which is a representative high-alloy tool steel employed in precision manufacturing, offering up to 1.5 times longer tool life and over 20% higher cutting speeds compared to conventional grades. In this study, the phase evolution of AM S390 steel during heat treatment, with particular emphasis on carbide precipitation behaviour, was systematically investigated using a combination of synchrotron X-ray and neutron techniques. The metastable M₂C carbides were found to dissolve during austenitisation, while the stable primary carbides MC and M₆C experienced coarsening with an average size increase of about 60 nm after just 2 min of tempering. Moreover, the austenite lattice parameters reduced from 3.618 to 3.608 Å within the first 10 min of tempering, suggesting carbon depletion in the steel matrix was likely associated with the formation of secondary carbides. This interpretation was substantiated by small-angle scattering results, which revealed the presence of nanoscale precipitates with a volume fraction of 3.1% after 60 min of tempering. These microstructural evolutions collectively accounted for the observed peak hardness of 921 HV. Furthermore, a comparative analysis of synchrotron and neutron small-angle scattering data highlighted the complementary strengths of each technique, offering critical insight into their suitability for characterising nanoscale features in AM high-alloy steels.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"123 ","pages":"Article 105219"},"PeriodicalIF":11.1,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147805255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards gradient multimaterial toolpath generation for direct ink writing with connected fermat spirals","authors":"M.R. Sage,&nbsp;R. Telles,&nbsp;H.R. Galvan,&nbsp;N.A. Dudukovic,&nbsp;A.E. Gongora,&nbsp;C.C. Cook,&nbsp;V.S. Vuppuluri,&nbsp;A.M. Golobic,&nbsp;B.L. Walton,&nbsp;D.T. Nguyen","doi":"10.1016/j.addma.2026.105214","DOIUrl":"10.1016/j.addma.2026.105214","url":null,"abstract":"<div><div>This work describes advances towards a reproducible, parametrically defined algorithm for generating graded multimaterial toolpaths for direct ink writing. Expanding on the existing Fermat space-filling algorithm and coupling with image-driven processing techniques, we demonstrate the fabrication of multimaterial structures. Here, material composition is encoded within toolpaths by parsing hue values from a multi-colored image. By performing dynamic velocity compensation based on local curvature and Euclidean distance filtering, internal voids are mitigated while optimizing print fidelity. The work opens new avenues for designing complex toolpaths with locally programmable composition.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"123 ","pages":"Article 105214"},"PeriodicalIF":11.1,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147805398","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Property optimization through full-part thermal history control in laser powder bed fusion additive manufacturing","authors":"William J. Frieden Templeton ,&nbsp;Jacob A. McCauley ,&nbsp;Mikhail Khrenov ,&nbsp;Shawn Hinnebusch ,&nbsp;Miguel Pena ,&nbsp;Lin Shao ,&nbsp;Albert C. To ,&nbsp;Sneha Prabha Narra","doi":"10.1016/j.addma.2026.105205","DOIUrl":"10.1016/j.addma.2026.105205","url":null,"abstract":"<div><div>Metal additive manufacturing (AM) enables rapid, on-demand production of parts ranging from prototypes to mission-critical components. However, achieving high-strength metallic components often relies on post-processing heat treatments for many alloys, adding time and cost. For instance, in Alloy 718, a common high-strength alloy used in laser powder bed fusion (L-PBF) AM, strengthening primarily relies on precipitation hardening during an aging heat treatment. Importantly, heating during the deposition process can also elevate temperatures into the precipitation hardening range, causing in-situ aging. Thus, this work leverages the elevated temperatures during fabrication to enable controlled in-situ aging that increases as-fabricated hardness and improves uniformity. For the first time, this is realized through full-part thermal history control during L-PBF fabrication of Alloy 718. The method embeds an experimentally fitted material hardening model in an axisymmetric lumped-layer thermal simulation to predict in-situ part hardness. The resulting thermal and hardness dynamics model is then used in conjunction with a trajectory optimization algorithm to determine time-varying laser power and baseplate temperature profiles. These optimized process conditions target a uniform hardness of 450 HV in an inverted cone geometry by intentionally inducing in-situ precipitation hardening. The planned trajectory increased the mean hardness and improved uniformity from <span><math><mrow><mn>374</mn><mo>±</mo><mn>41</mn></mrow></math></span> HV to <span><math><mrow><mn>439</mn><mo>±</mo><mn>29</mn></mrow></math></span> HV without a separate post-process aging heat treatment. These results are repeatable within 8% and establish a path to integrate microstructural aging control directly into the deposition step to achieve high-strength metallic components without an additional post-process heat treatment step.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"123 ","pages":"Article 105205"},"PeriodicalIF":11.1,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147805401","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Geometrical effects on the measured neutron residual stress in additively manufactured cold spray AA6061","authors":"C. Jacob Williamson ,&nbsp;Christopher M. Roper ,&nbsp;Jeffrey R. Bunn","doi":"10.1016/j.addma.2026.105218","DOIUrl":"10.1016/j.addma.2026.105218","url":null,"abstract":"<div><div>Aluminum cold spray additive builds were made with varying wall widths and geometries to explore the effects of build geometry on residual stress development in the additively sprayed material. Deposition rates of over 750 g/hr were achieved without any cracking or delamination of the additively manufactured components. Neutron residual stress measurements revealed a maximum tensile residual stress of 41 MPa at the interface of the substrate and a maximum compressive residual stress of −35 MPa in the cold sprayed material. While there was not found to be significant residual stress changes between the cold sprayed walls, the cold sprayed cylinder had varying residual stress throughout the diameter with the outer diameter having a higher tensile residual stress than the interior. The low residual stress and minimal geometrical dependency demonstrate further part size is possible without concerns for component failure in AA6061. The application of common coating residual stress models to full scale additive builds is evaluated and discussed. The lack of residual stress evolution was studied by in-situ coating property measurement that revealed that the deposition stress of the AA6061 sprays reduced with increased layer thickness. This study provides insight into the evolution of residual stress in cold spray additive components and how both the mechanics and material responses differ from coatings.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"123 ","pages":"Article 105218"},"PeriodicalIF":11.1,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147805400","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"RBF-PoroNet: A differentiable implicit framework for automated optimization of porous structures via a self-adaptive RBF neural network","authors":"Hao Du ,&nbsp;Shengfa Wang ,&nbsp;Liang Du,&nbsp;Yu Jiang,&nbsp;Jiangbei Hu,&nbsp;Zhongxuan Luo,&nbsp;Na Lei","doi":"10.1016/j.addma.2026.105192","DOIUrl":"10.1016/j.addma.2026.105192","url":null,"abstract":"<div><div>Triply periodic minimal surfaces (TPMSs) have recently emerged as effective templates for designing porous structures, showing significant potential in diverse applications. However, the automated and efficient optimized design of these complex structures remains a considerable challenge. To address this, we propose a fully differentiable method for the modeling and optimization of TPMS-based porous structures. The framework, <em>RBF-PoroNet</em>, introduces a self-adaptive Radial Basis Function (RBF) neural network (SA-RBFNN) for implicit multiscale modeling. The SA-RBFNN facilitates the dynamic and automatic optimization of RBF neuron parameters, including center positions, influence radii, and weights. This provides superior local control, enabling the neural network to adapt to physical fields and effectively optimize local topological (porosity) and geometric (thickness) characteristics. Furthermore, a pruning-and-seeding strategy is incorporated to dynamically manage the RBF neuron distribution, thereby enhancing the network’s representational power. Critically, the parameterized design approach is fully implicit and differentiable. By leveraging the automatic differentiation (AutoDiff) capabilities of the SA-RBFNN, sensitivity information for objective and constraint functions is computed directly, obviating the need for manual, explicit derivations. This not only enables a fully automated design optimization workflow but also renders the framework highly extensible to complex multi-objective and multi-constraint physical problems. The effectiveness and robustness of the proposed framework are validated through extensive numerical experiments, including structural and thermal compliance minimization, and multiphysics problems.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"123 ","pages":"Article 105192"},"PeriodicalIF":11.1,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147805399","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Temperature control in powder bed fusion of metals via inverse-designed laser beam shapes","authors":"Vijaya Holla ,&nbsp;Jonas Grünewald ,&nbsp;Richard Off ,&nbsp;Ruihang Dai ,&nbsp;Philipp Kopp ,&nbsp;Katrin Wudy ,&nbsp;Stefan Kollmannsberger","doi":"10.1016/j.addma.2026.105206","DOIUrl":"10.1016/j.addma.2026.105206","url":null,"abstract":"<div><div>Modern beam shaping technology provides much flexibility in customizing laser-based powder bed fusion of metals (PBF-LB/M). This work demonstrates how to control both the melt pool shape and the temperature distribution within a melt pool using beam shaping. It introduces several new laser beam shapes by gradient-based optimization of the temperature field obtained by a conduction-based simulation. The goal is to produce rectangular melt tracks with different levels of temperature control inside the melt pool. To account for machine capabilities and scan strategy-related constraints directly in the optimization, three beam shape parametrizations are employed: axi-symmetric, laterally symmetric, and unconstrained. The new beam shapes are experimentally reproduced using a highly flexible beam shaping setup based on spatial light modulators. The differences in melt track dimensions generally stay well below 20<!--> <!-->% compared to micrograph images. The simulated surface temperatures agree well with the measurements performed by multispectral imaging (MSI), a novel technique for obtaining absolute melt pool temperature maps. Relaxing the beam shape constraints results in a closer match to the optimization target, highlighting the advantages of flexible beam shaping. Imposing constraints on the temperature of the melt pool during optimization significantly reduces evaporation as observed in the MSI measurements. The experimental validation of such a diverse set of inverse-designed laser beam shapes demonstrates that numerical optimization can guide advanced beam shaping for improved process control in PBF-LB/M. The presented methodology, including the optimization code, is made available under an MIT license.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"123 ","pages":"Article 105206"},"PeriodicalIF":11.1,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147805266","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"MAM-PhyGNN: A Physics-Hardcoded Graph Neural Network for fast and accurate thermal simulation in metal additive manufacturing","authors":"Huaqing Zhang,&nbsp;Zhibin Zhao,&nbsp;Xingwu Zhang,&nbsp;Xuefeng Chen","doi":"10.1016/j.addma.2026.105208","DOIUrl":"10.1016/j.addma.2026.105208","url":null,"abstract":"<div><div>Accurate and efficient prediction of transient thermal fields in metal additive manufacturing (MAM) is critical for process control, but a persistent trade-off exists between fidelity and speed. High-fidelity solvers require hours of computation for a single simulation, while existing surrogates like Physics-Informed Neural Networks (PINNs) often fail in long-term predictions due to their topology-agnostic nature and soft physical constraints. To overcome these limitations, this paper introduces the Metal Additive Manufacturing Physics-Hardcoded Graph Neural Network (MAM-PhyGNN), a topology-aware Graph Neural Network (GNN) that architecturally embeds physical laws directly onto the unstructured simulation mesh. While the framework is designed for general MAM processes, its performance is validated on a challenging Laser Powder Bed Fusion (LPBF) case study. The framework formulates the heat transfer problem on an unstructured mesh as a dynamical system on a graph. Its core innovation is a dual-branch operator architecture: a deterministic, non-learnable Laplace Block hardcodes the fundamental physics of heat diffusion, providing a robust stability anchor, while a data-driven GNN learns a data-driven correction for complex nonlinear dynamics arising from temperature-dependent material properties and boundary conditions. In the LPBF case study, MAM-PhyGNN demonstrated exceptional performance. It remained stable through a 1000-step autoregressive long-term prediction on unseen data, maintaining a Pearson correlation of 0.98 with the ground truth. Crucially, MAM-PhyGNN achieved this with a computational speedup of approximately 850x over the high-fidelity solver, reducing simulation time from over 50 min to just 3.6 s. This work demonstrates that by architecturally embedding fundamental physics within a topology-aware GNN, it is possible to create surrogate models that are simultaneously fast, accurate, and stable for long-duration MAM simulations, thereby opening a viable pathway towards real-time digital twins for process optimization.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"122 ","pages":"Article 105208"},"PeriodicalIF":11.1,"publicationDate":"2026-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147748787","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fabrication of high-boron stainless steels via cored wire arc additive manufacturing: Processing characteristics, solidification behavior and mechanical performance","authors":"Wenjun Zhang ,&nbsp;Hao Yi ,&nbsp;Huajun Cao ,&nbsp;Han Zhou ,&nbsp;Jun Luo","doi":"10.1016/j.addma.2026.105212","DOIUrl":"10.1016/j.addma.2026.105212","url":null,"abstract":"<div><div>Borated stainless steels (BSS) are structural-functional integrated materials with significant application potential in the nuclear industry. To address the limitations of conventional manufacturing routes in fabricating large and complex BSS components, this study proposes a novel wire arc additive manufacturing (WAAM) approach based on cored wires. By introducing 304/FeB cored wires with different B contents (0.5 wt%, 1.0 wt% and 2.0 wt%), the long-standing technical bottleneck associated with the fabrication and processing of high-boron BSS solid wires was effectively overcome, enabling stable deposition and dense formation of high-B BSS under WAAM conditions. On this basis, the evolution of processing characteristics induced by variations in B content, the associated microstructural control mechanisms, and their synergistic effects on strength and ductility were systematically elucidated. The results indicate that the introduction of B via cored wires transforms the metal transfer mode from small-droplet spray transfer to large-droplet contact transfer, leading to a more dispersed arc energy distribution and an evolution of the molten pool morphology from a “deep and narrow” profile to a “shallow and wide” one. By significantly reducing the liquidus temperature and promoting boride precipitation, increasing B content exerts a strong influence on solidification behavior, shifting the solidification mode from δ/γ-dominated solidification to γ + M₂B eutectic-dominated solidification. Furthermore, B addition markedly enhances microhardness and strength through grain refinement and boride-induced dislocation accumulation; however, with increasing B content, the high fraction of continuously distributed brittle borides and eutectic structures leads to a deterioration in ductility. Overall, cored wire arc additive manufacturing (CWAAM) enables dense fabrication and compositional control of high-B stainless steels, providing a new processing route for the manufacture of large nuclear-grade BSS components.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"122 ","pages":"Article 105212"},"PeriodicalIF":11.1,"publicationDate":"2026-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147748788","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Partition laser assembling technique","authors":"Yueqiang Zhu ,&nbsp;Lijing Zhong ,&nbsp;Ce Zhang ,&nbsp;Baiqiang Yang ,&nbsp;Jianrong Qiu ,&nbsp;Chen Zhang ,&nbsp;Kaige Wang ,&nbsp;Jintao Bai ,&nbsp;Wei Zhao","doi":"10.1016/j.addma.2026.105119","DOIUrl":"10.1016/j.addma.2026.105119","url":null,"abstract":"<div><div>The advancement of micro/nanofabrication techniques with high throughput, efficiency, and flexibility is critical for fields like integrated photonics, biosensing, and medical diagnostics. This study presents Partition Laser Assembling (PLA), a novel laser technique for fabricating complex micro/nanostructures akin to puzzle pieces. By dividing the target patterns described by scalable vector graphics into partitions, any structures in each partition can be fabricated via structured lights as variable “light stamp” through spatial light modulation. Unlike traditional direct laser writing, PLA eliminates reliance on mechanical components, avoiding step-like artifacts and ensuring smoother fabrication of complex trans-scale structures. By seamlessly assembling basic shapes, PLA achieves intricate structures like micro artworks and meta-lens with unmatched precision and resolution. Leveraging two-photon fabrication, PLA guarantees high resolution and structural integrity, positioning it as a potential transformative tool for nanoscale 3D printing. With applications spanning research and industry, PLA paves the way for advanced optical devices, micro/nano-fabrications, and next-generation manufacturing technologies.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"119 ","pages":"Article 105119"},"PeriodicalIF":11.1,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146173073","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Assessment of the powder spreading parameters for non-spherical polymeric powder used in powder bed fusion process: A DEM simulation study","authors":"Sina Zinatlou Ajabshir ,&nbsp;Colin Hare ,&nbsp;Diego Barletta ,&nbsp;Massimo Poletto","doi":"10.1016/j.addma.2026.105099","DOIUrl":"10.1016/j.addma.2026.105099","url":null,"abstract":"<div><div>In this study, a Discrete Element Method (DEM)-based model was developed to simulate the powder spreading process in Powder Bed Fusion (PBF) using non-spherical Polyamide 6 (PA6) powder. Various spreading tools—including sharp blades, curved round blades, flat blades, a roller, and a rigid rake-style brush—were tested at three spreading speeds (3, 30 and 90 mm/s) to evaluate their impact on powder bed characteristics. Key metrics such as packing fraction (<span><math><mi>η</mi></math></span>), compressive force distribution, spreading density ratio, and surface roughness were analysed within a defined area of interest. Particle velocity distribution and the vertical-to-horizontal velocity ratio were investigated to understand particle dynamics and settling behaviour during spreading. Results revealed that curved round tools, especially the horizontal round blade and roller, delivered denser, smoother, and more uniform powder layers. In contrast, sharp and flat blades caused poor compaction and elevated roughness, especially at higher speeds. The brush and 135° blade showed moderate but consistent performance. These findings emphasize the importance of tool geometry–speed interaction and provide insight for optimizing spreading strategies in PBF processes.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"119 ","pages":"Article 105099"},"PeriodicalIF":11.1,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146173074","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}