Additive manufacturing最新文献

{"title":"User-enabled installation qualification method for laser-based powder bed fusion of metals (PBF-LB/M) machine scanner subsystem","authors":"B.L. Valadez Mesta ,&nbsp;H.C. Taylor ,&nbsp;J. Mireles ,&nbsp;D. Borup ,&nbsp;R.B. Wicker","doi":"10.1016/j.addma.2025.104694","DOIUrl":"10.1016/j.addma.2025.104694","url":null,"abstract":"<div><div>Installation qualification for laser-based powder bed fusion of metals (PBF-LB/M) machines is challenging due to the extensive labor, time, and financial costs required by current standards. These standards demand long builds, expensive equipment, and specialized expertise, primarily focusing on mechanical properties, which complicates the analysis of subsystem performance where attention may be required. Consequently, this makes machine installation qualification both inaccessible and inconsistent for typical PBF-LB/M users. This study presents a new methodology for installation qualification of PBF-LB/M scanner subsystem hardware and control software that addresses these challenges, empowering users to qualify their systems. A plate melt setup using a commercially available 25.4-millimeter square stainless-steel plate was designed to characterize scanner performance through a series of “pass” or “attention required” tests assessing laser and scanner delays, scanner acceleration, dimensional accuracy, and slicer file software interpretation. The method was then applied on four PBF-LB/M machines, with one plate scanned per laser under machine original equipment manufacturer (OEM) recommended build conditions. Laser power and scan speed parameters were specified to be the same for the four machines. The results show notable variations in scanner delays, scanner momentum control, and path planning file preparation that impact the results of the laser welding. A simple example of the machine-to-machine variability was captured when three out of the four machines tested were unable to produce dimensionally accurate 1 mm diameter circles. In addition, all machines required attention during numerous tests aimed at slicer file software interpretation, which highlights critical gaps in the physical and programmable scanner control of PBF-LB/M machines. Overall, this study demonstrates the potential of the proposed plate melt method to assess scanner subsystem performance without the challenges of current standards.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"100 ","pages":"Article 104694"},"PeriodicalIF":10.3,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143388346","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":"Autonomous exploration of the PBF-LB parameter space: An uncertainty-driven algorithm for automated processing map generation","authors":"Giulio Masinelli ,&nbsp;Lucas Schlenger ,&nbsp;Kilian Wasmer ,&nbsp;Toni Ivas ,&nbsp;Jamasp Jhabvala ,&nbsp;Chang Rajani ,&nbsp;Amirmohammad Jamili ,&nbsp;Roland Logé ,&nbsp;Patrik Hoffmann ,&nbsp;David Atienza","doi":"10.1016/j.addma.2025.104677","DOIUrl":"10.1016/j.addma.2025.104677","url":null,"abstract":"<div><div>Powder bed fusion with laser beam (PBF-LB) is a promising additive manufacturing technique that enables the production of complex geometries with fine resolution and material efficiency, offering significant design freedom and material versatility. However, its broader adoption is limited by the need for extensive parameter tuning, which is often dependent on the specific machine, as well as the material and batch of powder used. In this paper, we introduce a novel algorithm that autonomously identifies melting regimes in an unsupervised manner using optical data acquired from photodiodes — specifically optical emission and reflection. This method eliminates the need for labeled data and achieves an <em>F1</em>-score of 89.2% across both materials tested: Ti–6Al–4V and 316L. Additionally, we propose an uncertainty-driven iterative strategy designed to efficiently generate processing maps by performing experiments based on uncertainty. This approach enables up to a 67% reduction in the number of required experiments, significantly lowering the associated costs of parameter exploration, while sustaining a maximum performance reduction of only 8.88% compared to traditional full factorial designs. Our results demonstrate the potential of this method to streamline PBF-LB optimization, making it more feasible for industrial applications and paving the way for its broader adoption.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104677"},"PeriodicalIF":10.3,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143394593","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multimodal automated fabrication with concrete: Case study and structural performance of ribbed CFRP-reinforced concrete ceilings","authors":"Sven Engel,&nbsp;Josef Hegger,&nbsp;Martin Classen","doi":"10.1016/j.addma.2025.104689","DOIUrl":"10.1016/j.addma.2025.104689","url":null,"abstract":"<div><div>A significant amount of concrete in building construction can be conserved by implementing ribbed concrete ceilings. However, their fabrication remains challenging due to the extensive manual labor required for formwork production. This paper introduces a modular ribbed ceiling system that integrates topology-optimized design principles with advanced digital manufacturing techniques. The system consists of two key components: a point-supported slab-column connection module (SCCM) and an inter-column support strip module (SSM). To enable efficient production, an innovative multimodal automated fabrication approach is presented, combining robotic casting with 3D concrete printing and reinforcement integration. In this method, slender, bi-directionally oriented ribs are 3D printed onto a robotically pre-cast concrete plate, with protruding CFRP reinforcement guiding rib placement. This process enables the production of freeform, material-efficient ceilings with high geometric flexibility. Structural tests, including bending, shear, and punching shear assessments, were conducted to evaluate the load-bearing behavior of the system. The study demonstrates the feasibility of automated multimodal manufacturing techniques for producing optimized ribbed CFRP-reinforced concrete structures, paving the way for more sustainable and resource-efficient construction.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104689"},"PeriodicalIF":10.3,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143403382","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Expanding the print parameter window for continuous line formation in binder jet additive manufacturing through pre-wetting of the powder bed","authors":"Jacob E. Lawrence,&nbsp;Madi P. Lawrence,&nbsp;Nathan B. Crane","doi":"10.1016/j.addma.2025.104693","DOIUrl":"10.1016/j.addma.2025.104693","url":null,"abstract":"<div><div>Binder Jet (BJ) additive manufacturing creates parts by binding powder particles together with inkjet-printed droplets. BJ shows promise as an industrial process, but poor final part properties often limit applications. Prior work has shown that there is significant powder rearrangement from the kinetic impact of binder droplets that may contribute to the formation of defects in the final parts. This study builds upon previous research by studying the effects of print parameters, including droplet spacing and inter-arrival time, and droplet parameters, including droplet volume, velocity, and satellite formation, on the formation of lines. A new method, using an adhesive film, for extracting single-layer parts is described which allows for study of smaller, more sensitive primitives. The results show that pre-wetting the powder bed expands the feasible design space and allows printing with larger droplet spacings, smaller inter-arrival times, and slower droplet velocities. This enables up to 50 % faster print rates and the potential for reduced powder relocation due to droplet impact. Results from this work can be used to inform the selection of optimal process parameters and the design of new BJ systems to produce higher quality parts.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"100 ","pages":"Article 104693"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143270071","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":"In-situ controller autotuning by Bayesian optimization for closed-loop feedback control of laser powder bed fusion process","authors":"Barış Kavas ,&nbsp;Efe C. Balta ,&nbsp;Michael R. Tucker ,&nbsp;Raamadaas Krishnadas ,&nbsp;Alisa Rupenyan ,&nbsp;John Lygeros ,&nbsp;Markus Bambach","doi":"10.1016/j.addma.2025.104641","DOIUrl":"10.1016/j.addma.2025.104641","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) additive manufacturing (AM) traditionally relies on static parameter assignment in an open loop, which can lead to defects when faced with complex thermal histories and process variability. Closed-loop control offers a promising alternative that can enhance stability and mitigate defects. However, controller performance relies heavily on precise parameter tuning, a process that is typically manual and system-specific. This study employs Bayesian Optimization (BO) as an automated, sample-efficient method for tuning in-layer controllers in LPBF, leveraging the repetitive nature of the process for either online (in-process) or offline (pre-process) tuning. We experimentally apply BO to tune an in-layer PI controller to modulate laser power, assessing its performance on wedge geometries prone to overheating. The results show that BO significantly reduces overheating, outperforming uncontrolled settings. Notably, this study presents the first microstructural analysis of parts produced with in-layer controlled tuning, identifying lack-of-fusion porosities caused by the controller’s corrective adjustments. In summary, BO demonstrates strong potential for automated controller tuning in LPBF, with implications for broader applications in AM, suggesting a path towards more adaptive and robust control across diverse machines and materials.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104641"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137308","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":"Microstructure tailoring for crack mitigation in CM247LC manufactured by powder bed fusion – Laser beam","authors":"Ahmed Fardan ,&nbsp;Andrea Fazi ,&nbsp;Jakob Schröder ,&nbsp;Tatiana Mishurova ,&nbsp;Tobias Deckers ,&nbsp;Giovanni Bruno ,&nbsp;Mattias Thuvander ,&nbsp;Andreas Markström ,&nbsp;Håkan Brodin ,&nbsp;Eduard Hryha","doi":"10.1016/j.addma.2025.104672","DOIUrl":"10.1016/j.addma.2025.104672","url":null,"abstract":"<div><div>Tailored microstructures in powder bed fusion – laser beam (PBF-LB) can aid in crack mitigation of non-weldable Ni-base superalloys such as CM247LC. This study explores the effect of a range of stripe widths from 5 mm down to 0.2 mm to control solidification cracking, microstructure, and residual stress in CM247LC manufactured by PBF-LB. The decrease in melt pool depth with the reduction in stripe width from 5 to 0.2 mm promoted the &lt; 100 &gt; crystallographic texture along the build direction. The crack density measurements indicated that there is an increase from 0.62 mm/mm² (5 mm) to 1.71 mm/mm² (1 mm) followed by a decrease to 0.33 mm/mm² (0.2 mm). Atom probe tomography investigations at high-angle grain boundaries revealed that there is higher Hf segregation in 0.2 mm stripe width when compared to 5 mm. This indicates that the cracking behavior is likely influenced by the grain boundary segregation which in turn is dependent on melt pool shape/size and mushy zone length indicated by accompanying simulations. Residual stress, measured by X-ray diffraction, decreased from 842 MPa (5 mm) to 690 MPa (1 mm), followed by an abnormal rise to 842 MPa (0.7 mm) and 875 MPa (0.5 mm). This residual stress behavior is likely associated with the cracks acting as a stress relief mechanism. However, the 0.2 mm stripe width exhibited the lowest stress of 647 MPa, suggesting a different mechanism for stress relief, possibly due to re-melting. These findings highlight the critical role of stripe width as a scan strategy in PBF-LB processing of crack-susceptible alloys.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104672"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137445","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multicell interlacing IWP lattice metamaterials with superior low-frequency vibration isolation performance fabricated by laser powder bed fusion","authors":"Mengying Chen ,&nbsp;Di Lin ,&nbsp;Lei Yang ,&nbsp;Cong Zhang ,&nbsp;Hui Qiao ,&nbsp;Lei Kang ,&nbsp;Liu He ,&nbsp;Yunlong Ren ,&nbsp;Chunze Yan ,&nbsp;Yusheng Shi","doi":"10.1016/j.addma.2025.104681","DOIUrl":"10.1016/j.addma.2025.104681","url":null,"abstract":"<div><div>Lattice metamaterials have been proven to be effective for vibration reduction and isolation, but they do not perform well in the low-frequency bands. In this work, inspired by traditional Chinese Taoist concept, multiple IWP-type TPMS lattices are interlaced with each other to achieve low-frequency vibration isolation. The normal IWP lattice (NIL), double interlacing IWP lattice (DIIL), and quadruple interlacing IWP lattice (QIIL) are designed and prepared by the laser powder bed fusion (LPBF) technique. The frequency response and vibration isolation performance of the TPMS lattice metamaterials are analyzed through the dynamic vibration testing and shaft system vibration testing, respectively. The results reveal that the multicell interlacing IWP lattice metamaterials have better low-frequency vibration isolation performance than body centered cubic (BCC) and normal IWP lattices. With the increase of the interlacing-cell number, IWP lattice metamaterials have a better vibration isolation effect in the low-frequency band. Notably, the 316 L QIIL metamaterials have superior vibration isolation performance with the maximum vibration level difference of 47.44 dB. This study offers a new perspective for the application of lattice metamaterials in low-frequency vibration reduction and isolation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104681"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137892","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":"A detailed study of pre-heating effects in electron beam melting powder bed fusion process","authors":"E. Landau ,&nbsp;Y.I. Ganor ,&nbsp;D. Braun ,&nbsp;M. Strantza ,&nbsp;M.J. Matthews ,&nbsp;E. Tiferet ,&nbsp;G. Ziskind","doi":"10.1016/j.addma.2025.104656","DOIUrl":"10.1016/j.addma.2025.104656","url":null,"abstract":"<div><div>Metal-based additive manufacturing processes, such as powder bed fusion with electron beam (PBF-EB) process, also referred to as electron beam melting (EBM), can produce high-density parts with minimal residual stresses due to the uniform and coherent preheating of the powder bed. However, understanding and controlling the multiple stages of preheating is required to enable the production of high-quality, consistent parts of various materials. This work presents a large-scale, multi-layer, three-dimensional numerical analysis focused on studying the preheating stages for predicting thermal history during the PBF-EB process. The model follows a continuous multi-stage cyclic process, that incorporates all the main stages of the PBF-EB process for 316 L stainless steel. This includes the gradual deposition of a new powder layer, the first and second preheating levels of the powder bed, and the energy deposition during melting (excluding the actual melt-pool behavior simulation). The model employs an adaptive time-scaling approach that automatically adjusts the energy deposition for each solution time-increment. This allows for localized changes in time-resolution over an otherwise computationally expensive multi-layer procedure. The material property variations are also taken into account, with an emphasis on the subtle irreversible changes in powder effective thermal conductivity after the two requisite preheating stages of the powder bed. This effect is studied using simplified conductivity models from the literature for partially sintered powder, validated by a dedicated experiment and numerical simulation. The large-scale model is then used to estimate the actual temperatures during first and second preheating levels for 316 L steel, which is not yet fully supported commercially for PBF-EB. Model predictions are corroborated by experiments, using and analyzing IR images, taken at the completion of each layer by the machine’s built-in infrared camera. The current model also incorporates a qualitative assessment for the effects of conductivity change during pre-heating, as well as evaluates the applicability of the time-scaling approach.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104656"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137444","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Ti2AlNb microlattices via 3D ink-extrusion printing and sintering of precursor powders","authors":"Ya-Chu Hsu,&nbsp;David C. Dunand","doi":"10.1016/j.addma.2025.104673","DOIUrl":"10.1016/j.addma.2025.104673","url":null,"abstract":"<div><div>Microlattices are 3D-extruded with inks containing a blend of precursor Ti + Nb + TiAl₃ powders, and their struts are then densified through a series of heat treatments to eliminate organic binder, sinter porosity, and achieve compositional Ti₂AlNb homogeneity. The phase evolution of an as-printed filament (representative of a microlattice strut) is examined using <em>in-situ</em> X-ray diffraction, revealing a series of steps: (i) TiAl₃ decomposition, starting at 710 °C and ending at 780 °C, to form TiAl; (ii) Nb and Al interdiffusion, initiating at 820 °C, accompanied by the formation of Nb₂Al and Nb₃Al phases; (iii) the α→β Ti phase transformation and (iv) Ti₃Al formation, starting at 870 °C. Fully-homogenized Ti₂AlNb microstructures with low residual porosity, comprising a B2 matrix and two types of α₂ and O (orthorhombic) secondary phases, are achieved after sintering at 1300 °C for 5 h. Under compression at 1000 °C, microlattices with struts ∼400 µm in diameter show a good combination of yield strength (138 MPa) and ductility (48 %, with no catastrophic failure). Because of their low density (∼3 g/cm³) and high strength at high temperatures, Ti₂AlNb microlattices exhibit a specific strength higher than existing Ni- and Co-based superalloy microlattices above 900 °C. Finally, a complex Ti₂AlNb prototype heat exchanger is created <em>via</em> layer-by-layer ink-extrusion and sintering.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104673"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137894","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":"Structured, sintered, and rastered strategies for fluid wicking in additively manufactured heat pipes","authors":"Cameron Noe ,&nbsp;Swapnil Morankar ,&nbsp;Alexander S. Rattner ,&nbsp;Alexander Potts ,&nbsp;Zachary Goode ,&nbsp;Tatiana El Dannaoui ,&nbsp;John R. Sherbondy ,&nbsp;Nikhilesh Chawla ,&nbsp;William Sixel ,&nbsp;Sven Bilén ,&nbsp;Stephen Lynch ,&nbsp;Chad Westover ,&nbsp;Dhruv Bhate","doi":"10.1016/j.addma.2025.104669","DOIUrl":"10.1016/j.addma.2025.104669","url":null,"abstract":"<div><div>This work compares three different strategies for creating wicking structures with Laser Powder Bed Fusion (LPBF) for use in additively manufactured monolithic heat pipes: (i) structured wicks, fabricated with intentionally designed lattice geometries, (ii) sintered wicks, created by partially melting and fusing the metal powder used in the LPBF manufacturing processes, and (iii) rastered wicks, created by modifying the laser raster infill grid parameters to generate fluid flow paths. The study was performed in three phases. Phase I examined wick fluid absorption, porosity, volumetric energy density, and wick manufacturability for a broad range of production parameters. A subset of promising wick production approaches was identified for fluid rate-of-rise characterization in Phase II. One high performing wick production approach was selected for each strategy for detailed characterization in Phase III. In this last phase, the wick candidates were studied through X-ray microtomography, scanning electron microscope (SEM) imaging, porosity analysis, and computational simulations of directional sample permeability and thermal conductivity (using geometry data from X-ray imaging). Advantages and disadvantages of each wick design approach were explored in the context of both manufacturability using LPBF, and wick performance. Of the three strategies, the rastered approach was found to have the most potential for applications in future additively manufactured heat pipe designs due to its wide LPBF manufacturability process window and its relatively high permeability with low directional dependence.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104669"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137446","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}