Additive manufacturing最新文献

{"title":"On-line inspection of lattice structures and metamaterials via in-situ imaging in additive manufacturing","authors":"Bianca Maria Colosimo ,&nbsp;Federica Garghetti ,&nbsp;Marco Grasso ,&nbsp;Luca Pagani","doi":"10.1016/j.addma.2024.104538","DOIUrl":"10.1016/j.addma.2024.104538","url":null,"abstract":"<div><div>As advanced production capabilities are moving towards novel types of geometries as well as higher customization demands, a new and more efficient approach for process and part qualification is becoming an urgent need in industry. The layerwise nature of additive manufacturing (AM) potentially allows anticipating qualification tasks in-line and in-process, aiming at reducing the time and costs devoted to post-process inspections, enabling at the same time an early detection of defects since their onset stage. Such opportunity is particularly attractive in the presence of highly complex shapes like lattice structures or metamaterials, which have been increasingly investigated for industrial adoption in various sectors, aiming to achieve enhanced mechanical properties and innovative functionalities. This paper presents a novel methodology to inspect the geometry of lattice structures while the part is being built. The method is specifically designed to tackle the natural variability affecting layerwise images gathered in laser powder bed fusion. To this aim, it combines the segmentation of in-situ powder bed images of solidified layers with a data modelling approach to synthesize the 3-D shape of each unit cell into a 1-D profile representation. Such low-dimensional representation is suitable to quickly detect undesired distortions that may have a detrimental impact on final quality and performance. By using post-process X-ray computed tomography as ground truth reference, this study shows the effectiveness of the proposed approach for in-line inspection, opening a novel and cost-efficient way to address complex shape qualification for lattice structures in AM.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104538"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142663890","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":"Green synthesis of soybean oil-derived UV-curable resins for high-resolution 3D printing","authors":"Xinqi Wang ,&nbsp;Xincin Cai ,&nbsp;Jiwen Hu ,&nbsp;Jiayi Li ,&nbsp;Ruixiang Zhou ,&nbsp;Shudong Lin","doi":"10.1016/j.addma.2024.104543","DOIUrl":"10.1016/j.addma.2024.104543","url":null,"abstract":"<div><div>With the rapid development of 3D printing technology, it has penetrated various fields. In the context of global oil resource scarcity and increasing emphasis on environmental protection, developing high-performance bio-based 3D printing materials is a crucial means to overcome the limitations of petroleum resources and achieve sustainability. This paper proposed a \"green\" development method for high-performance, sunlight-curable vat photopolymerization 3D printing resins based on soybean oil and itaconic anhydride. Utilizing bio-based itaconic anhydride to replace traditional petroleum-based materials, a novel UV-curable prepolymer, IPESO, with 80.37 % high bio-carbon (<em>C</em>_bio) content and no volatile substances was synthesized. Simultaneously, a series of resins, IPESO-ETPTAx, with high mechanical and thermal properties were obtained utilizing ethoxylated trimethylolpropane triacrylate (ETPTA) as a diluent. Samples printed with IPESO-ETPTA40 achieve a high resolution of 40 µm on the xy-axis. This advanced material has broad application prospects in the field of vat photopolymerization 3D printing and provides a new strategy for the development of plant oil-based vat photopolymerization 3D printing resins.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104543"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142663892","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":"An additively manufactured heat-resistant Al-12Si alloy via introducing stable eutectic engineering","authors":"Jianying Wang ,&nbsp;Hailin Yang ,&nbsp;M.W. Fu","doi":"10.1016/j.addma.2024.104523","DOIUrl":"10.1016/j.addma.2024.104523","url":null,"abstract":"<div><div>The poor microstructural stability of crack-free Al alloys synthesized via additive manufacturing typically possesses poor heat resistance. In this work, a novel heat-resistant Al-12Si-1.5Ni-2.0Fe (wt%) alloy was fabricated by additive manufacturing, in which tensile strength reaches 271 MPa and 98.1 MPa at 300 ºC and 400 ºC, respectively. Calculation and electron microscopy characterizations show that Fe/Ni segregation with high partition coefficients and low diffusion rates delivers a high thermally stability, thus providing a robust pinning force to inhibit the broken-up of Si eutectics and a solid barrier for dislocation motion at elevated temperatures. In addition to providing weight reduction by substituting Steel, Ti, and Ni-based alloys at 200–450 °C, the adoption of low-cost and stable eutectic engineering reduces the economic barriers to additive manufacturing applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104523"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142592606","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 microscale cellular automaton method for solid-state phase transformation of directed energy deposited Ti6Al4V","authors":"Feiyu Xiong ,&nbsp;Yanping Lian ,&nbsp;Chinnapat Panwisawas ,&nbsp;Jiawei Chen ,&nbsp;Ming-jian Li ,&nbsp;Anwen Liu","doi":"10.1016/j.addma.2024.104517","DOIUrl":"10.1016/j.addma.2024.104517","url":null,"abstract":"<div><div>Directed energy deposition is a promising additive manufacturing technology that fabricates complex geometries by fusing feed material layer-by-layer. However, the formation mechanism of the directed energy deposited Ti6Al4V solid-state phase transformation process, which is crucial for understanding the process-structure–property relationship, has remained unclear. In this study, a microscale cellular automaton method is proposed to simulate the microstructure evolution process for Ti6Al4V, specifically the <span><math><mrow><mi>β</mi><mo>→</mo><mi>α</mi><mo>/</mo><msup><mrow><mi>α</mi></mrow><mrow><mo>′</mo></mrow></msup></mrow></math></span> phase transformation process within a few <span><math><mi>β</mi></math></span> grains. The method is further integrated with the mesoscale cellular automaton method, which predicts the prior <span><math><mi>β</mi></math></span> grain structure, the solid-state phase transformation kinetics model for the prediction of the phase volume fractions, and the finite volume method, which is used for the thermal-fluid flow modeling, providing a temperature field to the former. The integrated numerical framework not only links the thermal history with the phase volume fractions but also provides the columnar <span><math><mi>β</mi></math></span> grain structures and acicular <span><math><mrow><mi>α</mi><mo>/</mo><msup><mrow><mi>α</mi></mrow><mrow><mo>′</mo></mrow></msup></mrow></math></span> grain structures in satisfying agreement with the available experimental observation. Moreover, the predictions shed some light on the formation mechanism of the hierarchical <span><math><mrow><mi>α</mi><mo>/</mo><msup><mrow><mi>α</mi></mrow><mrow><mo>′</mo></mrow></msup></mrow></math></span> structure and their particular clusters. The influence of the cooling rate on the <span><math><mrow><mi>α</mi><mo>/</mo><msup><mrow><mi>α</mi></mrow><mrow><mo>′</mo></mrow></msup></mrow></math></span> grain formation is illustrated via the three-layer case simulation. The findings on the formation mechanism of <span><math><mrow><mi>α</mi><mo>/</mo><msup><mrow><mi>α</mi></mrow><mrow><mo>′</mo></mrow></msup></mrow></math></span> are beneficial in tailoring the microstructure of Ti6Al4V for excellent mechanical properties in directed energy deposited Ti6Al4V.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104517"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142663902","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":"Role of powder morphology in liquid phase sintering of binder jet additively fabricated WC–Co composite","authors":"K.N. Chaithanya Kumar ,&nbsp;Mohan Sai Ramalingam ,&nbsp;Sameehan S. Joshi ,&nbsp;Shashank Sharma ,&nbsp;Narendra B. Dahotre","doi":"10.1016/j.addma.2024.104520","DOIUrl":"10.1016/j.addma.2024.104520","url":null,"abstract":"<div><div>The present study explored the computational analysis of capillary forces and capillary pressure experienced by the liquid present between particles of various morphologies during liquid phase sintering of a binder jet additively fabricated WC–10 wt% Co composite. An integrated two-particle computational approach was adopted for morphologies gradually transitioning from spherical to cubical. The capillary forces depended on factors such as curvature of liquid meniscus, volume of liquid present between two neighboring particles, and changes in solid–liquid and liquid–vapor contact areas, which were influenced by the particle morphology. The results indicated that capillary forces increased as particle morphology changed from spherical to non-spherical, while increased particle separation led to a reduction in capillary force. Despite increased particle separation, the overall trend in effect of particle morphology on capillary force remained consistent. Additionally, a probability density function based on Rayleigh distribution was used to represent particle separation distances in a real system and variations in coordination number due to different particle morphologies and separation distances were considered. This model allowed estimation of overall effect of particle morphology on capillary force and capillary pressure in realistic systems. The model-based predictions confirmed the experimental observations of severely limited sintering in binder jet additively fabricated WC–10 wt% Co composite containing spherical particles compared to that containing the particles of irregular morphologies. This study provides valuable insights into the mechanics of capillary forces, capillary pressure, and their role in liquid phase sintering, with potential applications in the design and optimization of components of any material system produced using any additive manufacturing process involving liquid phase sintering.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104520"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142663998","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":"Enhancing thermal conductivity of AlN ceramics via vat photopolymerization through refractive index coupling and oxygen fixation","authors":"Maohang Zhang ,&nbsp;Chen Zhao ,&nbsp;Jiaming Bai ,&nbsp;Zhaoyang Hu ,&nbsp;Jiawei Cai ,&nbsp;Zhirui Zhang ,&nbsp;Mingli Qin ,&nbsp;Xuanhui Qu ,&nbsp;Baicheng Zhang","doi":"10.1016/j.addma.2024.104522","DOIUrl":"10.1016/j.addma.2024.104522","url":null,"abstract":"<div><div>Despite the growing development of ceramic fabrication by vat photopolymerization (VP), major gaps remain in application. Particularly in the case of VP-printed aluminum nitride (AlN) ceramic, the thermal conductivity is still below 170 W·m⁻¹·K⁻¹, a critical benchmark for efficient heat dissipation. To address this challenge, here we prepared an AlN slurry with high curing thickness through RI coupling between liquid-solid phase, and took into account of the rheological property under high solid loading. Full dense AlN green bodies with solid loading up to 50 vol% were successfully printed. Aiming to to tackle the degradation of thermal conductivity issue caused by oxygen increment of AlN via VP, we systemically studied the form of oxygen in AlN preparation processes. Through the sintering optimization, the oxygen element from the hydrolysis of AlN surface was fixated in the sintering aid Y₂O₃. Eventually, without any special process control or additional treatment, the final sintered AlN ceramics prepared by the developed slurry present a full densification and the highest thermal conductivity (up to 187.9 W∙m⁻¹∙K⁻¹) of any known additive manufactured ceramics.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104522"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142571351","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":"Dynamic formation of gradient structure by microparticle impact — A crystal plasticity material point method study","authors":"Cong Chen,&nbsp;TianYuan Guan,&nbsp;Xianheng Wang,&nbsp;Yan Liu","doi":"10.1016/j.addma.2024.104518","DOIUrl":"10.1016/j.addma.2024.104518","url":null,"abstract":"<div><div>Metallic materials with unique microstructure can achieve desirable strength-ductility synergy. However, effectively fabricating and precisely controlling microstructure distribution in metals remain challenging. Microparticle impact, the key process of cold spray technique, can lead to a gradient structure in the particle, which may also serve as a promising additive manufacturing technology. To investigate the dynamic formation mechanism of heterogeneous microstructure and its significant influencing factors, the crystal plasticity material point method (CPMPM) is developed, especially for microstructure formation under a high strain rate and large deformation. Our work provides a quantitative analysis of evolution of structural gradient during impact. It is found that decreasing grain size can afford a larger structural gradient and there is negligible influence on the compression ratio of particles. It suggests that microstructure distribution can be tailored by optimizing the impact process without influencing vertical deformation of particles.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104518"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142663898","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":"Abnormal aging behaviors induced by high-density dislocations for an ultra-high-strength titanium alloy prepared by laser-directed energy deposition","authors":"Junwei Yang ,&nbsp;Haibo Tang ,&nbsp;Yansong Zhang ,&nbsp;Yihe Zhang ,&nbsp;Yanyan Zhu ,&nbsp;Bingsen Liu ,&nbsp;Zhuodan Cui","doi":"10.1016/j.addma.2024.104559","DOIUrl":"10.1016/j.addma.2024.104559","url":null,"abstract":"<div><div>Additively manufactured high-strength titanium alloys generally possess equal strength and lower plasticity compared to wrought alloys owing to the different microstructures formed in the aging treatment. To examine the formation mechanism of these microstructures, an ultra-high-strength titanium alloy TB18(Ti-4.2Al-5V-5Cr-5Mo-1Nb) was prepared by laser direct energy deposition (LDED) and forging respectively, and the aging behaviors and microstructures were characterized and compared in depth. It is found that during aging, the precipitation of the LDEDed alloy is 1–2 h earlier than that of the wrought alloy, and precipitates primarily form at the reticular sub-grain boundaries. Fine short-rod α laths then form inside the sub-grains due to the inhibition of the reticulations. The sub-grain boundaries in LDEDed alloy are generated due to the local deformation and recovery of the inter-dendritic zone rich of Cr and O atoms and show high thermal stability in the solution treatment, which differs from that of the wrought alloys. These boundaries possess a dislocation density several times higher than that of the inner-grain zones and promote the prior precipitation of α laths with Type 2 orientations at the early stage of aging. In the tensile test of the aged alloys, the dislocations in the LDEDed alloy pile up at the α/β interface, which can cause stress concentration and damage the plasticity.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104559"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142664055","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 customized microneedle with high 3D capability and high structural precision","authors":"Zhaolun Chen ,&nbsp;Zhi Wang ,&nbsp;Lan Jiang ,&nbsp;Weina Han ,&nbsp;Zhuo Zhao ,&nbsp;Libo Ren ,&nbsp;Lingtao Zhang ,&nbsp;Jianhui Jiang ,&nbsp;Pei Zuo","doi":"10.1016/j.addma.2024.104509","DOIUrl":"10.1016/j.addma.2024.104509","url":null,"abstract":"<div><div>Advanced 3D fabrication techniques are essential for the processing of 3D devices, which mainly focusing on excellent 3D fabrication capability and high structural precision. Although 3D printing technology allows for the creation of complex 3D structures with extensive customization, it faces notable challenges in achieving precise micro/nanostructures within materials due to incomplete resin curing bonds. Here, we propose integrating projection micro-stereolithography (PμSL) with femtosecond (fs) laser Bessel beam drilling to create 3D structures with advanced customization, precise structures (including size accuracy and aspect ratio), and efficient processing. Starting with the drilling process using Bessel beams, we have achieved micro-holes with a diameter of approximately 1μm and the aspect ratio reached 1017:1 on 3D printed items by regulating the transparency and elasticity of the products. Furthermore, we have applied this technology to produce tailor-made microneedles, including slanted-tip microneedles and porous microneedles, demonstrating its ability for extensive, efficient micro-hole processing with a peak drilling speed of 200,000 holes per second. This technology offers an innovative approach to creating three-dimensional devices with intricate cavity structures, and its impressive processing capabilities suggest potential for broad industrial implementation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104509"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142571324","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":"Impact of melt pool geometry variability on lack-of-fusion porosity and fatigue life in powder bed fusion-laser beam Ti–6Al–4V","authors":"Justin P. Miner ,&nbsp;Austin Ngo ,&nbsp;Christian Gobert ,&nbsp;Tharun Reddy ,&nbsp;John J. Lewandowski ,&nbsp;Anthony D. Rollett ,&nbsp;Jack Beuth ,&nbsp;Sneha Prabha Narra","doi":"10.1016/j.addma.2024.104506","DOIUrl":"10.1016/j.addma.2024.104506","url":null,"abstract":"<div><div>Powder bed fusion-laser beam (PBF-LB) parts experience a significant decline in fatigue performance when process-induced defects are present. In this work, a decline in 4-point bend fatigue life was observed in PBF-LB Ti–6Al–4V coupons fabricated at constant power with increasing scanning velocity and which underwent subsequent stress relief and surface machining. Specifically, the presence of pores that resemble lack-of-fusion (LoF) and a decline in fatigue life were observed at scanning velocities lower than that expected from prior published work. It was hypothesized that this unexpected presence of LoF pores resulted from melt pool geometry variability that was not considered in prior work when the LoF criterion was implemented. Further, these pores can be small in size and infrequent in their occurrence when the melt pool geometry variability is not severe. Such sparse pores are challenging to characterize using conventional 2D characterization methods. This work leverages tall and narrow coupon geometry and high-resolution X-ray micro computed tomography (X-<span><math><mi>μ</mi></math></span>CT) to capture LoF porosity. The results show that a modified melt pool overlap-based LoF criterion considering melt pool geometry variability captures the unexpected occurrence of LoF pores observed in X-<span><math><mi>μ</mi></math></span>CT. In addition, the LoF percent metric displays a strongly negative correlation with fatigue performance. The insights from this work provide guidance on characterizing melt pool geometry variability across scan lines to systematically evaluate processing parameters that generate LoF pores, which, in turn, could lower fatigue performance.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"95 ","pages":"Article 104506"},"PeriodicalIF":10.3,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142592605","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}