Additive manufacturing最新文献

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High precision 3D contour detection for laser powder bed fusion in-process layerwise monitoring using active contours driven by multiple energy 利用多能量驱动的主动轮廓线进行激光粉末床熔合过程分层监测的高精度三维轮廓检测
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-12 DOI: 10.1016/j.addma.2025.104761
Yuze Zhang , Pan Zhang , Tan Cheng , Hui Li , Kai Zhong , Zhongwei Li , Yusheng Shi
{"title":"High precision 3D contour detection for laser powder bed fusion in-process layerwise monitoring using active contours driven by multiple energy","authors":"Yuze Zhang ,&nbsp;Pan Zhang ,&nbsp;Tan Cheng ,&nbsp;Hui Li ,&nbsp;Kai Zhong ,&nbsp;Zhongwei Li ,&nbsp;Yusheng Shi","doi":"10.1016/j.addma.2025.104761","DOIUrl":"10.1016/j.addma.2025.104761","url":null,"abstract":"<div><div>The Laser Powder Bed Fusion (LPBF) process utilizes a layered manufacturing approach, offering significant advantages in the fabrication of complex metal components. A key challenge in the production of high-precision, high-performance parts is the online monitoring of the solidified region in each layer of the powder bed, as well as identifying geometric defects. In this study, a novel approach for contour extraction is proposed, integrating multiple energy terms, including grayscale, entropy, phase difference, and photometric stereo, to drive the evolution of active contours. Various combinations of these energy terms are compared, and the effectiveness of each is validated. The results show that, compared to traditional active contour methods that consider only grayscale energy, the proposed method reduces the mean squared errors by 84.4 %, 61.7 %, and 95.8 % for ring contours, diamond ring contours, and center distances, respectively. These improvements contribute to the development of a quality monitoring and process parameter feedback system based on 3D geometric deviations in the solidified region, thus enhancing the precision and repeatability of LPBF processes.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104761"},"PeriodicalIF":10.3,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143842157","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Influence mechanism and visual monitoring of wire deviation in wire-based electron beam directed energy deposition 线材电子束定向能沉积中线材偏差的影响机理及可视化监测
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-11 DOI: 10.1016/j.addma.2025.104784
Zixiang Li , Boce Xue , Baohua Chang , Shuhe Chang , Zhenyu Liao , Yinan Cui , Changmeng Liu , Dong Du
{"title":"Influence mechanism and visual monitoring of wire deviation in wire-based electron beam directed energy deposition","authors":"Zixiang Li ,&nbsp;Boce Xue ,&nbsp;Baohua Chang ,&nbsp;Shuhe Chang ,&nbsp;Zhenyu Liao ,&nbsp;Yinan Cui ,&nbsp;Changmeng Liu ,&nbsp;Dong Du","doi":"10.1016/j.addma.2025.104784","DOIUrl":"10.1016/j.addma.2025.104784","url":null,"abstract":"<div><div>Wire-based electron beam directed energy deposition (DED) is acclaimed for its high deposition efficiency, optimal material utilization, and the ambient conditions of vacuum deposition. Nonetheless, the inherent stresses resulting from wire circular stockpiling, coupled with the thermal-induced deformation, readily lead to the deviation of feeding wire from the molten pool, which drastically impacts the forming quality and stability during the deposition process. Therefore, it is imperative to delve into the influence mechanisms of the wire deviation response and develop the corresponding online monitoring method. In this study, the wire deviation simulation model was originally established, and the experiment method was also combined to reveal the effects of wire deviation on the wire melting process, molten pool dynamics, and the as-printed part morphology. Furthermore, a visual sensing system and corresponding image extraction algorithms were also developed, specifically designed to monitor and analyze this behavior. Results indicate with increasing deviation distance, the wire melting pattern shifts from droplet to liquid bridge mode until it fails to melt. When the deviation distance is on a small-scale, it can cause molten pool liquid outflow (liquid transition mode) and a deviation in the deposition path location (droplet transition mode) despite the existence of obvious reflux behavior. In addition, the monitoring system developed in this study can effectively protect the camera lens from being contaminated by the metal vapor and the issue of unclear wire regions caused by the overexposure of the molten pool. The gray-level co-occurrence matrix was adopted to effectively overcome the issue of unclear boundaries at the wire center, and the texture entropy feature’s noise ratio only increased from 1.0 to 1.3, demonstrating good noise resistance. Based on the developed algorithm, the wire’s deflection distance can be detected with an error below 0.1 mm and a response time under 10 ms. The newly revealed mechanisms and the developed monitoring technologies lay a solid foundation for the subsequent closed-loop control of wire deviation behavior, making a significant enhancement of forming stability and automation level of wire-based DED technology.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104784"},"PeriodicalIF":10.3,"publicationDate":"2025-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143833463","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
Microstructure tailoring of a wire-arc DED processed Ti6242 alloy for high damage tolerance performance 线弧DED加工Ti6242合金的显微组织定制,以获得高损伤容限性能
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-11 DOI: 10.1016/j.addma.2025.104785
Farhana Zakir , Abdul Khadar Syed , Xiang Zhang , Alec E. Davis , Vivek K. Sahu , Armando E. Caballero , Romali Biswal , Philip B. Prangnell , Stewart Williams
{"title":"Microstructure tailoring of a wire-arc DED processed Ti6242 alloy for high damage tolerance performance","authors":"Farhana Zakir ,&nbsp;Abdul Khadar Syed ,&nbsp;Xiang Zhang ,&nbsp;Alec E. Davis ,&nbsp;Vivek K. Sahu ,&nbsp;Armando E. Caballero ,&nbsp;Romali Biswal ,&nbsp;Philip B. Prangnell ,&nbsp;Stewart Williams","doi":"10.1016/j.addma.2025.104785","DOIUrl":"10.1016/j.addma.2025.104785","url":null,"abstract":"<div><div>This paper examines the effects of interpass hammer peening and post-process β annealing on the tensile properties, high-cycle fatigue, and fatigue crack growth behaviour of the titanium alloy Ti-6Al-2Sn-4Zr-2Mo-0.1Si (Ti6242), processed via wire-arc directed energy deposition (w-DED, also known as WAAM). A major challenge in additive manufacturing of titanium alloys is the development of a coarse columnar grain structure under standard build conditions, leading to significant anisotropy and variability in mechanical properties. This study demonstrates that interpass peening effectively refines the grain structure by inducing recrystallization, resulting in isotropic properties and increased strength without compromising fatigue crack growth resistance. Additionally, post-deposition annealing above the β-transus temperature (β annealing) significantly reduces the fatigue crack growth rate by an order of magnitude through microstructural refinement. The formation of coarse single-variant lamellar colonies promotes crack path branching and deviation, enhancing fatigue crack growth performance. Combining in-process grain refinement via peening with post-process β annealing further increases the threshold stress intensity factor by 2.5 times. These improvements provide substantial benefits for damage-tolerant design principles.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104785"},"PeriodicalIF":10.3,"publicationDate":"2025-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143842156","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
In-situ alloying and microstructural control in high entropy alloys with nano-carbide-framework via powder bed fusion 粉末床熔合纳米碳化物框架高熵合金的原位合金化及显微组织控制
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-10 DOI: 10.1016/j.addma.2025.104766
Tan Shu , Jun Yuan , Feng Liu , Wei Shen , Gary J. Cheng
{"title":"In-situ alloying and microstructural control in high entropy alloys with nano-carbide-framework via powder bed fusion","authors":"Tan Shu ,&nbsp;Jun Yuan ,&nbsp;Feng Liu ,&nbsp;Wei Shen ,&nbsp;Gary J. Cheng","doi":"10.1016/j.addma.2025.104766","DOIUrl":"10.1016/j.addma.2025.104766","url":null,"abstract":"<div><div>High-entropy alloys (HEAs) are renowned for their exceptional mechanical properties, making them ideal candidates for use in demanding engineering applications such as aerospace, automotive, and defense industries. However, optimizing the balance between strength and ductility in HEAs remains a formidable challenge. In this study, we introduce a novel approach to enhance the mechanical properties of FeNiCrCo-based HEAs through in-situ alloying with nano-carbide-framework. By integrating nano-carbon into HEAs during laser powder bed fusion (LPBF), we were able to induce the formation of carbon-enriched nanostructures during the rapid melting and solidification processes of LPBF. Our methodology focuses on the strategic modulation of unique submicron-scale dislocation networks and the development of a nano-carbide-frameworks within the HEA matrix. The presence of Cr<sub>x</sub>C<sub>y</sub> compounds primarily at the grain boundaries and within dislocation networks significantly contributes to the mechanical strength of the alloy. By varying the nano-carbon content, we achieved control over the alloy’s microstructures, enabling a tailored balance between ultimate strength and ductility. This in-situ HEA alloying approach leads to the formation of a highly coherent nano-carbide-framework with the matrix, which not only enhances the ultimate strength of the HEAs (achieving values close to 1.4 GPa) but also maintains improved ductility. The nano-carbide-frameworks enabled microstructural design of HEAs provides a potent method for enhancing both the thermal stability and mechanical performance of the alloys. Our study paves the way for future research on the applicability of HEAs for applications in extreme conditions, and offers novel insights and methodologies for developing next-generation HEA with optimized performance.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104766"},"PeriodicalIF":10.3,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143826419","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
Resolving thermal gradients and solidification velocities during laser melting of a refractory alloy 求解激光熔化难熔合金的热梯度和凝固速度
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-10 DOI: 10.1016/j.addma.2025.104750
Hyunggon Park , Kaitlyn M. Mullin , Vijay Kumar , Olivia Wander , Tresa M. Pollock , Yangying Zhu
{"title":"Resolving thermal gradients and solidification velocities during laser melting of a refractory alloy","authors":"Hyunggon Park ,&nbsp;Kaitlyn M. Mullin ,&nbsp;Vijay Kumar ,&nbsp;Olivia Wander ,&nbsp;Tresa M. Pollock ,&nbsp;Yangying Zhu","doi":"10.1016/j.addma.2025.104750","DOIUrl":"10.1016/j.addma.2025.104750","url":null,"abstract":"<div><div>Metal additive manufacturing (AM) processes, such as laser powder bed fusion (L-PBF), can yield high-value parts with unique geometries and features, substantially reducing costs and enhancing performance. However, the material properties from L-PBF processes are highly sensitive to the laser processing conditions and the resulting dynamic temperature fields around the melt pool. In this study, we develop a methodology to measure thermal gradients, cooling rates, and solidification velocities during solidification of refractory alloy C103 using in situ high-speed infrared (IR) imaging with a high frame rate of approximately 15,000 frames per second (fps). Radiation intensity maps are converted to temperature maps by integrating thermal radiation over the wavelength range of the camera detector while also considering signal attenuation caused by optical parts. Using a simple method that assigns the liquidus temperature to the melt pool boundary identified ex situ, a scaling relationship between temperature and the IR signal was obtained. The spatial temperature gradients (<span><math><mrow><mi>d</mi><mi>T</mi><mo>/</mo><mi>d</mi><mi>x</mi></mrow></math></span>), heating/cooling rates (<span><math><mrow><mi>d</mi><mi>T</mi><mo>/</mo><mi>d</mi><mi>t</mi></mrow></math></span>), and solidification velocities (<span><math><mi>R</mi></math></span>) are resolved with sufficient temporal resolution under various laser processing conditions, and the resulting microstructures are analyzed, revealing epitaxial growth and nucleated grain growth. Thermal data shows that a decreasing temperature gradient and increasing solidification velocity from the edge to the center of the melt pool can induce a transition from epitaxial to equiaxed grain morphology, consistent with the previously reported columnar to equiaxed transition (CET) trend. The methodology presented can reduce the uncertainty and variability in AM and guide microstructure control during AM of metallic alloys.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104750"},"PeriodicalIF":10.3,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859861","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
Penalization and deep learning algorithms in Holographic Direct Sound Printing to improve print uniformity 全息直接声印刷中的惩罚和深度学习算法以提高印刷均匀性
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-10 DOI: 10.1016/j.addma.2025.104782
Mahdi Derayatifar , Mohsen Habibi , Rama Bhat , Muthukumaran Packirisamy
{"title":"Penalization and deep learning algorithms in Holographic Direct Sound Printing to improve print uniformity","authors":"Mahdi Derayatifar ,&nbsp;Mohsen Habibi ,&nbsp;Rama Bhat ,&nbsp;Muthukumaran Packirisamy","doi":"10.1016/j.addma.2025.104782","DOIUrl":"10.1016/j.addma.2025.104782","url":null,"abstract":"<div><div>Holographic Direct Sound Printing (HDSP) is a subclass of Direct Sound Printing (DSP) method based on on-demand polymerization induced by ultrasound waves. HDSP has the capability of printing in optically opaque material and more uniquely through optically opaque barriers. This method provides layerless and fast printing as opposed to the point-based methods. However, the HDSP is highly sensitive to the nonuniformity existing in the pressure pattern reconstructed with the conventional acoustic holography methods. This results in material accumulation and some parts in the pattern solidify faster than the rest, resulting in non-homogeneous geometry of the final printed part. We provide an effective method of mitigating this issue by optimizing the acoustic image reconstruction towards more uniform printing process. The general review and comparison of various optimization techniques is presented in terms of reconstruction quality and computation time. We have introduced a new penalization technique to improve the iterative convergence and quality of the patterned acoustic pressure and uniformity printed feature size. Furthermore, we have presented a fast and efficient deep learning-based technique that provides better uniformity and Peak-Sound-to-Noise-Ratio on the generated pattern for the printing, but also robust compared to the iterative methods. The experimental results show that the printing time is shortened as well as more uniformity is observed in the final parts due to uniform reconstructed holographic image, mitigating the problem of partially solidified parts thickening before print completion. The present paper introduces a crucial step towards applying HDSP without sacrificing the feature size and overall print quality.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104782"},"PeriodicalIF":10.3,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143847376","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
Impact of droplet oxidation on mechanical properties of an Al-7Si-0.4Mg alloy fabricated with liquid metal jetting 液滴氧化对液态金属喷射制造的 Al-7Si-0.4Mg 合金机械性能的影响
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-05 DOI: 10.1016/j.addma.2025.104775
Sumit Bahl , Gerry L. Knapp , Alexander Gomez , Jonathan D. Poplawsky , James A. Haynes , Ryan R. Dehoff , Alex Plotkowski , Amit Shyam
{"title":"Impact of droplet oxidation on mechanical properties of an Al-7Si-0.4Mg alloy fabricated with liquid metal jetting","authors":"Sumit Bahl ,&nbsp;Gerry L. Knapp ,&nbsp;Alexander Gomez ,&nbsp;Jonathan D. Poplawsky ,&nbsp;James A. Haynes ,&nbsp;Ryan R. Dehoff ,&nbsp;Alex Plotkowski ,&nbsp;Amit Shyam","doi":"10.1016/j.addma.2025.104775","DOIUrl":"10.1016/j.addma.2025.104775","url":null,"abstract":"<div><div>Droplet-on-demand liquid metal jetting (DOD-LMJ) is a new method for additive manufacturing of bulk structural alloys. Here, we report on the microstructure, tensile, and fatigue properties of an Al-7Si-0.4Mg (A356) alloy fabricated with LMJ. Liquid metal droplets were shielded by high-purity Ar gas shroud during deposition. Atom probe tomography revealed that a few nanometers thick (Al-Mg-Si)-O oxide film formed on the droplets despite Ar gas shielding. Tensile tests on peak-aged LMJ A356 alloy showed that yield strength was isotropic (250 MPa), but ductility was lower in the build direction (6.1 ± 1.4 %) compared to the transverse direction (9.4 ± 1.0 %). Lower ductility in the build direction was attributed to delamination of metal-oxide interfaces at layer boundaries. The ductility and yield strength of LMJ A356 were similar to cast A356 and laser powder bed fused (LPBF) A357 alloys, indicating the limited impact of oxide film on tensile properties. The oxide film severely impacted the fatigue properties. Fatigue resistance of LMJ A356 was limited by fatigue crack initiation at lack-of-fusion defects and fatigue crack propagation along layer boundaries by delamination of the metal-oxide interface. The fatigue strength of LMJ A356 at 60 MPa was lower than cast A356 and LPBF A357 alloys in the peak-aged condition. This research underscores the need for managing droplet oxidation during LMJ additive manufacturing of structural alloys.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104775"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783795","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
Particle-based friction stir additive manufacturing of an Al-Mg-Mn alloy Al-Mg-Mn合金的颗粒基搅拌摩擦增材制造
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-05 DOI: 10.1016/j.addma.2025.104768
Wancheng Lyu , Yizhou Shen , Yuzhe Tang , Kun Yang , Zexing Zhou , Chenglong Zhao , Yunjie Lu , Xunzhong Guo
{"title":"Particle-based friction stir additive manufacturing of an Al-Mg-Mn alloy","authors":"Wancheng Lyu ,&nbsp;Yizhou Shen ,&nbsp;Yuzhe Tang ,&nbsp;Kun Yang ,&nbsp;Zexing Zhou ,&nbsp;Chenglong Zhao ,&nbsp;Yunjie Lu ,&nbsp;Xunzhong Guo","doi":"10.1016/j.addma.2025.104768","DOIUrl":"10.1016/j.addma.2025.104768","url":null,"abstract":"<div><div>An innovative Particle-based Friction Stir Additive Manufacturing (P-FSAM) technique has been developed, featuring a continuous off-axis feeding mechanism for metallic particles. The process optimization focuses on the ratio of actuator reciprocating frequency to tool traverse speed, ensuring adequate heat generation and particle filling for high-quality deposition. Through the implementation of an optimized stirring pin and spiral groove design, the technique facilitates Z-direction flow of thermoplastic material, resulting in enhanced interfacial bonding and material flow characteristics. This study demonstrates the successful application of P-FSAM in producing Al-5356 alloy deposits with an equiaxed fine-grained microstructure, exhibiting mechanical isotropy and a balanced combination of strength and ductility. During the stable deposition of single-pass multilayers of this alloy, P-FSAM requires about 1 kN thrust force, with a maximum steady-state temperature exceeding 435°C. The deposits exhibit refined grain structures due to dynamic recrystallization, nearly complete dissolution of the Al<sub>3</sub>Mg<sub>2</sub> phase, while maintaining grain stability during thermal cycling. The deposits achieve favorable mechanical properties, with yield strength exceeding 210 MPa, ultimate tensile strength surpassing 350 MPa, and elongation over 20 % in both build and traverse directions, outperforming fusion-based additive manufacturing counterparts. P-FSAM expands the potential of solid-state additive manufacturing, paving the way for future applications involving composite particles, polymers, metal powders, and industrial scraps, as well as multi-channel off-axis feeding for gradient material fabrication and hybrid additive manufacturing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104768"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143786292","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
Rapid prediction of overload fatigue life based on phase-field modeling of microstructures under different scanning strategies 不同扫描策略下基于相场建模的微结构过载疲劳寿命快速预测
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-05 DOI: 10.1016/j.addma.2025.104771
Haifeng Zhai , Wei Jiang , Yang Wang , Yanzhao Yang , Haiting Lv
{"title":"Rapid prediction of overload fatigue life based on phase-field modeling of microstructures under different scanning strategies","authors":"Haifeng Zhai ,&nbsp;Wei Jiang ,&nbsp;Yang Wang ,&nbsp;Yanzhao Yang ,&nbsp;Haiting Lv","doi":"10.1016/j.addma.2025.104771","DOIUrl":"10.1016/j.addma.2025.104771","url":null,"abstract":"<div><div>Understanding the mechanisms of microstructure evolution is essential for accurately predicting and improving the final mechanical properties of materials. To enable efficient simulation of multi-layer, multi-track additive manufacturing (AM) processes with various scanning strategies, a three-dimensional phase-field (PF) model was developed to capture grain evolution in AM. The model effectively reproduces grain nucleation, epitaxial growth, and coarsening. Three representative scanning strategies (stripe, loop, and chessboard) were experimentally validated. The simulation results showed strong consistency with experimental observations regarding melt pool dynamics, grain morphology, and defect evolution. The crystal plasticity finite element method (CPFEM) was utilized to predict overload fatigue life, and a novel strategy was introduced to rapidly and efficiently estimate fatigue life by reconstructing the microstructure corresponding to different scanning strategies. This study offers novel methodological insights into grain growth and evolution mechanisms in AM and extends the predictive framework for overload fatigue life estimation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104771"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777121","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
Energy absorption of architectured PrintCast interpenetrating composites in tension 结构化 PrintCast 互穿复合材料在拉伸状态下的能量吸收
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-04-05 DOI: 10.1016/j.addma.2025.104769
Abdel R. Moustafa , Jiahao Cheng , Jason P. Allen , Xiaohua Hu , Amit Shyam , Ke An , Matthew Frost , Yan Chen , Derek A. Splitter
{"title":"Energy absorption of architectured PrintCast interpenetrating composites in tension","authors":"Abdel R. Moustafa ,&nbsp;Jiahao Cheng ,&nbsp;Jason P. Allen ,&nbsp;Xiaohua Hu ,&nbsp;Amit Shyam ,&nbsp;Ke An ,&nbsp;Matthew Frost ,&nbsp;Yan Chen ,&nbsp;Derek A. Splitter","doi":"10.1016/j.addma.2025.104769","DOIUrl":"10.1016/j.addma.2025.104769","url":null,"abstract":"<div><div>Additively manufactured (AM) metal-metal composites consisting of PrintCasted 316 L austenitic stainless-steel lattice structures infiltrated with A356 casting alloy, have recently been developed for use in high energy absorption systems with potential applications ranging from static load bearing to dynamic blast containment structures. This system has a unique mechanical behavior as the volume fraction of lattice increases showing a transition from localized to de-localized failure and dramatic increase in energy absorption capability. In this work, PrintCast A356/316 L composite tensile specimens were produced with lattice volume fractions ranging from 20 % to 50 % to capture the range of this behavior. Finite element simulations support neutron diffraction measurements of stress state. Results illustrate that in tension, the reinforcement material is in tension while the matrix support material is in compression, information offering significant insight into the transition to de-localized failure. Moreover, the simulation results provide further insight into how interfacial bonding (or lack of bonding) affects the energy absorption capabilities of the PrintCast composites.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104769"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143786291","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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