Additive manufacturing最新文献

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Characterizing gas flow in the build chamber of laser powder bed fusion systems utilizing particle image velocimetry: A path to improvements 利用粒子图像测速技术表征激光粉末床融合系统构建室中的气体流动:改进之路
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-10 DOI: 10.1016/j.addma.2025.104810
Aaron Abeyta , Cole Nouwens , Ashley M. Jones , Troy A. Haworth , Alex Montelione , Mamidala Ramulu , Dwayne Arola
{"title":"Characterizing gas flow in the build chamber of laser powder bed fusion systems utilizing particle image velocimetry: A path to improvements","authors":"Aaron Abeyta ,&nbsp;Cole Nouwens ,&nbsp;Ashley M. Jones ,&nbsp;Troy A. Haworth ,&nbsp;Alex Montelione ,&nbsp;Mamidala Ramulu ,&nbsp;Dwayne Arola","doi":"10.1016/j.addma.2025.104810","DOIUrl":"10.1016/j.addma.2025.104810","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (L-PBF) is increasingly being utilized for the manufacture of structural components for the aerospace industry. In L-PBF an inert gas is used to protect the melt pool from contamination by reactive elements in the build chamber and to carry away by-products generated by the laser-powder interaction, including soot, condensate, etc. Spatial variations or other undesirable characteristics (e.g., turbulence, dead zones, etc.) in the gas flow distribution could enable build defects to develop that cause spatial variability in metal quality and microstructure, as well as variability in the mechanical properties. This investigation analyzed the gas flow in a full-scale model of the build chamber for a commercial system utilizing high-fidelity Particle Image Velocimetry (PIV). Planar mode views showed that the gas flow within the build chamber is not uniform and that the flow distribution across the build plate undergoes a reduction in velocity laterally of nearly 50 %; the reduction in flow downstream from the gas inlet to the exit reaches nearly 70 %. Serial views involving multiple planes of evaluation revealed regions of stagnation as well as recirculation zones that could entrain soot and metal vapor condensate. Lastly, a modified Y-Duct design is conceived and shown through analysis performed using PIV to substantially improve the flow field distribution across the build plate. Details of the flow fields, locations of concern, and benefits of the PIV approach to assess and inform improvements in the gas flow distribution are discussed. These findings can lead to improvements in quality realized by part placement and distinguish opportunities for further tuning of the gas flow overall.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104810"},"PeriodicalIF":10.3,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143949083","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
Retraction Notice to “Additive manufacturing process parameter design for variable component geometries using reinforcement learning” [Addit. Manuf. 84C (2024), 104121] 对“使用强化学习的可变部件几何形状的增材制造工艺参数设计”的撤回通知[add .][第84C(2024)号,104121]
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-09 DOI: 10.1016/j.addma.2025.104796
Ehsan Vaghefi , Seyedmehrab Hosseini , Amir Hossein Afsharinejad , Bart Prorok , Elham Mirkoohi
{"title":"Retraction Notice to “Additive manufacturing process parameter design for variable component geometries using reinforcement learning” [Addit. Manuf. 84C (2024), 104121]","authors":"Ehsan Vaghefi ,&nbsp;Seyedmehrab Hosseini ,&nbsp;Amir Hossein Afsharinejad ,&nbsp;Bart Prorok ,&nbsp;Elham Mirkoohi","doi":"10.1016/j.addma.2025.104796","DOIUrl":"10.1016/j.addma.2025.104796","url":null,"abstract":"","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104796"},"PeriodicalIF":10.3,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144106354","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
Correlating the evolution of spatial-resolved microscale residual stress and the associated dislocation behavior in additively manufactured 316L stainless steel upon short-term annealing 增材制造316L不锈钢短期退火后空间分辨微尺度残余应力演变与位错行为的关系
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-09 DOI: 10.1016/j.addma.2025.104807
Dayong An , Xinxi Liu , Yao Xiao , Xifeng Li , Jun Chen
{"title":"Correlating the evolution of spatial-resolved microscale residual stress and the associated dislocation behavior in additively manufactured 316L stainless steel upon short-term annealing","authors":"Dayong An ,&nbsp;Xinxi Liu ,&nbsp;Yao Xiao ,&nbsp;Xifeng Li ,&nbsp;Jun Chen","doi":"10.1016/j.addma.2025.104807","DOIUrl":"10.1016/j.addma.2025.104807","url":null,"abstract":"<div><div>Additive manufacturing (AM) processes, such as laser powder bed fusion (L-PBF), <em>often</em> introduce significant residual stresses in components, which are typically mitigated through heat treatments (HTs) to optimize mechanical properties. However, the evolution of microscale residual stresses during annealing and their underlying mechanisms remain poorly understood. In this study, we employed quasi <em>in-situ</em> electron channeling contrast imaging (ECCI) combined with cross-correlation electron backscatter diffraction (CC-EBSD) to track the spatially resolved evolution of microscale residual stresses and associated dislocation behaviors in a L-PBF fabricated 316L stainless steel upon annealing. A direct correlation is established between dislocation arrangements within dislocation cells and sub-grain boundaries (SGBs) and the distribution of microscale residual stresses. Our results reveal that dislocation activity is modulated by the presence of these microscale residual stresses, which, subsequently, dictate their redistribution during annealing. Furthermore, the influence of different HTs on governing deformation mechanisms and microscale residual stress evolution under plastic deformation is quantitatively estimated. This work provides new insights into the intricate interplay between dislocation dynamics and microscale residual stress evolution during annealing, with implications for optimizing the mechanical properties of AM components.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104807"},"PeriodicalIF":10.3,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143936844","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
High-speed imaging investigation and process mapping of the plume behavior in laser powder bed fusion 激光粉末床熔合中羽流行为的高速成像研究和过程映射
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-09 DOI: 10.1016/j.addma.2025.104797
Alexander J. Myers, Christian Gobert, Jack L. Beuth, Jonathan A. Malen
{"title":"High-speed imaging investigation and process mapping of the plume behavior in laser powder bed fusion","authors":"Alexander J. Myers,&nbsp;Christian Gobert,&nbsp;Jack L. Beuth,&nbsp;Jonathan A. Malen","doi":"10.1016/j.addma.2025.104797","DOIUrl":"10.1016/j.addma.2025.104797","url":null,"abstract":"<div><div>In this work, high-speed imaging of experiments was conducted with varied processing conditions and materials to parametrically understand the plume’s severity, size, and trajectory on a commercial laser powder bed fusion (LPBF) machine. In this context, the plume refers to the bright melt-pool-scale metal vapor and condensate. A U-Net convolutional neural network (CNN) was trained to segment the plume from experimental images. A comparison of the plume generated from different metals shows that Ti-6Al-4V has a significantly brighter and larger plume than Inconel 718 and 316L SS, which may be attributed to increased emission from the melt pool, increased scattering of the emission from the melt pool, or elemental emission lines. The effect of powder was studied for both Ti-6Al-4V and 316L SS and shows a reduction in the size and brightness of the plume in most overhead images, suggesting that the plume visibility and/or the plume itself is suppressed by the powder and spatter. Process mapping the plume in power and scanning velocity space shows that the plume transitions from ejecting toward the rear of the melt pool in the transitional regime to ejecting directly above the melt pool in both the severe keyholing and conduction-dominated regimes, consistent with the vapor depression geometry under the laser. The temporal variability of the plume increases with increasing power-to-velocity ratio, which is attributed to melt pool and vapor depression instability, but can also be large at very low power-to-velocity ratios. This experimental study aims to increase our understanding of the plume’s behavior at the melt pool scale in LPBF and can be used to validate multi-physics models of the plume and inform parameter selection for both minimal melt-pool-scale laser-plume interaction and avoiding plume interference in melt pool imaging.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104797"},"PeriodicalIF":10.3,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143949084","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
Advances in 3D printed electromechanical sensors: Performance comparison, trends, and future directions 3D打印机电传感器的进展:性能比较、趋势和未来方向
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-08 DOI: 10.1016/j.addma.2025.104799
Anders Frem Wolstrup , Jon Spangenberg , Akio Yamamoto , Andrew Gleadall , Gabriel Zsurzsan
{"title":"Advances in 3D printed electromechanical sensors: Performance comparison, trends, and future directions","authors":"Anders Frem Wolstrup ,&nbsp;Jon Spangenberg ,&nbsp;Akio Yamamoto ,&nbsp;Andrew Gleadall ,&nbsp;Gabriel Zsurzsan","doi":"10.1016/j.addma.2025.104799","DOIUrl":"10.1016/j.addma.2025.104799","url":null,"abstract":"<div><div>3D printing has revolutionized electromechanical sensor design, enabling rapid prototyping and complex geometries, and driving significant growth in this research field. However, as more sensors are developed using diverse printing methods and sensing mechanisms, the need for standardized reporting and comparative metrics becomes increasingly critical. Without such metrics, new sensors cannot be properly contextualized or benchmarked against the state of the art, slowing progress in the field. This review addresses this gap by cataloguing key performance metrics from the literature, including input/output range, sensitivity, mechanical and electrical properties, and the specific 3D printing processes used, to enable meaningful comparison. These metrics are applied to quantitatively analyze 74 sensors reported across different additive manufacturing techniques. Additionally, underreported characteristics such as hysteresis, drift, and long-term stability are considered to provide a more complete assessment of sensor performance. Beyond quantitative comparison, this review introduces a framework for categorizing sensors based not only on electrical output type (e.g., resistive, capacitive) but also on the underlying sensing basis, distinguishing whether the response arises from intrinsic material properties (e.g., quantum tunneling, percolation) or from structure-induced mechanisms (e.g., constriction resistance). The review also highlights advances in 3D printing for electronics manufacturing to inspire future directions and concludes with six recommendations for sensor development, focusing on aligning sensing mechanisms with appropriate fabrication strategies and aiding metric standardization across the field.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104799"},"PeriodicalIF":10.3,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143942000","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
Understanding drying dynamics in Binder Jetting: Development of a physical model for improved selection of drying parameters and better control of binder saturation 了解粘结剂喷射干燥动力学:发展物理模型,以改进干燥参数的选择和更好地控制粘结剂饱和度
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-08 DOI: 10.1016/j.addma.2025.104798
Thomas Cheny , Christophe Colin , Sylvain Gailliègue , Paul Calves , Benoit Verquin
{"title":"Understanding drying dynamics in Binder Jetting: Development of a physical model for improved selection of drying parameters and better control of binder saturation","authors":"Thomas Cheny ,&nbsp;Christophe Colin ,&nbsp;Sylvain Gailliègue ,&nbsp;Paul Calves ,&nbsp;Benoit Verquin","doi":"10.1016/j.addma.2025.104798","DOIUrl":"10.1016/j.addma.2025.104798","url":null,"abstract":"<div><div>Binder Jetting is a layer-by-layer 3D printing process that consists of selectively binding particles together on each layer to create 2D patterns of a part. A drying step is usually performed after printing to evaporate some of the binder solvents before the next layer is applied. However, optimization of binder drying for improved part manufacturing has received little attention. In this paper, a dedicated test bench was used to measure binder mass loss over time under various drying conditions. By establishing a methodology and an experimentally validated drying model, this work represents a significant advance in the understanding of the drying phase and binder behavior between the deposition of successive layers. A time-dependent conceptualization of binder saturation within a layer of powder is presented for the first time, and valuable insights are provided to pave the way for improved selection of printing and drying parameters for aqueous binders in Binder Jetting.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104798"},"PeriodicalIF":10.3,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143949081","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
Sequential-crosslinking facilitated droplet-droplet collision inkjet 3D printing of soft biomaterials 顺序交联促进了软质生物材料的液滴碰撞喷墨3D打印
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-07 DOI: 10.1016/j.addma.2025.104809
Dengke Zhao , Heqi Xu , Zhichao Ye , Jianing Yan , Huayong Yang , Yifan Wang , Jun Yin
{"title":"Sequential-crosslinking facilitated droplet-droplet collision inkjet 3D printing of soft biomaterials","authors":"Dengke Zhao ,&nbsp;Heqi Xu ,&nbsp;Zhichao Ye ,&nbsp;Jianing Yan ,&nbsp;Huayong Yang ,&nbsp;Yifan Wang ,&nbsp;Jun Yin","doi":"10.1016/j.addma.2025.104809","DOIUrl":"10.1016/j.addma.2025.104809","url":null,"abstract":"<div><div>Droplet-droplet collision (DDC) inkjet three-dimensional (3D) printing presents a novel approach to additive manufacturing (AM) of soft biomaterials for tissue engineering, bioelectronics, and food science, etc. However, limited ink materials and elusive dynamics of the printing process pose significant challenges. This work introduces a sequential-crosslinking facilitated printing strategy that leverages rapid ionic crosslinking triggered by in-air droplet collision to retain structure during printing and entrap the target biomaterial, which is further crosslinked after printing. This versatile approach enables the effective printing of both photocrosslinkable and non-photocrosslinkable soft biomaterials that are challenging to be printed with normal DDC inkjet 3D printing. The dynamics of DDC process with crosslinking is revealed and two distinct DDC modes are identified, namely, coalescence and stretching separation; dimensionless phase diagrams and semi-empirical transition boundaries of DDC modes are developed to improve the stability of printing process and guide the optimization of printing parameters. On this basis, lines exhibiting a minimum width of 122 μm and delicate motifs containing intricate microfeatures are printed. Moreover, the printing process has proved its biocompatibility by imposing negligible effect on the viability and proliferation of printed living cells. This study is believed to expedite the voxelated AM of broader soft biomaterials for healthcare and industry.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104809"},"PeriodicalIF":10.3,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143929629","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
High-efficiency multi-scale strategy for TPMS-based conformal heterogeneous structures 基于tpms的保形异质结构的高效多尺度策略
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-07 DOI: 10.1016/j.addma.2025.104808
H.Y. Ning , W.S. Huang , G.H. Tang
{"title":"High-efficiency multi-scale strategy for TPMS-based conformal heterogeneous structures","authors":"H.Y. Ning ,&nbsp;W.S. Huang ,&nbsp;G.H. Tang","doi":"10.1016/j.addma.2025.104808","DOIUrl":"10.1016/j.addma.2025.104808","url":null,"abstract":"<div><div>Heterogeneous structures are widely used in additive manufacturing for lightweight and versatility due to their superior flexibility and physical properties. However, previous fusion methods struggle with transition region control, parameter matching, and solving, leading to structural deformation and mechanical failures. Additionally, heterogeneous design is always accompanied by conformal designs to meet specific application scenarios, yet its computational cost and accuracy have received insufficient attention. This work introduces a multi-scale strategy to accelerate the design and fabrication of conformal heterogeneous products by interacting field variables at different scales. The structures are represented using triply periodic minimal surfaces (TPMS). We propose a novel fusion method that directly employs driving fields to generate smooth heterogeneous structures while ensuring precise transition control. Furthermore, we propose an adaptive signed distance field algorithm to reduce the computational cost. The proposed methods are comprehensively evaluated through simulations and physical experiments. Results demonstrate that our method is highly effective in precise control, smooth transition, load carrying, and energy absorption. Compared with existing methods, our method exhibits superior robustness, efficiency, and accuracy. This work provides a novel solution for computer-aided design and additive manufacturing, enabling the rapid development and fabrication of conformal heterogeneous structures with higher energy absorption and precise controllability.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104808"},"PeriodicalIF":10.3,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143936845","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
Electrohydrodynamic jet printing of micro-structured electrode featuring 3D gold micropillar array for non-enzymatic detection of glucose 用于葡萄糖非酶检测的三维金微柱阵列微结构电极的电流体动力喷射打印
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-06 DOI: 10.1016/j.addma.2025.104806
Zhaofa Zhang , Li Wang , Tianxue Yin , Yulin Zheng , Yuechen Pei , Shijia Wei , Yu Luo , Huaying Wu , Bingheng Lu
{"title":"Electrohydrodynamic jet printing of micro-structured electrode featuring 3D gold micropillar array for non-enzymatic detection of glucose","authors":"Zhaofa Zhang ,&nbsp;Li Wang ,&nbsp;Tianxue Yin ,&nbsp;Yulin Zheng ,&nbsp;Yuechen Pei ,&nbsp;Shijia Wei ,&nbsp;Yu Luo ,&nbsp;Huaying Wu ,&nbsp;Bingheng Lu","doi":"10.1016/j.addma.2025.104806","DOIUrl":"10.1016/j.addma.2025.104806","url":null,"abstract":"<div><div>Three-dimensional (3D) micro-structured gold electrodes offer remarkable advantages in electrochemical sensing, electrocatalysis and energy storage. However, conventional cleanroom fabrication methods, such as lithography and vapor deposition, rely on expensive equipment and often involve material waste. This work proposes an EHD jet printing process for fabricating a micro-structured electrode featuring a 3D gold micropillar array (GMA) using water-based gold nanoparticle ink. Through COMSOL simulations, the utilization and avoidance of the electrostatic autofocusing effect is proposed in terms of the single micropillar and micropillar array, thereby obtaining the optimal micropillar height and spacing for the GMA. To address the tilting and detachment issues, the GMA was printed on an electrochemically deposited gold particle-dendrite layer, significantly enhancing the adhesion between the micropillars and substrate. Along with the proposed stepwise sintering process, the fabricated 3D GMA electrode exhibited excellent structural integrity. Subsequently, the fabricated 3D GMA electrode was applied to non-enzymatic electrochemical glucose detection and the results show that, compared to a planar electrode, the hybrid working electrode of the sensor demonstrated a 534 % increase in electrochemical active surface area and a notably high ratio of 6.25 cm<sup>2</sup>/cm<sup>2</sup> was obtained. This work highlights the potential of EHD jet printing for fabricating robust 3D micro-structured gold electrodes, offering a reliable, cost-effective and promising solution for applications in biomedical detection and advanced healthcare technologies.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104806"},"PeriodicalIF":10.3,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143929628","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
Recycling nickel aluminium bronze grinding chips to feedstock for directed energy deposition via impact whirl milling: Investigation on processability, microstructure and mechanical properties 通过冲击旋磨回收镍铝青铜磨屑作为定向能沉积的原料:加工性能、微观结构和力学性能的研究
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-05-05 DOI: 10.1016/j.addma.2025.104804
Vinzenz Müller , Janek Maria Fasselt , Christian Klötzer-Freese , Tobias Kruse , Rafael Kleba-Ehrhardt , Max Biegler , Michael Rethmeier
{"title":"Recycling nickel aluminium bronze grinding chips to feedstock for directed energy deposition via impact whirl milling: Investigation on processability, microstructure and mechanical properties","authors":"Vinzenz Müller ,&nbsp;Janek Maria Fasselt ,&nbsp;Christian Klötzer-Freese ,&nbsp;Tobias Kruse ,&nbsp;Rafael Kleba-Ehrhardt ,&nbsp;Max Biegler ,&nbsp;Michael Rethmeier","doi":"10.1016/j.addma.2025.104804","DOIUrl":"10.1016/j.addma.2025.104804","url":null,"abstract":"<div><div>During the production of ship propellers, considerable quantities of grinding chips from nickel aluminium bronze are produced. This paper examines the mechanical comminution of such chips via impact whirl milling and the utilization of two chip-powder batches as feedstock for a laser-based directed energy deposition process. The materials are characterized via digital image analysis, standardized flowability tests, scanning electron microscopy and energy dispersive X-ray spectroscopy and are compared to conventional, gas atomized powder. The specimens deposited via directed energy deposition are analyzed for density, hardness and microstructure and tensile properties for vertical and horizontal build up directions are compared. At elevated mill rotation speeds, the comminution with impact whirl milling produced rounded particles, favorable flow properties and particle size distribution, making them suitable to deposit additive specimens. The microstructure exhibited characteristic martensitic phases due to the high cooling rates of the additive manufacturing process. The presence of ceramic inclusions was observed in both the powder and on the tensile fracture surfaces, partly impairing the mechanical properties. However, specimens in the vertical build-up direction (Z) showed competitive tensile results, with 775 MPa in tensile strength, 455 MPa in yield strength and 12.6 % elongation at break. The findings of this study indicate that recycling of machining chips to additive manufacturing feedstock can be a viable option for reducing material costs and environmental impact.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104804"},"PeriodicalIF":10.3,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143906400","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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