Additive manufacturing最新文献

{"title":"Transfer learning enabled geometry, process, and material agnostic RGNN for temperature prediction in directed energy deposition","authors":"Jin Young Choi ,&nbsp;Sina Malakpour Estalaki ,&nbsp;Daniel Quispe ,&nbsp;Rujing Zha ,&nbsp;Rowan Rolark ,&nbsp;Mojtaba Mozaffar ,&nbsp;Jian Cao","doi":"10.1016/j.addma.2025.104876","DOIUrl":"10.1016/j.addma.2025.104876","url":null,"abstract":"<div><div>Thermal simulation in directed energy deposition is an area of active interest, as the evolution of the temperature field during deposition is a key variable that affects resulting build properties. Surrogate machine learning models enable an accelerated alternative to finite element analysis, but often face challenges in generalizing new inference conditions. In this work, we present a geometry- and process-agnostic recurrent graph neural network (RGNN) that preserves the mesh connectivity through graph nodes and edges. Compared to finite element analysis, the RGNN model provides thermal predictions up to 405 times faster in computational speed. Furthermore, we demonstrate the effectiveness of transfer learning (TL) via fine-tuning to adapt the pretrained model for a new material system with distinct heat transfer characteristics. We evaluate the TL model in a challenging scenario, where it successfully predicts thermal behavior over an extended 1000 time steps using a new geometry. The TL model exhibits much lower error accumulation over time compared to the pretrained model, while requiring only a fraction of training data and training time. The TL predictions show a good match with an experimental temperature field obtained from IR imaging, demonstrating its robustness and adaptability.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104876"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703828","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":"Melt pool overlap as a key tool for microstructure design in PBF-LB/M of a Ni-based superalloy: Empirical and analytical approaches","authors":"I. Rodríguez-Barber ,&nbsp;M.T. Pérez-Prado","doi":"10.1016/j.addma.2025.104901","DOIUrl":"10.1016/j.addma.2025.104901","url":null,"abstract":"<div><div>This work presents a streamlined and industrially scalable methodology to design and control the microstructure in Inconel 939 (IN939) components fabricated by laser powder bed fusion (PBF-LB/M). Through a combination of empirical and analytical approaches, we identify the melt pool overlap perpendicular to the scan direction (SD) and to the build direction (BD) as a key metric to predict the formation of either columnar grains with strong &lt; 001 &gt; //BD fiber textures or equiaxed, weakly oriented microstructures. We demonstrate that combinations of processing parameters (laser power, scan speed, hatch distance, scan track length) leading to overlaps below a critical threshold of 0.6 inhibit epitaxial growth, yielding equiaxed, weakly textured grains. Multitrack experiments are introduced as a high-throughput method to construct melt pool overlap maps for a broad range of processing conditions, enabling rapid empirical selection of scan parameters. Furthermore, we propose an analytical framework based on a modified Rosenthal equation and a reformulated normalized volumetric energy density (<em>E</em>_<em>v</em>*), incorporating scan geometry and material properties. A simple logarithmic regression linking <em>E</em>_<em>v</em>* to melt pool overlap allows for the prediction of suitable process windows beyond those directly tested. This combined methodology offers a practical pathway for microstructure-informed design in PBF-LB/M of high-performance Ni-based superalloys, facilitating microstructural control in engineering components with complex geometries.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104901"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144694570","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 and mechanical properties of wear-resistant SiCp/Al composite layers on 6061 aluminum alloy fabricated by additive friction stir deposition","authors":"Bin He ,&nbsp;Caiyan Deng ,&nbsp;Haining Yao ,&nbsp;Sijia Wang ,&nbsp;Yiming Huang ,&nbsp;Hongbin Zhu ,&nbsp;Lei Cui","doi":"10.1016/j.addma.2025.104880","DOIUrl":"10.1016/j.addma.2025.104880","url":null,"abstract":"<div><div>Due to the excellent wear properties of the SiC particles reinforced aluminum matrix composites(SiC_p/Al) and its good compatibility with the aluminum alloy substrate, the fabrication of a SiC_p/Al layer is an effective way to improve the surface wear resistance of aluminum alloys. In this study, the microstructure and mechanical properties of a 20 vol% SiC_p+ZL101 composite deposition layer on the surface of 6061-T6 fabricated by the additive friction stir deposition (AFSD) process. The results show that plastic deformation leads to approximately 97 % grain refinement in the deposition layer compared to the rod material (RM). SiC_p are fragmented and refined, with an average size reduction from 4.54 μm × 2.80 μm (RM) to 2.40 μm × 1.52 μm, achieving a uniform distribution. The tensile strength of deposition layer reaches 300 MPa, a 47 % improvement over the RM. A defect-free metallurgical bond is formed at the interface, and fine-grained regions at the interface enhance crack resistance, with a shear strength of 177 MPa. Both RM and the deposition layer exhibited characteristics of abrasive wear and oxidative wear. Compared to the RM, the deposition layer showed a ∼10 % reduction in wear rate. The tensile strength of the deposit layer has been enhanced without compromising wear resistance. This study provides insights for using AFSD in fabricating wear-resistant surface layers or surface-modified components.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104880"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144564051","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":"Breaking barriers in soft material printing: High-fidelity DLP fabrication of silk sericin via height-adjusted curing and local error optimization","authors":"Xuanwen Wang,&nbsp;Xiaoliang Cui,&nbsp;Hui Wang,&nbsp;Jun Zhang,&nbsp;Ke-Qin Zhang","doi":"10.1016/j.addma.2025.104877","DOIUrl":"10.1016/j.addma.2025.104877","url":null,"abstract":"<div><div>Digital Light Processing (DLP) faces significant challenges in printing ultra-soft hydrogels due to their weak mechanical properties and the lack of robust accuracy evaluation systems. Here, we overcome these limitations by introducing silk sericin (SS) - a protein recovered from alkaline thermal degumming water - as a sustainable bioink. Through glycidyl methacrylate (GMA) modification, we developed methacrylated silk sericin (SerMA) with enhanced curability while preserving its inherent biocompatibility. A \"Height Gradient Screening\" approach was innovatively applied to the Jacob's working curve, enabling precise determination of cured depth under real-world printing conditions by addressing light scattering and self-focusing effects. Furthermore, we proposed the \"Tangent Cylindrical Model\", a novel framework to quantify localized printing errors across dynamic illumination source spacings, achieving resolutions as fine as 300 µm channel gaps and 400 µm hole structures-surpassing current capabilities for weak hydrogels. The printed SerMA constructs demonstrated excellent cytocompatibility (L929 cell viability&gt;95 % over 168 h) and supported cell adhesion/spreading, validated via Live/Dead assays and F-actin staining. This work not only expands the DLP material library to include recovered, mechanically fragile proteins but also establishes a universal methodology for high-precision printing of soft biomaterials, with direct implications for tissue engineering, microfluidics, and biosensing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104877"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144572716","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":"Simulation-driven development of in-situ alloying Cu-25Cr by electron beam powder bed fusion","authors":"Robert Scherr,&nbsp;Tobias Hirschfelder,&nbsp;Matthias Markl,&nbsp;Carolin Körner","doi":"10.1016/j.addma.2025.104874","DOIUrl":"10.1016/j.addma.2025.104874","url":null,"abstract":"<div><div>Based on its excellent electrical conductivity in combination with a high arc erosion resistance and withstand voltage, the alloy Cu-25Cr is widely applied as a contact material for high-power vacuum interrupters. The utilization of the electron beam powder bed fusion (PBF-EB) method for the processing of this material offers the major advantage of producing extremely fine Cr precipitates due to the rapid solidification of the melt pool, which can further improve the application-specific properties significantly.</div><div>In this work, the in-situ alloying of Cu-25Cr from an elemental powder blend via PBF-EB was investigated numerically and experimentally, which resulted in the development of a first process window for the production of dense and well-mixed samples. In doing so, the number of necessary experimental tests could be greatly reduced by using numerical predictions for the definition of the design of experiments. In addition, simulations were used to gain an understanding of the formation mechanism of characteristic defects. These calculations were carried out using an in-house developed software, which was successfully validated against the experimental results.</div><div>As part of the experimental tests, it was demonstrated that the powder mixture does not segregate during its application on the start plate, which forms the basis for the reliable production of components with a consistent composition. At a build temperature of approximately 600<!--> <!-->°C, it was then possible to produce cuboid samples with a porosity of smaller than 0.1% and a fraction of unmolten Cr particles of smaller than 0.2%.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104874"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611648","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":"Magnetically assisted direct writing 3D printing programmable magnetically responsive origami actuator","authors":"Chao Xu ,&nbsp;Pengbo Zhou ,&nbsp;Xueli Zhou ,&nbsp;Lu Zhang ,&nbsp;Qingping Liu ,&nbsp;Luquan Ren","doi":"10.1016/j.addma.2025.104898","DOIUrl":"10.1016/j.addma.2025.104898","url":null,"abstract":"<div><div>Magnetically responsive origami actuators have significant potential in soft robotics and biomedicine, but their development is limited by complex preparation processes, limited material compatibility, and a single deformation mode. In this study, we propose an innovative strategy to achieve synergistic regulation of magnetic domain space programming and structural stiffness gradient by integrating magnetically-assisted direct-write 3D printing technology and notch design. The novel magnetic ink developed based on PDMS/Ecoflex elastic matrix and neodymium-iron-boron (NdFeB) magnetic particles, combined with the real-time magnetic field orientation technology, enables accurate programming of the magnetic moment directions during the printing process to construct complex magnetic domain distributions. The introduction of the notch structure significantly reduces the local stiffness and concentrates the deformation on the pre-programmed creases, improving driving efficiency. By combining the multi-axis magnetron platform with origami geometries (e.g., Miura, Kresling, and jig origami configurations), the actuator exhibits multi-modal deformation capabilities such as reversible folding, rolling, and metamaterial shrinkage. Experiments and simulations show that the notch design improves the bending angle of the actuator by a factor of 2.8 under a 50 mT magnetic field compared to the non-notched structure. In addition, the functionalized application verification includes clamping (8 g load), bionic pumping (7.8 mL of liquid per pumping cycle), and adjustable stiffness loading (10 g capacity), highlighting its applicability in soft robotics and microfluidic systems. This study provides a mold-less and scalable fabrication platform for high-precision magnetically driven origami structures, which promotes the development of smart devices toward multimodal actuation and functional integration.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104898"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144679996","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":"Multi-material printing of 3D heterogeneous structures with embedded microscale conductive features for electromagnetic function","authors":"Kun Yu ,&nbsp;Wenyou Zhang ,&nbsp;Jiakun Feng ,&nbsp;Junyu Yue ,&nbsp;Yi Ding ,&nbsp;Qingxuan Liang ,&nbsp;Yi Cao ,&nbsp;Dichen Li ,&nbsp;Jiankang He","doi":"10.1016/j.addma.2025.104890","DOIUrl":"10.1016/j.addma.2025.104890","url":null,"abstract":"<div><div>Multi-material printing has recently gained extensive attention as an efficient strategy for the integrated fabrication of 3D heterogeneous structures with microscale conformal/embedded electronics in the field of antennas or metasurface. However, as one of the most popularly utilized multi-material printing processes, fused filament fabrication (FFF) commonly suffers from poor surface morphology, which poses a significant challenge for the subsequent deposition of conductive features with micro-resolution and stable conductivity. Here, we propose a novel multi-material printing strategy by combining coaxial electrohydrodynamic (CEHD) printing and FFF for the one-step fabrication of 3D heterogeneous structures with conformal or embedded microelectronics. It is found that the outer polyimide (PI) layer applied during the CEHD process can locally smooth the FFF-printed PEEK surfaces with varying roughness and enables the direct deposition of microscale core-shell conductive features with stable conductivity. Remarkably, the smallest conductive linewidth of Ag that can be achieved on an FFF-printed surface with a roughness of 23.57 ± 6.24 μm is 42.10 ± 3.45 μm, showing a conductivity of (0.32 ± 0.01) × 10⁷ S/m. The proposed strategy demonstrates wide applicability across different substrate materials and geometries, and exhibits strong interfacial bonding strength and excellent electrical stability under different mechanical/physical conditions. More importantly, the presented multi-material printing technique offers great flexibility in integrally fabricating 3D heterogeneous structures with built-in microelectronics. The patterns of the embedded microelectronics exhibit a layer-specific variation, which demonstrates an innovative strategy to modulate the electromagnetic functionalities of the resultant heterogeneous structures. We envision that the proposed multi-material printing technique offers a unique capability to integrally fabricate mechanical/electrical structures with designed electromagnetic functionalities, enabling applications in curved conformal antennas and electromagnetic shielding devices.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104890"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654356","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":"Corrigendum to “Fine-grained binder jetted tungsten heavy alloys with in situ nano-La2O3 addition via a novel metal salt binder” [Addit. Manuf. 109 (2025) 104843]","authors":"Yuhua Heng,&nbsp;Yiwei Mao,&nbsp;Kunhao Feng,&nbsp;Jiangtao Sun,&nbsp;Jianan Zheng,&nbsp;Yingmi Xie,&nbsp;Qingsong Wei","doi":"10.1016/j.addma.2025.104865","DOIUrl":"10.1016/j.addma.2025.104865","url":null,"abstract":"","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104865"},"PeriodicalIF":11.1,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144828241","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":"Bead geometry prediction in wire arc directed energy deposition using physics-informed machine learning and low-fidelity data","authors":"Asif Rashid,&nbsp;Farzad Vatandoust,&nbsp;Akshar Kota,&nbsp;Shreyes N. Melkote","doi":"10.1016/j.addma.2025.104881","DOIUrl":"10.1016/j.addma.2025.104881","url":null,"abstract":"<div><div>Wire Arc Directed Energy Deposition (Wire Arc DED) is a promising metal additive manufacturing technique, yet accurate bead geometry prediction remains a challenge due to the complex thermal and geometric interactions in the process. In this study, we present a coupled Physics-Informed Neural Network (PINN) framework to predict the bead geometry by integrating the governing process physics and experimental data, thereby addressing the limitations of both computationally expensive numerical models and purely data-driven approaches. The model employs a sequential two-step workflow, where a thermal model first predicts temperature evolution, which subsequently informs a geometry model for predicting the bead geometry. Results indicate that a high-fidelity PINN model with high spatiotemporal resolution captures the intricately coupled thermal and geometric variations inherent to bead deposition with good predictive accuracy albeit at a higher computational cost, while a low-fidelity PINN model with lower spatiotemporal resolution offers a computationally efficient alternative with marginally higher errors. The incorporation of measured bead geometry data significantly enhances prediction accuracy, with a minimal amount of low-fidelity data sufficing to refine predictions effectively. Moreover, the model generalizes well across different bead locations along the deposition length, demonstrating reliable performance. The high-fidelity PINN model, using a temporal step size of 0.2 s, achieves an average height prediction error of 8.38 % and width error of 1.09 % after approximately 12.7 hours of training on four H100 GPUs. In contrast, the low-fidelity model, with a coarser temporal step size of 0.5 s, reaches nearly the same accuracy (8.33 % height error, 1.56 % width error) with just 2.7 h of training on a single H100 GPU. This corresponds to a 79 % reduction in training time and substantially lower hardware requirements, highlighting the scalability and efficiency of the proposed hybrid modeling approach.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104881"},"PeriodicalIF":10.3,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144632424","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":"Laser powder bed fusion vs. single track laser melting of martensitic Ti-Nb: Phase and microstructure formation","authors":"Florian Senftleben ,&nbsp;Mariana Calin ,&nbsp;Jürgen Eckert ,&nbsp;Matthias Bönisch","doi":"10.1016/j.addma.2025.104884","DOIUrl":"10.1016/j.addma.2025.104884","url":null,"abstract":"<div><div>The aim of this work is to explore the fabrication of α″ Ti-Nb via laser powder bed fusion (LPBF) using pre-alloyed ball-milled feedstock powders. Ti-29Nb alloy powder was prepared by mechanical alloying of elemental Ti and Nb powders, using NaCl as milling agent. Pre-alloyed powders were consolidated into bulk cuboids via LPBF and the effect of different build settings on resulting phases, microstructure and porosity was studied. Phases and microstructures of the LPBF parts were compared with those of single tracks on α″ martensitic substrates. Depending on the Nb content, LPBF leads to either planar or cellular-dendritic solidification. α′ and α″ martensites, β and α phase form in the as-built parts. Single track experiments show that planar growth is conducive for the formation of α″ martensite post-solidification. While in-situ alloying is possible for specific LPBF settings, the use of pre-alloyed powders is recommended to enlarge the build parameter space for reproducible as-built microstructures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104884"},"PeriodicalIF":11.1,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144720954","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}