Additive manufacturing最新文献_第8页

Regulated the orientation of graphene nanoplatelets via flow field in material extrusion for enhancing thermal conductivity

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-20 DOI: 10.1016/j.addma.2025.104718

Gang Chen , Zhuandong Zhu , Zhentao Lu , Wenyan Wang , Shuai Zhang , Pan He , Yujun Wei , Rui Han , Biyou Peng , Ning Chen

{"title":"Regulated the orientation of graphene nanoplatelets via flow field in material extrusion for enhancing thermal conductivity","authors":"Gang Chen , Zhuandong Zhu , Zhentao Lu , Wenyan Wang , Shuai Zhang , Pan He , Yujun Wei , Rui Han , Biyou Peng , Ning Chen","doi":"10.1016/j.addma.2025.104718","DOIUrl":"10.1016/j.addma.2025.104718","url":null,"abstract":"<div><div>Developing polymer composites with high thermal conductivity while maintaining low filler content remains a challenge. The aim of this study is to arrange graphene nano-platelets (GNP) into highly aligned structure within polypropylene (PP) matrix by utilizing the flow field during the material extrusion (MatEx) additive manufacturing process. Finite element simulation was employed to clarify the flow field distribution under varying nozzle diameters and printing speeds. The dispersion and orientation of GNP were systematically characterized, and the microstructure of the printed composites was further correlated with their thermal conductivity. It was found that the orientation degree of GNP is strongly dependent on the intensity of flow field during the MatEx process. By reducing nozzle diameter from 0.6 mm to 0.3 mm and increasing printing speed from 200 mm/min to 600 mm/min, the Hermans orientation factor <em>f</em> of GNP increases from 0.28 at 0.6 mm nozzle and 200 mm/min to 0.74 at 0.3 mm nozzle and 600 mm/min. This enhancement facilitates the formation of efficient and ordered thermally conductive pathways along the through-plane direction. Moreover, the through-plane thermal boundary resistance is also notably improved, decreasing from 7.25 × 10<sup>−5</sup> to 1.17 × 10<sup>−5</sup> m<sup>2</sup>K/W. The aligned microstructure of the composites, printed using a 0.3 mm nozzle at a 600 mm/min printing speed, yields a superior thermal conductivity of 2.18 W/m·K with only 1.23 vol% GNP, indicating an impressive enhancement efficiency of 690 %. Coupled with the capability of MatEx to construct complex structures and shapes, this strategy holds great promise for achieving efficient heat dissipation devices with low filler loading.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104718"},"PeriodicalIF":10.3,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143488175","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

Large-scale additive manufacturing of optimally-embedded spinodal material architectures

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-20 DOI: 10.1016/j.addma.2025.104700

Andrea Nale , Andrea Chiozzi , Fernando V. Senhora , Glaucio H. Paulino

{"title":"Large-scale additive manufacturing of optimally-embedded spinodal material architectures","authors":"Andrea Nale , Andrea Chiozzi , Fernando V. Senhora , Glaucio H. Paulino","doi":"10.1016/j.addma.2025.104700","DOIUrl":"10.1016/j.addma.2025.104700","url":null,"abstract":"<div><div>We present a synergistic methodology to design large-scale 3D-printed structures based on a multi-material topology optimization formulation, which leads to the realization of three-dimensional hierarchical structures with spatially oriented non-periodic spinodal microstructures. The inherent characteristics of these unstructured architectures allow the design of optimized layouts with smooth transitions of spinodal material classes, accounting for varying porosity and orientation. The design and manufacturing processes are bridged by a topology-by-material optimization approach, in which the iterative process preserves the macro-scale continuity, while the microstructural topological space is optimized by a suitable distribution of multiple spinodal architected materials. To illustrate both the design and the manufacturing processes, we leverage the features of a large-scale water jetting powder-bed 3D printing technology, which makes use of aggregates obtained from powdered stone-like materials and magnesium-based binders. The optimized model is transferred to the printer by means of a voxel-based generation strategy. The approach, exemplified by means of several numerical simulations and physical 3D-printed samples, connects design conceptualization, material properties at different length scales, and the complex process of additively manufacturing load-bearing structures in a large-scale framework.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104700"},"PeriodicalIF":10.3,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143508391","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}

引用次数: 0

Eliminating structural defects in large area mechanical metamaterials via hot lithography in large-area projection micro-stereolithography

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-19 DOI: 10.1016/j.addma.2025.104717

David Hahn , Vatsa Gandhi , Huachen Cui , Angkur Shaikeea , Zhenpeng Xu , Zac Gwennap , Vikram Deshpande , Xiaoyu (Rayne) Zheng

{"title":"Eliminating structural defects in large area mechanical metamaterials via hot lithography in large-area projection micro-stereolithography","authors":"David Hahn , Vatsa Gandhi , Huachen Cui , Angkur Shaikeea , Zhenpeng Xu , Zac Gwennap , Vikram Deshpande , Xiaoyu (Rayne) Zheng","doi":"10.1016/j.addma.2025.104717","DOIUrl":"10.1016/j.addma.2025.104717","url":null,"abstract":"<div><div>Additive manufacturing has enabled the creation of new classes of architected meta-materials with exceptional structural and functional properties. Large-area projection micro-stereolithography (LAPµSL) has the potential for producing large volume metamaterials with millions of micro-scale unit cells and multiple orders of magnitude in length scales. Nevertheless, as part size grows with increasing number of unit cells, probability of finding embedded defects becomes significantly higher. Structural defects, such as internal cracks and non-uniformity embedded within networks of micro-scale unit cells, often remain undetected due to flawless external appearances. Herein, we elucidate the mechanisms underlying embedded structural defects during the free surface metamaterial printing. Our experimental investigations and theoretical calculations reveal a growing trend of surface tension effect at the interface between solidified pattern and uncured liquid. We found that this surface tension effect plays a dominant role in defect generation. We present a novel approach that uses in-situ Joule-heating to effectively minimize the free surface bulging phenomenon and enables the production of large, defect-free, low-density mechanical metamaterials. Our results are validated through in-situ non-contact resin surface profiling and X-ray computed tomography (XCT), confirming mechanical properties close to theoretical predictions. This work forms the basis of production of large volume metamaterials with millions of micro-scale features for advanced engineering applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104717"},"PeriodicalIF":10.3,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143508393","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

Investigating the effects of processing parameters in reactive extrusion additive manufacturing

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-19 DOI: 10.1016/j.addma.2025.104716

Hongtao Song , Michael J. Fogg , Mehran Tehrani , Carolyn Seepersad

{"title":"Investigating the effects of processing parameters in reactive extrusion additive manufacturing","authors":"Hongtao Song , Michael J. Fogg , Mehran Tehrani , Carolyn Seepersad","doi":"10.1016/j.addma.2025.104716","DOIUrl":"10.1016/j.addma.2025.104716","url":null,"abstract":"<div><div>Reactive Extrusion additive manufacturing (REAM) is an additive manufacturing (AM) process in which a liquid thermoset feedstock is deposited and cured <em>in situ</em>. The REAM process has many unique advantages such as the ability to fabricate parts with isotropic mechanical properties, initiate curing without external energy input, and utilize high extrusion rates. However, there are many complex factors such as curing kinetics, feedstock rheology, and thermal gradients that can influence the capabilities of the REAM system and the resulting dimensional accuracy and mechanical properties of the fabricated parts. Understanding the processing parameters of an AM process is crucial to resolving complex features and producing high-quality parts repeatably. While REAM has been documented in the literature, no in-depth studies investigating these processing parameters exist. In this work parameters such as the extrusion rate, deposition speed, and the elapsed time between layers are investigated, and their effect on resulting part properties are characterized. Additionally, the ability to fabricate unsupported overhangs and bridges is also studied as a function of different processing parameters. By understanding these variables and their effects, the system can be tuned to improve accuracy, repeatability, and feature resolution.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104716"},"PeriodicalIF":10.3,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143519967","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

z-GrAdd – Facile fabrication of various functional gradient materials by 3D printing using the gradual addition of reagents

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-19 DOI: 10.1016/j.addma.2025.104713

Niloofar Nekoonam , Seyed Alireza Sheikholeslami , Silvio Tisato , Pang Zhu , Ramin Montazeri , Zahra Hosneolfat , Dorothea Helmer

{"title":"z-GrAdd – Facile fabrication of various functional gradient materials by 3D printing using the gradual addition of reagents","authors":"Niloofar Nekoonam , Seyed Alireza Sheikholeslami , Silvio Tisato , Pang Zhu , Ramin Montazeri , Zahra Hosneolfat , Dorothea Helmer","doi":"10.1016/j.addma.2025.104713","DOIUrl":"10.1016/j.addma.2025.104713","url":null,"abstract":"<div><div>Control over physical and chemical properties during additive manufacturing is highly advantageous for fabricating functional gradient materials (FGM) with diverse applications. Conventional methods like vat exchange or grayscale light projection are often limited in producing graded properties or compositional gradients and they suffer from slow speed and complicated setups. Here, we present the z-GrAdd (z-Gradient by Addition of a reagent) method, a facile method for Digital Light Processing (DLP)-based vat photopolymerization of FGMs in a single structure through the gradual addition of a resin component to the vat during printing. The z-GrAdd enables continuous alteration of resin composition during the printing, resulting in gradient properties in z-direction. We demonstrate FGM fabrication with gradients of surface energy, porosity, and hardness using a range of acrylate-based resins. Surface energy gradients (18–29 mN/m) and hardness gradients (19.2–29.6 shore D) were achieved by gradual variation of the hydrophilic monomer and crosslinker content, respectively. Porosity was modulated by gradual increase in porogen (non-solvent) which implied polymerization-induced phase separation, resulting in a pore size increase and a corresponding roughness between 52–401 nm (S<sub>q</sub>). The versatility of the FGMs with wettability gradients was shown for passive droplet manipulation and liquid imbibition control. To further highlight the versatility of the z-GrAdd for fabricating different gradients, structures with ascending and descending hardness gradients by consecutive addition of two different reagents were produced. In conclusion, z-GrAdd is suitable for various acrylate-based compositions allowing for an easy cost-effective implementation, and fabrication of a wide variety of applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104713"},"PeriodicalIF":10.3,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143480218","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}

引用次数: 0

Laser additive manufacturing of lunar regolith simulant: New insights from in situ synchrotron X-ray imaging

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-18 DOI: 10.1016/j.addma.2025.104711

Caterina Iantaffi , Chu Lun Alex Leung , George Maddison , Eral Bele , Samy Hocine , Rob Snell , Alexander Rack , Martina Meisnar , Thomas Rohr , Iain Todd , Peter D. Lee

{"title":"Laser additive manufacturing of lunar regolith simulant: New insights from in situ synchrotron X-ray imaging","authors":"Caterina Iantaffi , Chu Lun Alex Leung , George Maddison , Eral Bele , Samy Hocine , Rob Snell , Alexander Rack , Martina Meisnar , Thomas Rohr , Iain Todd , Peter D. Lee","doi":"10.1016/j.addma.2025.104711","DOIUrl":"10.1016/j.addma.2025.104711","url":null,"abstract":"<div><div>The establishment of on-site autonomous manufacturing capabilities for a sustainable long term lunar base can benefit from additive manufacturing. While previous studies have demonstrated that laser powder bed fusion (LPBF) can manufacture lunar Regolith parts, significant challenges remain in fabricating large structural parts with consistent properties due to the complexities of LPBF process and the variability in the mineralogical composition of Regolith. This study examines process instabilities, melt flow dynamics and defect evolution during LPBF of lunar Mare Regolith simulant LMS-1, using <em>in situ</em> and <em>operando</em> synchrotron X-ray imaging and <em>ex situ</em> characterisation techniques across a range of processing parameters. Five processing regimes for LPBF of LMS-1 were identified: (i) no deposition, (ii) balling, (iii) sintering, (iv) vitrification, and (v) vaporization. The optimal LPBF parameters are 145 W laser power, 390 mm/s scan speed, and 0.25 mm hatch spacing. A laser re-scan strategy is used to further improve sample consolidation and minimise thermal stress accumulation in LMS-1 parts. Essential materials data and <em>in situ</em> X-rays images of melt pool geometry evolution for validating multiphysics numerical models of lunar Regolith laser melting are provided.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104711"},"PeriodicalIF":10.3,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143488176","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}

引用次数: 0

Water-based hydroxyapatite photocurable feedstock for the manufacture of architectured parts by vat photopolymerization

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-18 DOI: 10.1016/j.addma.2025.104710

Simão Santos, Manuel F.R.P. Alves, Georgina Miranda , Susana M. Olhero

{"title":"Water-based hydroxyapatite photocurable feedstock for the manufacture of architectured parts by vat photopolymerization","authors":"Simão Santos, Manuel F.R.P. Alves, Georgina Miranda , Susana M. Olhero","doi":"10.1016/j.addma.2025.104710","DOIUrl":"10.1016/j.addma.2025.104710","url":null,"abstract":"<div><div>Hydroxyapatite (HAp) is a biocompatible, osteoconductive, and biodegradable material widely studied for tissue engineering applications. Additive manufacturing, particularly vat photopolymerization technologies, enable the manufacture of custom-made, highly precise solutions. In this work, a colloidal approach was used to develop a water-based photocurable HAp-loaded feedstock with low viscosity, high solid loading (45 vol%), and low amount of organic compounds (10 vol%). Two distinct types of dispersants were evaluated to modify the surface of the HAp powders to enhance stability and dispersion. Rheological experiments were conducted to determine the optimal dispersant concentration, solid-loading, and pre-polymer content. Photorheological experiments were also performed to identify the printing parameters suitable for the vat photopolymerization technology. This work’s approach, characterized by its low organic content, enabled a fast-debinding process (≈13.5 h) when compared to the conventional photocurable ceramic-based feedstock. Different sintering temperatures were tested (1150 °C → 1350 °C) and X-ray diffraction was used to evaluate the crystallographic composition at each temperature. Additionally, the relative density of the sintered parts was calculated and the compressive strength determined. The results demonstrated that sintering temperature enables high customization to meet specific end-user requirements. Architectured structures with interconnected porosity were successfully printed as a proof-of-concept of the potential printability of the developed aqueous-based feedstock. The eco-friendly photopolymerizable feedstock developed in this work should strongly impact the production cycle of resorbable bioceramic-based components.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104710"},"PeriodicalIF":10.3,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143508390","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}

引用次数: 0

Smooth 3D transition cell generation based on latent space arithmetic

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-18 DOI: 10.1016/j.addma.2025.104714

Xiaochen Yu , Bohan Peng , Ajit Panesar

{"title":"Smooth 3D transition cell generation based on latent space arithmetic","authors":"Xiaochen Yu , Bohan Peng , Ajit Panesar","doi":"10.1016/j.addma.2025.104714","DOIUrl":"10.1016/j.addma.2025.104714","url":null,"abstract":"<div><div>Lattice structures with multiple unit cell types diversify the property space by offering more design freedom, encouraging adaptation of metamaterials in engineering applications. It is essential to ensure structural connectivity and smooth transition among different cell types to avoid pre-mature failure. In this work, we propose a framework based on latent space operations to generate smoothly morphing and fully connected transition cells, addressing the current research gap in realising lattice designs of dissimilar unit cells. Latent embedding – a low-dimensional representation of the original microstructure – is obtained through a variational autoencoder. Different types of triply periodic minimal surface (TPMS) lattice were chosen as the targets to demonstrate the capability of the algorithm in handling complex 3D geometries within a physically restricted transition region. Both qualitative and quantitative evaluations are provided to illustrate the connectivity and geometric similarity of the generated transition. Benchmark comparisons against both analytical and existing machine learning (ML) based solutions indicate the superior efficacy and generality of the proposed framework.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104714"},"PeriodicalIF":10.3,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143464537","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}

引用次数: 0

The nature of oxide films in process-induced lack-of-fusion defects on laser powder bed fusion-fabricated Hastelloy X Ni-based alloy

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-17 DOI: 10.1016/j.addma.2025.104709

Xing He , Reynier I. Revilla , Decheng Kong , Xiaoqing Ni , Wei Zhang , Kunjie Dai , Chaofang Dong

{"title":"The nature of oxide films in process-induced lack-of-fusion defects on laser powder bed fusion-fabricated Hastelloy X Ni-based alloy","authors":"Xing He , Reynier I. Revilla , Decheng Kong , Xiaoqing Ni , Wei Zhang , Kunjie Dai , Chaofang Dong","doi":"10.1016/j.addma.2025.104709","DOIUrl":"10.1016/j.addma.2025.104709","url":null,"abstract":"<div><div>This study investigates the oxide films formed on the inner walls of lack-of-fusion (LOF) defects in Hastelloy X Ni-based alloy produced by laser powder bed fusion (LPBF) and their influence on corrosion behavior. Using X-ray CT and high-resolution transmission electron microscope, we revealed that these oxide films, located at the pore-matrix interfaces, exhibit an uneven thickness and play a significant structural role relative to the voids. The oxide film consists of a 6.3 nm NiO inner layer and a 1.2 nm amorphous outer layer, with the inner layer maintaining a coherent orientation with the matrix, minimizing interface strain. Electrochemical analyses showed that the existence of oxide films would reduce the diffusion coefficient of point defects and the concentration of dissolved metal cations in the passive film formed on the LOF defects while also boosting the outward diffusion rate of cations therein. This process diminishes the rate of dissolution associated with surface activity for LPBF Hastelloy X Ni-based alloy in corrosive mediums, ultimately promoting the repassivation process and improving the corrosion resistance properties.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104709"},"PeriodicalIF":10.3,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143428989","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

Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-02-17 DOI: 10.1016/j.addma.2025.104707

Ismael E. Coello , Jennifer A. Glerum , Clement N. Ekaputra , Jon-Erik Mogonye , David C. Dunand

{"title":"Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion","authors":"Ismael E. Coello , Jennifer A. Glerum , Clement N. Ekaputra , Jon-Erik Mogonye , David C. Dunand","doi":"10.1016/j.addma.2025.104707","DOIUrl":"10.1016/j.addma.2025.104707","url":null,"abstract":"<div><div>Microstructure and creep properties are studied in a eutectic AlSi10Mg alloy modified with Zr and Sc additions (Al-9.8Si-0.32Mg-0.70Zr-0.23Sc, wt%) manufactured through laser powder-bed fusion (L-PBF). Three types of Zr/Sc-bearing powders - elemental, master-alloy, and pre-alloyed - are employed in the fabrication process, with the pre-alloyed powders providing the highest incorporation of Zr and Sc in the Al matrix. The as-printed alloy exhibits a fine cellular Al-Si eutectic structure which fragments and coarsens into micron-sized Si particles during aging at 300 ºC, leading to a steady drop in alloy microhardness between 0.1 and 1000 h. Coarsening of the eutectic Si phase during aging is not measurably affected by Zr and Sc in solid solution, which precipitate during aging and increases strength, compensating weakening from Si coarsening between 1 and 200 h at 300 ºC. Atom-probe analysis in the peak-aged condition (96 h/300 °C) confirms the presence of Al<sub>3</sub>(Sc,Zr) secondary nano-precipitates with an average radius of 1.0 nm and some Si solubility. Micron-sized grains are present throughout the alloy, with ultra-fine-grained regions at the melt pool boundaries, neither of which coarsen during long-term aging at 300 ºC. Under creep conditions at 300 °C, the Zr/Sc-bearing alloy with Al<sub>3</sub>(Sc,Zr) nano-precipitates exhibits power-law behavior, with a high apparent stress exponent (<em>n</em><sub><em>a</em></sub> = 9) and a high threshold stress (<em>σ</em><sub><em>th</em></sub> = 43 MPa), exhibiting nearly double the strength of a Zr/Sc-free AlSi10Mg control alloy (<em>σ</em><sub><em>th</em></sub> = 22 MPa).</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104707"},"PeriodicalIF":10.3,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143464535","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