Additive manufacturing最新文献

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Warpage of thin additively manufactured continuous fiber thermoset composites 薄增材制造连续纤维热固性复合材料的翘曲
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-25 DOI: 10.1016/j.addma.2025.104749
Mateo Diaz, Jeffery W. Baur
{"title":"Warpage of thin additively manufactured continuous fiber thermoset composites","authors":"Mateo Diaz,&nbsp;Jeffery W. Baur","doi":"10.1016/j.addma.2025.104749","DOIUrl":"10.1016/j.addma.2025.104749","url":null,"abstract":"<div><div>Additive manufacturing (AM) of thin continuous fiber thermoset composites can have large and anisotropic residual stresses that result in out of plane shape distortion, or warpage, and limits applicability to thin structures. In this study, the warpage of thin AM laminates was investigated as a function of deposited fiber direction and microstructure heterogeneity. The experimental results were compared with predictions made by Classical Lamination Theory (CLT), which assumed homogeneous deposited layers, and microstructure-informed CLT, which accounted for heterogeneity in the thickness direction. For thin unidirectional laminates, a curvature was observed in the transverse direction upon slow (0.3 °C/min) unconstrained cooling from the maximum curing temperature (140°C). Magnitudes of the observed curvatures (<span><math><mi>κ</mi></math></span>) decreased as the number of deposited layers (n) increased from n = 1 (<span><math><mi>κ</mi></math></span> = 8 m<sup>−1</sup>) to n = 8 (<span><math><mi>κ</mi></math></span> = 1 m<sup>−1</sup>) and did not match the CLT prediction of zero curvature. The variation in through-thickness fiber volume fraction was quantified by optical cross-section micrographs and used to make microstructure-informed CLT predictions which ranged from <span><math><mi>κ</mi></math></span> = ∼0.6 m<sup>−1</sup> (n = 8) to <span><math><mi>κ</mi></math></span> = 26 m<sup>−1</sup> (n = 1). While the curvature of the symmetrically stacked cross-ply laminates (0° and 90°) had near zero curvature and agreed with CLT predictions, the asymmetrically stacked cross-ply laminates predicted a large saddle-like curvature that was not fully observed due to delamination between orthogonally aligned layers. For thin (≤4 layers, ∼0.24 mm/layer) AM thermosetting laminates without delamination, the experimentally observed curvature values were roughly bounded between predictions made by CLT and by microstructure-informed CLT.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"102 ","pages":"Article 104749"},"PeriodicalIF":10.3,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687773","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
Unveiling ultra-stable cyclic martensitic transformation behavior of an additively manufactured NiTiCu shape memory alloy 揭示了一种增材制造NiTiCu形状记忆合金的超稳定循环马氏体相变行为
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-25 DOI: 10.1016/j.addma.2025.104742
Dan Zheng , Ruidi Li , Jingtao Kang , Changjun Han , Tiechui Yuan
{"title":"Unveiling ultra-stable cyclic martensitic transformation behavior of an additively manufactured NiTiCu shape memory alloy","authors":"Dan Zheng ,&nbsp;Ruidi Li ,&nbsp;Jingtao Kang ,&nbsp;Changjun Han ,&nbsp;Tiechui Yuan","doi":"10.1016/j.addma.2025.104742","DOIUrl":"10.1016/j.addma.2025.104742","url":null,"abstract":"<div><div>Additively manufactured (AM) nickel-titanium (NiTi) shape memory alloys (SMAs) often suffer from functional fatigue due to intrinsic large hysteresis and process complexities during cyclic operation. This study, by optimizing lattice compatibility between the parent and martensitic phases, presents a laser-directed energy deposited (LDED) Ni40-Ti50-Cu10 (at%) SMA that simultaneously achieves low hysteresis and enhanced cyclic stability in martensitic transformation behavior. Only 0.31°C of martensitic transformation temperature shift was observed after 50 thermal cycles, significantly outperforming conventional SMAs. The non-equilibrium solidification of the LDED process generates cross-scale microstructures and a distinct (100) growth texture, while excellent lattice compatibility restricts martensitic variants to favorable orientations of (010)<sub>B2</sub> || (001)<sub>B19</sub> and (101)<sub>B2</sub> || (010)<sub>B19</sub>. Dominant (011) type I twin relationship between martensitic variants is observed with coherent twin interfaces. These characteristics reduce the energy barrier at the phase transition interface, effectively mitigating interface stress and preventing irreversible defects, minimizing hysteresis, and ensuring ultra-stable cyclic martensitic transformation. Additionally, Ti<sub>2</sub>Cu precipitates, formed at twin ridges due to cyclic heating during fabrication, pin dislocations and prevent their movement across twin interfaces, ensuring repeatability and reversibility in each cycle. The utilization of pre-alloyed powder guarantees macroscopic uniformity in phase composition and transition behavior, resulting in consistent cycle stability along the build direction. This study provides new insights into the high cyclic stability of LDED-fabricated NiTiCu10 SMAs and advances the development of high-performance SMAs with degradation-free cyclic phase transformation using AM technology.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"102 ","pages":"Article 104742"},"PeriodicalIF":10.3,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143687763","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
Exploring inorganic particle-inclusive RAFT-controlled radical polymerization: Advancing precision in ceramic 3D printing 探索包含无机颗粒的raft控制自由基聚合:提高陶瓷3D打印的精度
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-25 DOI: 10.1016/j.addma.2025.104757
Yixuan Gong , Ruoyu Wang , Siyu Pan , Zeyu Ma , Xiyu Zhu , Ye Song , Haitao Song , Lei Tao , Dongxue Cao , Wei Lin
{"title":"Exploring inorganic particle-inclusive RAFT-controlled radical polymerization: Advancing precision in ceramic 3D printing","authors":"Yixuan Gong ,&nbsp;Ruoyu Wang ,&nbsp;Siyu Pan ,&nbsp;Zeyu Ma ,&nbsp;Xiyu Zhu ,&nbsp;Ye Song ,&nbsp;Haitao Song ,&nbsp;Lei Tao ,&nbsp;Dongxue Cao ,&nbsp;Wei Lin","doi":"10.1016/j.addma.2025.104757","DOIUrl":"10.1016/j.addma.2025.104757","url":null,"abstract":"<div><div>Stereolithography is a highly effective method for fabricating intricate ceramic parts, offering fast molding speeds and a diverse range of material options. However, it still faces significant precision challenges due to the incorporation of inorganic ceramic particles, which alters the propagation path of the incident light and affects the region where the polymerization reaction occurs. Herein, we regulate the polymerization reaction kinetics by introducing reversible addition-fragmentation chain transfer (RAFT) controlled radical polymerization into ceramic stereolithography, successfully reducing the minimum printable feature size of Al<sub>2</sub>O<sub>3</sub> photosensitive slurry to 200 μm and achieving over 86.7 % fidelity across all tested feature sizes. The RAFT-based ceramic stereolithography system enhances the uniformity of the polymer network and reduces the formation of high cross-link density microgels with a high refractive index. Additionally, incorporating RAFT agents increases the critical energies in both depth and width directions, mitigating out-of-target area curing caused by radical diffusion. Furthermore, the RAFT formulation significantly reduces the attenuation length in the width direction, broadening the printing operational window and improving dimensional stability. Finally, the cross-section exposure distribution simulations under varying conditions suggest that RAFT-slurry reduces the broadening of the cure diameter caused by scattering effects and enhances inter-layer interactions during printing. This work presents a new technological approach for the advanced manufacturing of fine ceramic structures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104757"},"PeriodicalIF":10.3,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739660","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
Investigate mechanisms of different printing parameters on the mechanical anisotropy of 3D concrete printing elements by using computed tomography scan and computational fluid dynamics methods 采用计算机断层扫描和计算流体力学方法,研究了不同打印参数对3D混凝土打印构件力学各向异性的影响机理
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-24 DOI: 10.1016/j.addma.2025.104760
Zhenbang Liu , Mingyang Li , Xiangyu Wang , Teck Neng Wong , Ming Jen Tan
{"title":"Investigate mechanisms of different printing parameters on the mechanical anisotropy of 3D concrete printing elements by using computed tomography scan and computational fluid dynamics methods","authors":"Zhenbang Liu ,&nbsp;Mingyang Li ,&nbsp;Xiangyu Wang ,&nbsp;Teck Neng Wong ,&nbsp;Ming Jen Tan","doi":"10.1016/j.addma.2025.104760","DOIUrl":"10.1016/j.addma.2025.104760","url":null,"abstract":"<div><div>3D concrete printing (3DCP) elements show significant mechanical anisotropy. Printing parameters can affect the mechanical anisotropy of 3DCP elements. However, most studies have focused on the effects of printing parameters on the interlayer bond strength at a macroscale level. The mechanisms of printing parameters on the mechanical anisotropy of 3DCP elements remain unclear. To fill research gaps, computed tomography (CT) scans, computational fluid dynamics (CFD) numerical simulations, and uniaxial compression tests (UCTs) were conducted with the printing parameters of the expansion state of the nozzle flow channel, overflow ratio, stand-off distance, and flow rate involved. The results of CT scans, CFD simulations, and UCTs revealed the mechanism that the printing parameters affect porosity distribution and pore anisotropy by influencing the normalized local pressure at interlayer and fluid velocity gradients, respectively, which further results in the modification of the mechanical anisotropy of 3DCP elements.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104760"},"PeriodicalIF":10.3,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143734905","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
Printing dense and low-resistance copper microstructures via highly directional laser-induced forward transfer 利用高定向激光诱导正向转移技术打印致密低阻铜微结构
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-24 DOI: 10.1016/j.addma.2025.104755
Jiangyou Long , Yujun Zhou , Jinghao Lin , Bingjun Luo , Zhiheng Wu , Xinhong Su
{"title":"Printing dense and low-resistance copper microstructures via highly directional laser-induced forward transfer","authors":"Jiangyou Long ,&nbsp;Yujun Zhou ,&nbsp;Jinghao Lin ,&nbsp;Bingjun Luo ,&nbsp;Zhiheng Wu ,&nbsp;Xinhong Su","doi":"10.1016/j.addma.2025.104755","DOIUrl":"10.1016/j.addma.2025.104755","url":null,"abstract":"<div><div>Laser-induced forward transfer (LIFT) can be used to print micrometer-scale metallic three-dimensional (3D) structures. However, the structures produced by this method exhibit high porosity and poor electrical properties due to the non-vertical ejection and loose stacking of transfer particles. In this study, we replace the conventional copper (Cu) monolayer donor film with a chromium-copper (Cr-Cu) bilayer film. We demonstrate that this bilayer enhances laser absorption and improves glass-metal adhesion through the spontaneous formation of a CrO<sub><em>x</em></sub> interlayer. The improved laser absorption reduces the optimal pulse energy required for transfer, while the interlayer stabilizes the transfer process, promoting more vertical ejection of material. This enhanced directionality leads to denser structures, even when the donor and receiver are placed at a larger distance. The resulting structures exhibit a porosity of 4.8 % and a specific resistance 2.9 times that of bulk copper. Cross-sectional electron microscopy is employed to investigate the microstructure and elucidate the mechanisms behind the reduced resistance. Additionally, we demonstrate the application of this 3D printing method in creating high aspect ratio microstructures and repairing open defects on printed circuit boards (PCBs).</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104755"},"PeriodicalIF":10.3,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143715396","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
Analytical prediction of lack-of-fusion porosity including uncertainty and variable melt pools for powder bed fusion 含不确定性和可变熔池的粉末床熔合未熔合孔隙率的分析预测
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-21 DOI: 10.1016/j.addma.2025.104733
Brodan Richter , Joshua D. Pribe , George R. Weber , Vamsi Subraveti , Caglar Oskay
{"title":"Analytical prediction of lack-of-fusion porosity including uncertainty and variable melt pools for powder bed fusion","authors":"Brodan Richter ,&nbsp;Joshua D. Pribe ,&nbsp;George R. Weber ,&nbsp;Vamsi Subraveti ,&nbsp;Caglar Oskay","doi":"10.1016/j.addma.2025.104733","DOIUrl":"10.1016/j.addma.2025.104733","url":null,"abstract":"<div><div>Powder bed fusion (PBF) additive manufacturing (AM) technology has greatly matured in recent years driven by numerous industrial applications. However, lack-of-fusion (LoF) porosity is a significant challenge during PBF, and LoF pores can form even when processing with optimized deposition parameters. This paper proposes an analytical approach for simulating LoF porosity during PBF AM on the basis of a semi-elliptical model of the melt pool cross-section. Melted area, reference area, and LoF area fraction calculations are developed for the case where only one layer melts the reference area because of a shallow melt pool. In more complex cases where two layers melt a portion of the initial layer, the melted volume, reference volume, and LoF volume fraction calculations are developed using a change of coordinate system and integration. Finally, the model is extended to an arbitrary number of layers by assuming LoF porosity exponentially decays as the number of interacting layers increases. The analytical model predicts LoF porosity for both identical and variable melt pools and enables uncertainty analysis for LoF porosity calculations through the rapid sampling of a large number of experimentally-determined melt pool geometries. The model is used to calculate porosity fraction across the melt pool depth, melt pool width, hatch spacing, and layer thickness processing space. The accuracy of the model is demonstrated through comparisons with experimental data, and the effect of melt pool geometric uncertainty on the PBF process window is demonstrated through experimental comparisons. A new LoF porosity criterion for variable melt pools is proposed that simplifies to a previously defined, widely used LoF porosity criterion in the case of identical melt pools. Overall, the new approach presented provides a straightforward, low computational cost method for calculating LoF porosity that incorporates uncertainty for PBF AM processing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104733"},"PeriodicalIF":10.3,"publicationDate":"2025-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739409","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
I-wi: Multifunctional 3D-printable stretchable ionogel and ionic eutectogel wires with AC and DC signal transmission I-wi:具有交直流信号传输功能的多功能 3D 打印可拉伸离子凝胶和离子共晶凝胶导线
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-16 DOI: 10.1016/j.addma.2025.104743
Sergey Nechausov, Yi Jiang, Aslan Miriyev
{"title":"I-wi: Multifunctional 3D-printable stretchable ionogel and ionic eutectogel wires with AC and DC signal transmission","authors":"Sergey Nechausov,&nbsp;Yi Jiang,&nbsp;Aslan Miriyev","doi":"10.1016/j.addma.2025.104743","DOIUrl":"10.1016/j.addma.2025.104743","url":null,"abstract":"<div><div>Recent advances in technologies based on soft matter functionality have spurred the demand for flexible and stretchable conductors. However, state-of-the-art stretchable conductors suffer from trade-offs between material compositions, design and scale factors, electrical properties, durability, and precise fabrication methods, thus sacrificing critical parameters and hindering performance. The longstanding challenge in the field has been co-developing reliable, stretchable, and highly electrically conductive bulk elastomers with precise fabrication methods for transferring diverse signals over distances, while both at rest and in a stretched state under both DC and AC conditions. In this study, we developed, characterized, and showcased i-wi (ionic wires) — soft, stretchable, and 3D-printable ionogels and ionic eutectogels designed for applications in soft stretchable electronics under both DC and AC. We combined imidazolium-based ionic liquids (ILs) or ethaline and glyceline deep eutectic solvents (DESs) with photopolymer compositions to obtain ionogels or eutectogels, respectively, that combine elastic deformation with high ionic conductivity and that can be precisely 3D-printed using the vat photopolymerization method. We showed that i-wi can transfer both DC and AC signals in various implementation scenarios, extending the horizon for myriad applications. We demonstrated the multifunctionality of i-wi in multimaterial connectors, which conducted signals to light LEDs, play music, and perform electric guitar, while both at rest and under stretching, and which functioned as precise temperature and strain sensors. We suggest that i-wi may become a core component of physically intelligent systems, including morphological computing, advanced wearable and medical devices, and the broader field of soft robotic systems.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104743"},"PeriodicalIF":10.3,"publicationDate":"2025-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800253","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
Warpage correction for vat photopolymerization 3D printing 还原光聚合3D打印翘曲校正
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-15 DOI: 10.1016/j.addma.2025.104740
Taehyub Lee , Chin Siang Ng , Pei-Chen Su
{"title":"Warpage correction for vat photopolymerization 3D printing","authors":"Taehyub Lee ,&nbsp;Chin Siang Ng ,&nbsp;Pei-Chen Su","doi":"10.1016/j.addma.2025.104740","DOIUrl":"10.1016/j.addma.2025.104740","url":null,"abstract":"<div><div>Warp or curl distortion significantly negatively impacts print accuracy and polymer characterization. This issue is exacerbated by the inherent mechanisms of vat photopolymerization (VP) 3d printing. In the VP irradiation step, the amount of the light energy absorbed in the prior layers accumulates, leading to a difference in the degree of curing compared to a newer layer. This causes uneven shrinkage of the individual printing layers, which causes bending deformation. In this study, we corrected the warpage by ensuring uniform light energy absorption across all layers using the modified Beer-Lambert’s law. We investigated the warpage angle of both warped and corrected samples, varying by layer and part thickness. Furthermore, we conducted three-point bending tests of dynamic mechanical analysis (DMA) to verify the consistency of measurements from the corrected samples. The results show significant improvements in warpage across various printing parameters and enhanced consistency in DMA tests. Significantly, this study offers straightforward, robust guidance for setting printing parameters of newly developed resins, ensuring reliable samples to characterize polymers.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"102 ","pages":"Article 104740"},"PeriodicalIF":10.3,"publicationDate":"2025-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143642610","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
Phase-separation induced dislocation-network cellular structures in Ti-Zr-Nb-Mo-Ta high-entropy alloy processed by laser powder bed fusion 激光粉末床熔合Ti-Zr-Nb-Mo-Ta高熵合金相分离诱导的位错网络细胞结构
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-12 DOI: 10.1016/j.addma.2025.104737
Han Chen , Daisuke Egusa , Zehao Li , Taisuke Sasaki , Ryosuke Ozasa , Takuya Ishimoto , Masayuki Okugawa , Yuichiro Koizumi , Takayoshi Nakano , Eiji Abe
{"title":"Phase-separation induced dislocation-network cellular structures in Ti-Zr-Nb-Mo-Ta high-entropy alloy processed by laser powder bed fusion","authors":"Han Chen ,&nbsp;Daisuke Egusa ,&nbsp;Zehao Li ,&nbsp;Taisuke Sasaki ,&nbsp;Ryosuke Ozasa ,&nbsp;Takuya Ishimoto ,&nbsp;Masayuki Okugawa ,&nbsp;Yuichiro Koizumi ,&nbsp;Takayoshi Nakano ,&nbsp;Eiji Abe","doi":"10.1016/j.addma.2025.104737","DOIUrl":"10.1016/j.addma.2025.104737","url":null,"abstract":"<div><div>Hierarchical structures, such as cellular structures, elemental segregations, and dislocation-network, are often proposed to enhance the mechanical properties of high-entropy alloys (HEAs) fabricated via additive manufacturing (AM). The formation of cellular structures is often attributed to elemental segregation during the solidification process or thermal strain resulting from the AM process. Here, we present a novel cellular structure where phase-separation and dislocation-network coupled in Ti-Zr-Nb-Mo-Ta HEA processed by laser powder bed fusion (L-PBF). Electron microscopy observations and X-ray diffraction (XRD) analyses show that this unique cellular structure consists of Zr-rich and Ta-rich body-center cubic (BCC) phases as the cell-wall and the cell-core, respectively, with their lattice constant difference of about 1 %. Moreover, a higher density of dislocations forming distinct networks is detected within this cellular structure, whose density reached 8 × 10<sup>14</sup> m<sup>−2</sup>. Machine learning analysis reveals that the dislocations preferentially occur on the Zr-rich BCC side, thus accommodating the strains significant around the boundaries between the two BCC phases. With the aid of thermodynamic simulations, we propose a formation mechanism of the present cellular structure, which is governed by the elemental partitioning behavior of Zr and Ta during a solid-state phase separation under rapid cooling. Boundaries with this phase separation are introduced as semi-coherent interfaces with misfit dislocations, introducing a high-density dislocation in the present material. This novel cellular structure can significantly enhance the strength of AM HEAs, providing valuable insights for developing high-performance AM metals through the design of hierarchical microstructures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"102 ","pages":"Article 104737"},"PeriodicalIF":10.3,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143621444","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
Accurate inverse process optimization framework in laser directed energy deposition 激光定向能沉积精确逆工艺优化框架
IF 10.3 1区 工程技术
Additive manufacturing Pub Date : 2025-03-12 DOI: 10.1016/j.addma.2025.104736
Xiao Shang, Ajay Talbot, Evelyn Li, Haitao Wen, Tianyi Lyu, Jiahui Zhang, Yu Zou
{"title":"Accurate inverse process optimization framework in laser directed energy deposition","authors":"Xiao Shang,&nbsp;Ajay Talbot,&nbsp;Evelyn Li,&nbsp;Haitao Wen,&nbsp;Tianyi Lyu,&nbsp;Jiahui Zhang,&nbsp;Yu Zou","doi":"10.1016/j.addma.2025.104736","DOIUrl":"10.1016/j.addma.2025.104736","url":null,"abstract":"<div><div>In additive manufacturing (AM), particularly in laser-based metal AM, process optimization is crucial to the quality of products and the efficiency of production. The identification of optimal process parameters out of a vast parameter space, however, is a daunting task. Despite advances in simulations, the process optimization for specific materials and geometries is developed through a sequential and time-consuming trial-and-error approach and often lacks the versatility to address multiple optimization objectives. Machine learning (ML) provides a powerful tool to accelerate the optimization process, but most current studies focus on simple single-track prints, which hardly translate to manufacturing 3D bulk components for engineering applications. In this study, we develop an <em>A</em>ccurate <em>I</em>nverse process optimization framework in laser <em>D</em>irected <em>E</em>nergy <em>D</em>eposition (AIDED), based on machine learning models and a genetic algorithm, to aid the process optimization in laser DED. Using AIDED, we demonstrate the following: (i) Accurate prediction of the area of single-track melt pool (<em>R</em><sup><em>2</em></sup> score 0.995), the tilt angle of multi-track melt pool (<em>R</em><sup><em>2</em></sup> score 0.969), and the cross-sectional geometries of multi-layer melt pool (1.75 % and 12.04 % errors in width and height, respectively) directly from process parameters; (ii) Determination of appropriate hatch spacing and layer thickness for fabricating fully dense (density &gt; 99.9 %) multi-track and multi-layer prints; (iii) Inverse identification of optimal process parameters directly from customizable application objectives within 1–3 hours. We also validate the effectiveness of the AIDED experimentally by solving a multi-objective optimization problem to identify the optimal process parameters for achieving high print speeds with small effective track widths. Furthermore, we show the transferability of the framework from stainless steel to pure nickel using a small amount of additional data on pure nickel. With such transferability in AIDED, we pave a new way for “aiding” the process optimization of the laser-based AM processes that applies to a wide range of materials.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"102 ","pages":"Article 104736"},"PeriodicalIF":10.3,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143629526","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
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