Additive manufacturing最新文献

{"title":"Impact of droplet oxidation on mechanical properties of an Al-7Si-0.4Mg alloy fabricated with liquid metal jetting","authors":"Sumit Bahl ,&nbsp;Gerry L. Knapp ,&nbsp;Alexander Gomez ,&nbsp;Jonathan D. Poplawsky ,&nbsp;James A. Haynes ,&nbsp;Ryan R. Dehoff ,&nbsp;Alex Plotkowski ,&nbsp;Amit Shyam","doi":"10.1016/j.addma.2025.104775","DOIUrl":"10.1016/j.addma.2025.104775","url":null,"abstract":"<div><div>Droplet-on-demand liquid metal jetting (DOD-LMJ) is a new method for additive manufacturing of bulk structural alloys. Here, we report on the microstructure, tensile, and fatigue properties of an Al-7Si-0.4Mg (A356) alloy fabricated with LMJ. Liquid metal droplets were shielded by high-purity Ar gas shroud during deposition. Atom probe tomography revealed that a few nanometers thick (Al-Mg-Si)-O oxide film formed on the droplets despite Ar gas shielding. Tensile tests on peak-aged LMJ A356 alloy showed that yield strength was isotropic (250 MPa), but ductility was lower in the build direction (6.1 ± 1.4 %) compared to the transverse direction (9.4 ± 1.0 %). Lower ductility in the build direction was attributed to delamination of metal-oxide interfaces at layer boundaries. The ductility and yield strength of LMJ A356 were similar to cast A356 and laser powder bed fused (LPBF) A357 alloys, indicating the limited impact of oxide film on tensile properties. The oxide film severely impacted the fatigue properties. Fatigue resistance of LMJ A356 was limited by fatigue crack initiation at lack-of-fusion defects and fatigue crack propagation along layer boundaries by delamination of the metal-oxide interface. The fatigue strength of LMJ A356 at 60 MPa was lower than cast A356 and LPBF A357 alloys in the peak-aged condition. This research underscores the need for managing droplet oxidation during LMJ additive manufacturing of structural alloys.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104775"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783795","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Particle-based friction stir additive manufacturing of an Al-Mg-Mn alloy","authors":"Wancheng Lyu ,&nbsp;Yizhou Shen ,&nbsp;Yuzhe Tang ,&nbsp;Kun Yang ,&nbsp;Zexing Zhou ,&nbsp;Chenglong Zhao ,&nbsp;Yunjie Lu ,&nbsp;Xunzhong Guo","doi":"10.1016/j.addma.2025.104768","DOIUrl":"10.1016/j.addma.2025.104768","url":null,"abstract":"<div><div>An innovative Particle-based Friction Stir Additive Manufacturing (P-FSAM) technique has been developed, featuring a continuous off-axis feeding mechanism for metallic particles. The process optimization focuses on the ratio of actuator reciprocating frequency to tool traverse speed, ensuring adequate heat generation and particle filling for high-quality deposition. Through the implementation of an optimized stirring pin and spiral groove design, the technique facilitates Z-direction flow of thermoplastic material, resulting in enhanced interfacial bonding and material flow characteristics. This study demonstrates the successful application of P-FSAM in producing Al-5356 alloy deposits with an equiaxed fine-grained microstructure, exhibiting mechanical isotropy and a balanced combination of strength and ductility. During the stable deposition of single-pass multilayers of this alloy, P-FSAM requires about 1 kN thrust force, with a maximum steady-state temperature exceeding 435°C. The deposits exhibit refined grain structures due to dynamic recrystallization, nearly complete dissolution of the Al₃Mg₂ phase, while maintaining grain stability during thermal cycling. The deposits achieve favorable mechanical properties, with yield strength exceeding 210 MPa, ultimate tensile strength surpassing 350 MPa, and elongation over 20 % in both build and traverse directions, outperforming fusion-based additive manufacturing counterparts. P-FSAM expands the potential of solid-state additive manufacturing, paving the way for future applications involving composite particles, polymers, metal powders, and industrial scraps, as well as multi-channel off-axis feeding for gradient material fabrication and hybrid additive manufacturing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104768"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143786292","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Rapid prediction of overload fatigue life based on phase-field modeling of microstructures under different scanning strategies","authors":"Haifeng Zhai ,&nbsp;Wei Jiang ,&nbsp;Yang Wang ,&nbsp;Yanzhao Yang ,&nbsp;Haiting Lv","doi":"10.1016/j.addma.2025.104771","DOIUrl":"10.1016/j.addma.2025.104771","url":null,"abstract":"<div><div>Understanding the mechanisms of microstructure evolution is essential for accurately predicting and improving the final mechanical properties of materials. To enable efficient simulation of multi-layer, multi-track additive manufacturing (AM) processes with various scanning strategies, a three-dimensional phase-field (PF) model was developed to capture grain evolution in AM. The model effectively reproduces grain nucleation, epitaxial growth, and coarsening. Three representative scanning strategies (stripe, loop, and chessboard) were experimentally validated. The simulation results showed strong consistency with experimental observations regarding melt pool dynamics, grain morphology, and defect evolution. The crystal plasticity finite element method (CPFEM) was utilized to predict overload fatigue life, and a novel strategy was introduced to rapidly and efficiently estimate fatigue life by reconstructing the microstructure corresponding to different scanning strategies. This study offers novel methodological insights into grain growth and evolution mechanisms in AM and extends the predictive framework for overload fatigue life estimation.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104771"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777121","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Energy absorption of architectured PrintCast interpenetrating composites in tension","authors":"Abdel R. Moustafa ,&nbsp;Jiahao Cheng ,&nbsp;Jason P. Allen ,&nbsp;Xiaohua Hu ,&nbsp;Amit Shyam ,&nbsp;Ke An ,&nbsp;Matthew Frost ,&nbsp;Yan Chen ,&nbsp;Derek A. Splitter","doi":"10.1016/j.addma.2025.104769","DOIUrl":"10.1016/j.addma.2025.104769","url":null,"abstract":"<div><div>Additively manufactured (AM) metal-metal composites consisting of PrintCasted 316 L austenitic stainless-steel lattice structures infiltrated with A356 casting alloy, have recently been developed for use in high energy absorption systems with potential applications ranging from static load bearing to dynamic blast containment structures. This system has a unique mechanical behavior as the volume fraction of lattice increases showing a transition from localized to de-localized failure and dramatic increase in energy absorption capability. In this work, PrintCast A356/316 L composite tensile specimens were produced with lattice volume fractions ranging from 20 % to 50 % to capture the range of this behavior. Finite element simulations support neutron diffraction measurements of stress state. Results illustrate that in tension, the reinforcement material is in tension while the matrix support material is in compression, information offering significant insight into the transition to de-localized failure. Moreover, the simulation results provide further insight into how interfacial bonding (or lack of bonding) affects the energy absorption capabilities of the PrintCast composites.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104769"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143786291","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Smoothed Particle Hydrodynamics-based geometric modeling of lattice structures with controllable manifold nodes","authors":"Zhuangyu Li,&nbsp;Ziqi Zhou,&nbsp;Wenlei Xiao,&nbsp;Gang Zhao,&nbsp;Changri Xiong","doi":"10.1016/j.addma.2025.104744","DOIUrl":"10.1016/j.addma.2025.104744","url":null,"abstract":"<div><div>The advancement of additive manufacturing has necessitated the development of high-performance geometric modeling methods for lattice structures. A critical challenge in current additive manufacturing technologies is effectively controlling the geometric shape of nodes within lattice structures to achieve specific functional enhancements, such as strengthening mechanical properties, thereby reducing stress concentration issues. This study presents a novel geometric modeling method employing Smoothed Particle Hydrodynamics (SPH) to smoothly control the geometric shape of nodes in lattice structures, suitable for variable-radius, heterogeneous configurations. This method is named SPH-based Lattice Geometric Modeling (SLGM). The SLGM comprises two primary steps: initially representing the geometric form around each node using a particle set, followed by the application of the SPH Particle Dynamics Model (SPDM) to control the geometric shape of each node in parallel. The method was applied to several intricate lattice structure designs, confirming its extensive broad applicability. Two optimized lattice-based beams were designed and subjected to three-point bending tests. The results showed a significant enhancement in structural load-bearing capacity for both models, with different levels of improvement, demonstrating the effectiveness of the proposed geometric modeling method. The modeling algorithm features high parallelism, making it suitable for generating large-scale models. This method provides effective strategies for structural optimization and efficient resource utilization in additive manufacturing, with the potential to advance the technology’s application in high-performance domains.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104744"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767500","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":"D-ECOmposer: Sustainable part decomposition for additive manufacturing using machine learning based life cycle assessment","authors":"Minseok Ko ,&nbsp;Yeongjun Yoon ,&nbsp;Jaeyeon Kim ,&nbsp;Samyeon Kim ,&nbsp;Soonjo Kwon","doi":"10.1016/j.addma.2025.104759","DOIUrl":"10.1016/j.addma.2025.104759","url":null,"abstract":"<div><div>Additive Manufacturing (AM) has garnered significant attention due to its potential for sustainable production. To further enhance this potential, Design for Additive Manufacturing (DfAM) methodologies are frequently employed. However, traditional design approaches often fall short in addressing the inherent limitations of AM, such as build size constraints, extended lead time, and the necessity for support structure. However, due to these limitations, part decomposition (PD) has recently gained prominence as a viable solution. While the benefits of PD might be less pronounced if a model can be produced in its entirety on a single AM device, this study assumes scenarios where the model is too large for the build space of the AM device, making decomposition necessary. This study proposes a grid-based PD method that utilizes machine learning-based Life Cycle Assessment (LCA) to minimize environmental impact. The experimental data in this study were collected and analyzed based on the FDM(Fused deposition modeling) process. Initially, a predictive model is developed to quickly and accurately estimate the carbon footprint of a design candidate based on the geometric characteristics of a 3D model. This predictive model is subsequently employed as the objective function in the optimization of PD using a genetic algorithm (GA). To validate the efficacy of the proposed method, experiments were conducted on four test models using FDM. While this study focuses on FDM, the proposed methodology has potential applicability to other AM processes. The experimental results clearly demonstrate that the proposed method outperforms traditional empirical approaches in reducing the carbon footprint.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104759"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767498","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":"Pioneering techniques for achieving high-resolution, ultrasmooth surfaces via LCD 3D printing technology","authors":"Jui-Fu Tang,&nbsp;Kuan-Wu Lin,&nbsp;Tsung-Hsien Lin,&nbsp;Wei-Chun Lin","doi":"10.1016/j.addma.2025.104764","DOIUrl":"10.1016/j.addma.2025.104764","url":null,"abstract":"<div><div>Recently, the photocured polymerization method in 3D printing technology has gained popularity on the market due to its advantages of high resolution, low cost, and easy operation. However, the presence of surface texture defects resulting from the LCD panel's pixel array has limited the smoothness of the printed models, rendering the array unsuitable for optical component fabrication. These texture defects are attributed to the black matrix area created by the pixel array, which becomes an apparent voxel defect in the SEM image and leads to an uneven printing surface. To overcome this challenge, a novel design with hybrid LCD films has been developed to eliminate voxel defects. The upper LCD panel is designed to control the direction of light by the voltage-modulated liquid crystal. The scattered light covers the black matrix, achieving a continuous and uniform printed surface. In this research, it is confirmed that the hybrid LCD system significantly alleviates texture defects caused by the black matrix among pixels. The results successfully revealed an ultrasmooth surface, achieving an 80 % reduction in roughness through this modified LCD system without compromising printing resolution. The ultrasmooth surface also reduced the shrinkage by up to 95 % and improved the mechanical properties of the printed material due to the dense adhesion of each layer.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104764"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767499","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":"Alternate projection optimization in ceramic vat photopolymerization","authors":"Yuzhen Zhang ,&nbsp;Wenyan Duan ,&nbsp;Xingyao Sun ,&nbsp;Shuyu Zhou ,&nbsp;Kaixiang Zhang ,&nbsp;Shan Li ,&nbsp;Bingshan Liu ,&nbsp;Gong Wang","doi":"10.1016/j.addma.2025.104777","DOIUrl":"10.1016/j.addma.2025.104777","url":null,"abstract":"<div><div>The stresses generated during ceramic vat photopolymerization can lead to significant dimensional deformation of the ceramic green body, severely limiting the practical application of this technology. In this work, the alternate projection method was successfully applied to ceramic vat photopolymerization for the first time. The effects of different alternate projection parameters on the accuracy and properties of the ceramic green bodies were compared. By optimizing the parameters and lattice skeleton, the low-deformation ceramic green bodies were successfully prepared. In addition, ceramic parts with complex structures were fabricated after thermal binder removal and sintering. Alternate projection optimization enables the preparation of high-precision ceramic parts without requiring modifications to the ceramic material or printing equipment. This method is highly practical and cost-effective, especially suitable for rapid iteration of high-precision complex structural parts, and can be widely used in semiconductor, aerospace, and other technical fields.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104777"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783794","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":"Going against the grain: Porous defects in polymer-zeolite composite extrusion to enhance contaminant adsorption","authors":"Alan J. Kennedy ,&nbsp;Christopher B. Williams ,&nbsp;Stephen M. Martin ,&nbsp;Chris S. Griggs ,&nbsp;Travis L. Thornell ,&nbsp;Lauren R. May ,&nbsp;Michael J. Bortner","doi":"10.1016/j.addma.2025.104762","DOIUrl":"10.1016/j.addma.2025.104762","url":null,"abstract":"<div><div>While engineers seek to reduce voids and mechanical anisotropies to match injection molding properties, this investigation embraces voids inherent to polymer melt Additive Manufacturing (AM) to enable innovative water treatment solutions. Extrusion of polymer-zeolite micro-composite filaments was exploited to increase structural porosity to enhance contaminant adsorption through print parameter selection, correlating process physics and material physical properties to printed structure performance. Zeolite (32 % w/w) was immobilized in polylactic acid (PLA) filament by twin screw extrusion. Since increasing zeolite loading in dense printed structures did not improve adsorption, we hypothesized that applying print parameters to enhance voids would. While high surface area geometries are an obvious choice for water treatment, this research isolated how print parameters alone affect porous deposition and adsorptive performance at smaller dimensional scales than intentionally printed infill. Experiments determined printing PLA-zeolite faster (80 mm/s) at lower temperature (190 °C) through larger nozzles (0.8 mm) and layer heights (0.3 mm) improved porous structure-adsorptive property relationships, promoting faster ammonia adsorption. Impactful findings include: (1) dense PLA-zeolite injection molds performed poorly, emphasizing layered structure is imperative to allow voids; (2) evidence that controlling physical (roadway spacing) and rheological (extrusion/deposition/solidification) considerations are critical for functional porous structures; and (3) zeolite presence alters rheological controls to achieve printed porosity relative to neat PLA. This work catalyzes new thinking in application-specific success metrics in printed hierarchical structures for both designed and actual deposited structures and an expansion of research avenues in novel environmental applications to optimize printing away from fully dense structures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104762"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767497","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":"Residual stress prediction in machining of parts fabricated by directed energy deposition","authors":"Shenliang Yang ,&nbsp;Alistair Speidel ,&nbsp;Adam T. Clare ,&nbsp;Chris Bennett ,&nbsp;Xiaoliang Jin","doi":"10.1016/j.addma.2025.104765","DOIUrl":"10.1016/j.addma.2025.104765","url":null,"abstract":"<div><div>The residual stress exhibited in post-machined metallic components fabricated by directed energy deposition (DED) determines their final mechanical performance and reliability in mission-critical applications. This study develops a numerical model to predict the final surface residual stress after the orthogonal cutting of DED-produced IN718, which integrates two critical factors: DED-induced initial residual stress states and microstructure properties. Using the developed modeling procedure, the penetration depth of post-machining into the initial residual stress distribution can be effectively quantified, which aligns with residual stress measurements through X-ray diffraction. The developed model is further employed to quantify the cumulative effects of initial residual stress states and grain size on cutting forces and final surface residual stress profiles. The results suggest that, under the given orthogonal cutting conditions of DED parts, variations in the initial residual stress states of the chip formation region have negligible effects on cutting forces. However, magnitudes of surface compressive residual stress in the longitudinal direction reduce by 21.8 %-52.3 % as the initial residual stress states shift from compressive-dominant to tensile-dominant, and decrease by 23.8 %-54.0 % as the built-in grain size (<em>d</em>_{<em>g</em>_<em>x</em>}) increases from 10 μm to 100 μm. With a comprehensive understanding of post-machining DED processes using this numerical modeling procedure, post-treatment techniques can now be tailored to achieve surface residual stress profiles on DED-generated or other additively manufactured metallic components to meet various industrial requirements.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104765"},"PeriodicalIF":10.3,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792433","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}