Additive manufacturing letters最新文献

High-fidelity thermomechanical simulation of laser powder bed fusion process: Impact of constitutive model choice 激光粉末床熔合过程的高保真热力学模拟：本构模型选择的影响

IF 4.7

Additive manufacturing letters Pub Date : 2025-09-17 DOI: 10.1016/j.addlet.2025.100324

P. Markovic , P. Scheel , R. Wróbel , S. Van Petegem , C. Leinenbach , E. Mazza , E. Hosseini

{"title":"High-fidelity thermomechanical simulation of laser powder bed fusion process: Impact of constitutive model choice","authors":"P. Markovic , P. Scheel , R. Wróbel , S. Van Petegem , C. Leinenbach , E. Mazza , E. Hosseini","doi":"10.1016/j.addlet.2025.100324","DOIUrl":"10.1016/j.addlet.2025.100324","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (LPBF) is a widely adopted metal additive manufacturing technology that enables the fabrication of intricate metal components, yet it faces challenges arising from intrinsic residual stress and distortion development. High-fidelity thermomechanical simulations offer essential insights for predicting and mitigating these effects. The reliability of such simulations depends on various factors, but critically on the material input data, primarily the constitutive model which should accurately represent the material’s deformation behaviour under the complex loading conditions expected during LPBF. The present study integrates an advanced elastic-viscoplastic constitutive model into the LPBF thermomechanical simulation, capable of capturing the cyclic response of LPBF Hastelloy X across a broad range of temperatures and strain rates, and accounting for both isotropic and kinematic hardening. Simulation outcomes are validated against in-situ temperature and distortion measurements obtained during an LPBF experiment for Hastelloy X. Acknowledging the extensive effort required to develop such an advanced constitutive model, this study also calibrates three alternative models of simpler formulation to assess the impact of model selection on simulation outcomes and computational cost. The four investigated models span from rate-dependent elastic-viscoplastic to rate-independent elastic-plastic formulations, each with different capabilities for representing the alloy’s cyclic hardening response. The results provide valuable insights into trade-offs between simulation accuracy, constitutive model development effort, and computational efficiency in LPBF thermomechanical simulations.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100324"},"PeriodicalIF":4.7,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145105126","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Additively manufactured self-expandable stents from Zr-based bulk metallic glasses via laser powder bed fusion 以zr基大块金属玻璃为材料，采用激光粉末床熔接技术增材制造自膨胀支架

IF 4.7

Additive manufacturing letters Pub Date : 2025-09-13 DOI: 10.1016/j.addlet.2025.100325

Jan Wegner , Lars Bruckhaus , Daniel Leonardo Schwöppe , Hanna Schönrath , Stefan Kleszczynski

{"title":"Additively manufactured self-expandable stents from Zr-based bulk metallic glasses via laser powder bed fusion","authors":"Jan Wegner , Lars Bruckhaus , Daniel Leonardo Schwöppe , Hanna Schönrath , Stefan Kleszczynski","doi":"10.1016/j.addlet.2025.100325","DOIUrl":"10.1016/j.addlet.2025.100325","url":null,"abstract":"<div><div>Self-expandable stents are among the most implanted biomedical devices. We investigate the feasibility of additive manufacturing via laser powder bed fusion to fabricate Zr-based bulk metallic glasses into self-expandable stents to enable automated and customizable stent fabrication while implementing a novel class of materials with superior resilience compared to established alloys such as Nitinol. Three geometries are investigated with different cell dimensions. The additively manufactured stents are analyzed by µCT, SEM imaging and DSC. Overhanging geometry features show increasing crystalline defects in the amorphous matrix. However, with steep elevation angles, an amorphous fraction of up to 97.3 ± 1% is achieved in the struts. Three-point bending tests reveal large resilience of the structures, allowing for full compaction for diamond shaped cells with a height of 7 mm and an elevation angle of 77.5°, without fracture. Our findings offer preliminary evidence supporting the potential of additive manufacturing for Zr-based bulk metallic glass stents, while further studies are necessary to validate and optimize the process.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100325"},"PeriodicalIF":4.7,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145105127","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

From micro- to macro-cracks and recrystallization in a non-weldable Ni-based superalloy manufactured by electron beam powder bed fusion 电子束粉末床熔合制备不可焊镍基高温合金的微观到宏观裂纹和再结晶

IF 4.7

Additive manufacturing letters Pub Date : 2025-09-11 DOI: 10.1016/j.addlet.2025.100323

Hamid Aghajani, Ehsan Toyserkani

{"title":"From micro- to macro-cracks and recrystallization in a non-weldable Ni-based superalloy manufactured by electron beam powder bed fusion","authors":"Hamid Aghajani, Ehsan Toyserkani","doi":"10.1016/j.addlet.2025.100323","DOIUrl":"10.1016/j.addlet.2025.100323","url":null,"abstract":"<div><div>In the present study, CM247LC, a non-weldable Ni-base superalloy, was fabricated by electron beam powder bed fusion (EB-PBF) over a wide energy levels. For this purpose, variable process parameters were adjusted to investigate their effect on microstructure and crack formation. Samples fabricated at both low and high area energies exhibited pronounced crack susceptibility. At very low energy densities, lack of fusion (LoF) and porosities were observed, while higher energy densities produced denser samples. Adjustments to energy density and process parameters resulted in a grain structure transition from fine-columnar to coarse-columnar and near-single crystal morphologies. Despite these changes, the cracking issue persisted, with micro-cracks observed in low-energy samples and macro-scale cracks, several millimeters long, forming at higher energy densities, highlighting the material’s high sensitivity to crack formation. Both solidification and liquation cracking were identified— the former showing dendritic crack surfaces, and the latter associated with eutectic phases and grain boundary precipitates. Severe recrystallization around cracks was observed at high energy densities, characterized by elevated dislocation densities. EDS analysis revealed hafnium- and silicon-rich precipitates in interdendritic regions and near cracks, contributing to severe hot cracking in the material.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100323"},"PeriodicalIF":4.7,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145049658","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Reassessing the biodegradation behavior of pure iron and iron-manganese alloys fabricated by laser powder bed fusion 激光粉末床熔合法制备纯铁和铁锰合金的生物降解性能研究

IF 4.7

Additive manufacturing letters Pub Date : 2025-09-08 DOI: 10.1016/j.addlet.2025.100321

Fanshuo Wang , Qiyang Tan , Ting Liu , Jeffrey Venezuela , Zhiming Shi , Sarah Hurley , Anh Ly , Chun Xu , Deniz U. Erbulurt , Jun Yin , Yue Zhao , Mingxing Zhang

{"title":"Reassessing the biodegradation behavior of pure iron and iron-manganese alloys fabricated by laser powder bed fusion","authors":"Fanshuo Wang , Qiyang Tan , Ting Liu , Jeffrey Venezuela , Zhiming Shi , Sarah Hurley , Anh Ly , Chun Xu , Deniz U. Erbulurt , Jun Yin , Yue Zhao , Mingxing Zhang","doi":"10.1016/j.addlet.2025.100321","DOIUrl":"10.1016/j.addlet.2025.100321","url":null,"abstract":"<div><div>This study investigates the biodegradation of pure Fe, Fe-25Mn, and Fe-30Mn alloys fabricated with laser powder bed fusion (LPBF). Unlike conventionally produced Fe-Mn alloys, in the scheme of LPBF, the addition of 25 wt.% and 30 wt.% Mn showed limited efficacy in enhancing the corrosion rates when compared with the LPBF-fabricated Fe. The rapid cooling during LPBF produced a refined grain structure in pure Fe, substantially increased the grain boundary density, and enhanced the corrosion rates. This effect resulted in a corrosion rate of LPBF-processed Fe (0.04mm/year) that matched the corrosion rate of the LPBF-fabricated Fe-25Mn (0.05mm/year) with enhanced galvanic corrosion due to a high ε-martensite to γ-austenite ratio. Whereas in the LPBF-fabricated Fe-30Mn alloy, a reduced corrosion rate (0.01mm/year) was determined because of its coarse columnar grains and constrained micro-galvanic effects derived from the low ε-martensite to γ-austenite ratio. These findings suggest that when LPBF is used to produce biodegradable Fe-based alloys, Fe could be a more optimal option than its Fe- (25 and 30 wt.%) Mn counterparts in terms of pursuing a faster degradation rate.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100321"},"PeriodicalIF":4.7,"publicationDate":"2025-09-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145049657","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Wear of ultra-high molecular weight polyethylene manufactured with laser powder bed fusion 用激光粉末床熔合制造超高分子量聚乙烯的磨损

IF 4.7

Additive manufacturing letters Pub Date : 2025-09-08 DOI: 10.1016/j.addlet.2025.100322

Morgan Mosco, Christopher B. Williams, Bart Raeymaekers

{"title":"Wear of ultra-high molecular weight polyethylene manufactured with laser powder bed fusion","authors":"Morgan Mosco, Christopher B. Williams, Bart Raeymaekers","doi":"10.1016/j.addlet.2025.100322","DOIUrl":"10.1016/j.addlet.2025.100322","url":null,"abstract":"<div><div>Ultra-high molecular weight polyethylene (UHMWPE) is widely used in applications that need abrasion resistance, impact toughness, and chemical inertness, including bushings, prosthetic joints, naval dock bumpers, and mooring buoys. However, its high molecular weight restricts conventional processing to ram extrusion or compression molding, which require a die or mold that limits the complexity and customizability of part geometries. Additive manufacturing (AM) offers an alternative to producing complex UHMWPE parts without the need for specialized tooling. Recent advances have demonstrated AM of UHMWPE via a process chain that combines laser powder bed fusion (L-PBF) with a pressure-assisted thermal post-processing step. However, despite the critical importance in most of its applications, no information exists about wear of L-PBF printed UHMWPE compared to that of conventionally processed parts. Here, UHMWPE specimens of controlled density are produced using the L-PBF process chain and their process-structure-wear relationship is characterized. The results reveal that the steady-state wear rate decreases exponentially with increasing density and approaches that of conventionally processed benchmark specimens. This improvement is attributed to reduced porosity and corresponding increased hardness. This study provides the first process-structure-wear relationship for additively manufactured UHMWPE, and demonstrates that L-PBF can deliver wear resistance comparable to conventional processing while enabling complex, customized geometries. These findings establish a scientific and technological foundation for extending L-PBF of UHMWPE into advanced applications such as precision bushings, orthopedic components, and other high-performance parts that require both geometric freedom and excellent tribological performance.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100322"},"PeriodicalIF":4.7,"publicationDate":"2025-09-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145049659","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Fatigue assessment of laser powder bed fused aluminum alloys via non-destructive examination 激光粉末床熔接铝合金的无损检测疲劳评定

IF 4.7

Additive manufacturing letters Pub Date : 2025-08-28 DOI: 10.1016/j.addlet.2025.100320

Shaharyar Baig , Alireza Jam , Stefano Beretta , Shuai Shao , Nima Shamsaei

{"title":"Fatigue assessment of laser powder bed fused aluminum alloys via non-destructive examination","authors":"Shaharyar Baig , Alireza Jam , Stefano Beretta , Shuai Shao , Nima Shamsaei","doi":"10.1016/j.addlet.2025.100320","DOIUrl":"10.1016/j.addlet.2025.100320","url":null,"abstract":"<div><div>This study evaluated the effectiveness of x-ray computed tomography (XCT) based examinations in assessing the fatigue lives of laser powder bed fused (L-PBF) aluminum alloys. L-PBF AlSi10Mg and Scalmalloy specimens with varying defect populations were examined via XCT prior to uniaxial fatigue testing. By correlating the post-fracture surface information with XCT data, the fatigue critical defects were identified and quantified; and the efficacy of XCT in accurately capturing these defects and measuring their sizes was assessed. The results indicated that lack-of-fusions (LoFs) with thin webbed features were prone to significant loss of information in XCT scans compared to bulky shaped defects, leading to frequent misidentification of critical defects and/or misrepresentation of their actual size. Accordingly, fatigue modelling relying solely on the largest detected entities in XCT scans of L-PBF aluminum alloys, which contained large critical LoFs, resulted in severely non-conservative fatigue life predictions. It was demonstrated that a distance-based criterion can help address the limitations in XCT data by allowing for the defect morphology to be reconstructed, which gave rise to improved size estimates, and in many cases, the correct identification of the critical defect. Incorporating corrected XCT data into crack growth based models enabled accurate and moderately conservative fatigue life estimates for non-destructive structural integrity assessments.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100320"},"PeriodicalIF":4.7,"publicationDate":"2025-08-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144917775","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

In situ porosity imaging with synchrotron X-ray tomography during laser rescanning of Zr-based metallic glass by laser powder bed fusion 激光粉末床熔合zr基金属玻璃激光重扫描过程中同步加速器x射线层析成像

IF 4.7

Additive manufacturing letters Pub Date : 2025-08-16 DOI: 10.1016/j.addlet.2025.100318

Camille Pauzon , Rémi Daudin , Pierre Lhuissier , Xavier Bataillon , Pierre Lapouge , Pierre Hébrard , Patrice Peyre , Frédéric Coste , Lucas Varoto , Elodie Boller , Jean-Jacques Blandin

{"title":"In situ porosity imaging with synchrotron X-ray tomography during laser rescanning of Zr-based metallic glass by laser powder bed fusion","authors":"Camille Pauzon , Rémi Daudin , Pierre Lhuissier , Xavier Bataillon , Pierre Lapouge , Pierre Hébrard , Patrice Peyre , Frédéric Coste , Lucas Varoto , Elodie Boller , Jean-Jacques Blandin","doi":"10.1016/j.addlet.2025.100318","DOIUrl":"10.1016/j.addlet.2025.100318","url":null,"abstract":"<div><div>When laser powder bed fusion (LPBF) is applied to bulk metallic glasses rather than traditional crystalline alloys, one has to avoid conditions that could cause crystals to form. To achieve a balance between the porosity content and devitrification in the heat affected zone, it is common practice to process such material with a thin layer thickness, and thereby reduce the laser power necessary for melting. In this manufacturing regime, lack-of-fusion defects typically subsist. This work investigates how laser rescanning can densify metallic glasses while still ensuring their amorphous nature. Synchrotron X-ray Computed Tomography during LPBF allows imaging in situ the pores upon the glass construction. This non-destructive cutting-edge technique helps understanding the consolidation mechanism associated with rescanning and in particular its effect on layer surface roughness and the homogeneity of the powder recoating. Applied to the well-established Zr-Cu-Al-Nb grade, this work paves the way towards the adoption of less thermally stable glasses for LPBF, and the control of defect distribution. In particular, it is revealed that the hatch spacing effect is of primary importance in the production of viscous materials such as glasses, and that laser rescanning allows the surface of the deposited layer to be smoothed, improving consolidation without associated crystallisation.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100318"},"PeriodicalIF":4.7,"publicationDate":"2025-08-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144866102","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Load direction and temperature impacts on cyclic creep behavior of laser-based powder bed fusion-produced WE43 magnesium alloy 载荷方向和温度对激光粉末床熔敷WE43镁合金循环蠕变行为的影响

IF 4.7

Additive manufacturing letters Pub Date : 2025-08-11 DOI: 10.1016/j.addlet.2025.100316

Alexander Koch , Sebastian Stammkoetter , Arvid Abel , Abootorab Chehreh , Joerg Hermsdorf , Stefan Kaierle , Frank Walther

{"title":"Load direction and temperature impacts on cyclic creep behavior of laser-based powder bed fusion-produced WE43 magnesium alloy","authors":"Alexander Koch , Sebastian Stammkoetter , Arvid Abel , Abootorab Chehreh , Joerg Hermsdorf , Stefan Kaierle , Frank Walther","doi":"10.1016/j.addlet.2025.100316","DOIUrl":"10.1016/j.addlet.2025.100316","url":null,"abstract":"<div><div>Magnesium alloys are renowned for their high strength-to-weight ratio and low density, making them highly sought-after in the lightweight engineering sector. Among these, the high-strength magnesium alloy WE43, characterized by its Mg-4Y-3RE composition, stands out for its superior mechanical strength and thermal stability. These properties, coupled with its creep resistance, render WE43 a suitable alloy in elevated temperature applications, particularly in aerospace and automotive engineering. Despite its potential, the characterization of the load direction- and temperature-dependent deformation behavior remains incomplete for WE43, especially in additive manufacturing contexts. This study explores the quasi-static and cyclic creep properties of WE43 produced via laser-based powder bed fusion.</div><div>The research involved tensile and compression testing to evaluate quasi-static deformation and tensile-compression asymmetry. Cyclic creep behavior was studied under diverse mechanical (tension, compression) and thermal (RT, 200 °C, 300 °C) conditions by load-increase fatigue tests. Microstructural analyses based on cross-sections, XRD and computed tomography were conducted to assess manufacturing quality and identify potential inhomogeneities. The results reveal the interplay between mechanical load, temperature, and structural integrity in WE43. It could be shown that especially at 300 °C increased creep rates occure.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100316"},"PeriodicalIF":4.7,"publicationDate":"2025-08-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144907320","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Influence of aging time to achieve tensile build direction heat treated T74 forging properties in lubricant free AFSD AA7050 时效时间对在无润滑油AFSD AA7050中实现拉伸构建方向热处理T74锻件性能的影响

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100296

I. Liu , J. Hoarston , N. Zhu , A. Birt , N. Palya , B.J. Phillips , D.Z. Avery , P.G. Allison , J.B. Jordon

{"title":"Influence of aging time to achieve tensile build direction heat treated T74 forging properties in lubricant free AFSD AA7050","authors":"I. Liu , J. Hoarston , N. Zhu , A. Birt , N. Palya , B.J. Phillips , D.Z. Avery , P.G. Allison , J.B. Jordon","doi":"10.1016/j.addlet.2025.100296","DOIUrl":"10.1016/j.addlet.2025.100296","url":null,"abstract":"<div><div>The need for long-lead time aluminum alloy casting and forging replacements requires innovative solutions such as Additive Friction Stir Deposition (AFSD), a solid-state additive manufacturing technique that uses frictional heat and severe plastic deformation to create metallurgical bonds through layer-by-layer deposition. While AFSD has demonstrated isotropic mechanical properties in the as-deposited condition, post-deposition heat treatment (PDHT) of precipitation hardened aluminum alloys processed by AFSD has led to poor ductility, particularly in the build direction. In this feasibility study, a lubricant-free twin rod AFSD (TR-AFSD) approach printed a 100 millimeter tall AA7050 build. Mechanical properties in the build direction were determined for a range of artificial aging times. Experimental results showed that a one hour aging time following a 24-hour solution treatment produced tensile yield, ultimate tensile strength, and strain to failure results of 360 ± 5.5 MPa, 463 ± 10.3 MPa, and 7.55 ± 2.00 %, respectively. Our feasibility study shows that forging-like tensile properties can be achieved in the build direction from TR-AFSD prints using a featureless tool coupled with a temperature control lubricant-free round feedstock approach and a custom PDHT schedule.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100296"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144535579","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

On joining additive manufactured metals via friction welding technology: a comprehensive mechanical and microstructural study on 316 L stainless steel components 用摩擦焊技术连接增材制造金属：316l不锈钢构件力学和显微组织的综合研究

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100309

Fatma Nur Depboylu , Loïc Jegou , Luciana Tavares , Andrei-Alexandru Popa

{"title":"On joining additive manufactured metals via friction welding technology: a comprehensive mechanical and microstructural study on 316 L stainless steel components","authors":"Fatma Nur Depboylu , Loïc Jegou , Luciana Tavares , Andrei-Alexandru Popa","doi":"10.1016/j.addlet.2025.100309","DOIUrl":"10.1016/j.addlet.2025.100309","url":null,"abstract":"<div><div>Rotational Friction Welding (RFW) is a solid-state joining technique that enables the assembly of metallic components below their melting temperature, while also avoiding harmful gas emissions commonly associated with fusion-based methods. Despite their high mechanical strength, parts manufactured by RFW often struggle to meet the industrial demand for complex geometries beyond their typical cylindrical and disc shapes. Laser Powder Bed Fusion (PBF-LB/M) allows fabrication of geometrically intricate parts with high precision and mechanical reliability. However, it faces challenges such as high production costs and dimensional limitations. Combining PBF-LB/M with RFW enables the production of larger and complex metal parts. The purpose of this study is to demonstrate the feasibility and benefits of this hybrid approach for 316 L stainless steel (SS). To accomplish this, 316 L SS parts were initially fabricated using PBF-LB/M and then joined by RFW. The joints were analyzed to evaluate weld integrity, microstructural evolution, phase stability, and mechanical performance. The analysis reveals three distinct microstructural zones: the weld zone, the thermo-mechanically affected zone, and the base metal zone. Grain refinement is observed in the weld zone, whereas coarser grains appear toward the base metal zone. Phase analysis exhibits a fully austenitic structure without any detrimental secondary phases. Mechanical testing shows increased hardness in the weld zone associated with grain refinement. Tensile tests reveal that the fracture occurred outside the welding region, specifically in the base metal zone. These findings highlight a finer, defect-free weld zone without secondary phases in RFW joined PBF-LB/M 316 L SS components.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100309"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703767","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0