Additive manufacturing letters最新文献_第2页

Processing of Thermoelectric Fe2VAl Heusler-compounds by laser powder bed fusion: From single scan tracks to bulk material 热电Fe2VAl heusler化合物的激光粉末床熔合加工：从单一扫描轨迹到块状材料

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100305

M. Delcroix, G. Roy, C. van der Rest, V. Marchal-Marchant, P.J. Jacques

{"title":"Processing of Thermoelectric Fe2VAl Heusler-compounds by laser powder bed fusion: From single scan tracks to bulk material","authors":"M. Delcroix, G. Roy, C. van der Rest, V. Marchal-Marchant, P.J. Jacques","doi":"10.1016/j.addlet.2025.100305","DOIUrl":"10.1016/j.addlet.2025.100305","url":null,"abstract":"<div><div>In the present study, the n-type Fe<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> VAl<sub>0.9</sub> Si<sub>0.1</sub> was printed by laser powder bed fusion (L-PBF) for the first time. This work highlights the complexity of processing non-metallic materials by L-PBF and the need for advanced optimization strategies. A Single Scan Tracks (SSTs) analysis was conducted as usually done for materials newly processed by L-PBF as well as a top-down approach based on printing parameters of stainless steel. Process parameter sets based on SST analysis led to overheating while the stainless-steel-based strategy successfully produced bulk samples. Printed samples transitioned rapidly from cold defects (i.e. lack-of-fusion) to overheating as the printing parameters were varied. Moreover, high density samples were printed with parameters that would produce insufficient melting in the case of SSTs. Successive parallel tracks were printed and revealed a transition from unmelting to balling to continuous densification, demonstrating the critical role of heat accumulation. The microstructure of printed samples was analyzed, and their thermoelectric properties were measured. Transverse cold cracks, perpendicular to the scanning direction were observed. Statistical analysis on SST demonstrated that these cracks were insensitive to laser parameter variations, significantly decreasing the thermoelectric performance of bulk samples.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100305"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144766968","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

Rapid exploration of nanoparticle-modified alloys in metal additive manufacturing by combining inkjet printing and laser powder bed fusion 结合喷墨打印和激光粉末床熔接技术在金属增材制造中纳米颗粒改性合金的快速探索

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100315

Emre Tekoglu , Shuheng Liao , Zachary Kutschke , Alexander D. O’Brien , Bethany Lettiere , Ju Li , A. John Hart

{"title":"Rapid exploration of nanoparticle-modified alloys in metal additive manufacturing by combining inkjet printing and laser powder bed fusion","authors":"Emre Tekoglu , Shuheng Liao , Zachary Kutschke , Alexander D. O’Brien , Bethany Lettiere , Ju Li , A. John Hart","doi":"10.1016/j.addlet.2025.100315","DOIUrl":"10.1016/j.addlet.2025.100315","url":null,"abstract":"<div><div>The development of new metal alloys is key to the continued advances in critical technologies such as jet engines operating at higher temperatures, rocket engines with longer lifetime and reusability, and reactors for fusion and fission energy generation. While additive manufacturing (AM) is attractive for both prototyping and production of advanced alloys and components, the experimental screening and validation of new alloys typically requires costly synthesis of custom powder feedstocks. We present a technique for high-throughput screening of nanoparticle-enhanced alloys for AM, combining inkjet printing and laser powder bed fusion (LPBF). Alloyed specimens are prepared on metal substrates with shallow machined cavities; a nanoparticle-containing ink is printed into the cavities via inkjet deposition; powder is manually spread into the wells; and then the material is melted by scanning of a laser as in traditional LPBF. We exercise this workflow using Niobium as the base metal and with custom-formulated inks containing Si and/or Ti nanoparticles. The alloyed specimens exhibit locally defined composition, microstructure, and hardness. We demonstrate control of minority element composition of <1 % to >10 % over <1 mm distances, and along with the capability to create multi-material gradients exhibiting complex microstructural effects.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100315"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144827674","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

Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries 复杂几何形状的增材制造超高强度钢结构的裂缝预防和性能改进

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100307

Jun Wang , Mark Taylor , Chenglei Diao , Ed Pickering , Jian Qin , Yao Lu , Sonia Martins Meco , Jialuo Ding , Stewart Williams

{"title":"Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries","authors":"Jun Wang , Mark Taylor , Chenglei Diao , Ed Pickering , Jian Qin , Yao Lu , Sonia Martins Meco , Jialuo Ding , Stewart Williams","doi":"10.1016/j.addlet.2025.100307","DOIUrl":"10.1016/j.addlet.2025.100307","url":null,"abstract":"<div><div>Hybrid wire-arc directed energy deposition (WDED), in which complex features are deposited onto a forged base, offers a cost-effective solution for manufacturing geometrically complex ultra-high-strength steel components, particularly for aerospace applications. However, cracking at the base forging/build interface during post-build heat treatment limits its widespread application. This study investigates the underlying causes of interfacial cracking, highlighting microstructural inhomogeneity, elemental segregation and transformation stresses as likely key contributing factors. A modified three-step post-build heat treatment incorporating a normalisation step was developed to mitigate some of these issues. The optimised process successfully suppressed cracking by refining prior-austenite grains before the application of a conventional quenching step. This enhanced tensile performance beyond AMS6419K standards, supporting the industrial implementation of hybrid WDED in aerospace structures.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100307"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144686272","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

Toward sustainable additive manufacturing of PEKK/Martian regolith composite for lightweight structural applications on Mars PEKK/火星风化层复合材料的可持续增材制造，用于火星上的轻型结构应用

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100297

Farshad Malekpour , Marjan Abdali , Mehdi Hojjati , Krzysztof Skonieczny

{"title":"Toward sustainable additive manufacturing of PEKK/Martian regolith composite for lightweight structural applications on Mars","authors":"Farshad Malekpour , Marjan Abdali , Mehdi Hojjati , Krzysztof Skonieczny","doi":"10.1016/j.addlet.2025.100297","DOIUrl":"10.1016/j.addlet.2025.100297","url":null,"abstract":"<div><div>Advances in sustainable resource utilization and innovative manufacturing techniques are driving efforts toward the prospect of human settlement on Mars, led by programs such as SpaceX’s Occupy Mars initiative. One promising approach involves the development of materials and processes that leverage in-situ Martian resources. In this study, we investigate the fabrication and characterization of a composite material consisting of Polyether-Ketone-Ketone (PEKK) incorporated with Martian Regolith Simulant (MRS), targeting sustainable applications in outer space. Amorphous PEKK was pulverized and mixed with sieved MRS particles, followed by extrusion through a twin-screw extruder to produce a filament with a consistent diameter suitable for Material Extrusion Additive Manufacturing (MEAM). A post-processing protocol, including annealing, was implemented to optimize the degree of crystallinity and improve mechanical properties. The filament quality and dispersion of regolith within the matrix were evaluated, and the composite was characterized through mechanical and thermomechanical analyses. Based on the material properties achieved, a conceptual Mars rover wheel featuring a lightweight graded structure was designed and successfully fabricated. These results demonstrate the early-stage feasibility of producing high-quality, mechanically robust 3D-printed components from regolith-based composites, highlighting the potential of integrating additive manufacturing with local resources as a step toward sustainable extraterrestrial exploration.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100297"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144579815","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

Towards fully 3D printed dielectric elastomer actuators—A mini review 迈向完全3D打印的介电弹性体致动器-一个小型回顾

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100304

Rollo Pattinson , Nathan Ellmer , Mokarram Hossain , Rogelio Ortigosa , Jesús Martínez-Frutos , Antonio J. Gil , Anil Bastola

{"title":"Towards fully 3D printed dielectric elastomer actuators—A mini review","authors":"Rollo Pattinson , Nathan Ellmer , Mokarram Hossain , Rogelio Ortigosa , Jesús Martínez-Frutos , Antonio J. Gil , Anil Bastola","doi":"10.1016/j.addlet.2025.100304","DOIUrl":"10.1016/j.addlet.2025.100304","url":null,"abstract":"<div><div>Dielectric elastomer actuators (DEAs) have attracted the interest of researchers in soft robotics and biomimetics, due to their versatile capabilities, explored through numerical analysis and experimentation. Advances in computational simulation techniques have accelerated numerical studies on DEAs, enabling even design optimisation for improved performance. However, as computational models grow in sophistication, the fabrication methods required often exceed the capabilities of traditional manufacturing. Additive manufacturing, in particular 3D printing, offers a promising solution to the challenges of realising intricate multi-functional designs developed through topology optimisation. Its precision and ability to create complex geometries make it well-suited for translating computational designs into functional DEA devices. This mini-review examines recent progress in 3D printing for DEA fabrication, emphasising its role in bridging the gap between computational design and physical devices. It also highlights emerging technologies and key challenges that must be addressed to fully realise topologically optimised DEA designs.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100304"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144722272","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

Dual-matrix interface strength of 3D printed continuous carbon fiber reinforced composites: Quantitative assessment methodology and critical influencing factors 3D打印连续碳纤维增强复合材料双基体界面强度：定量评估方法及关键影响因素

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100303

Xiaofei Lou , Lei Dong , Xin'an Tang , Xiaohui Nan , Teng Zhang , Li Zhao

{"title":"Dual-matrix interface strength of 3D printed continuous carbon fiber reinforced composites: Quantitative assessment methodology and critical influencing factors","authors":"Xiaofei Lou , Lei Dong , Xin'an Tang , Xiaohui Nan , Teng Zhang , Li Zhao","doi":"10.1016/j.addlet.2025.100303","DOIUrl":"10.1016/j.addlet.2025.100303","url":null,"abstract":"<div><div>In 3D printed continuous carbon fiber reinforced dual-matrix composites, the resin matrix in the carbon fiber prepreg filament is not the same with the matrix in the composite, and the dual-matrix interface plays an important role on the mechanical properties of structures. In this paper, a method for testing the interface shear strength (IFSS) of the dual-matrix is proposed. The interfaces between carbon fiber reinforced polyamide-6 prepreg filament and different polylactic acid matrices are selected, and the strengths of the dual-matrix interface are investigated under different printing temperatures, printing speeds, layer thicknesses, and prepreg filament volume fractions. The results show that the polylactic acid matrix with lower crystallinity is capable to form stronger interface with the polyamide-6 material. The printing temperature and printing speed need to be controlled within a certain range to ensure a reasonable viscosity range and printing quality, which will achieve a higher dual-matrix IFSS. The increase of prepreg filament volume fraction and the decrease of layer thickness are conducive to the improvement of dual-matrix interfacial properties. In addition, finite element analysis based on the cohesive model is used to analyze the interface debonding behavior, which validates the test method proposed in this paper.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100303"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144653846","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

A new approach to laser DED as a repair technology with laser mesh deposition 用激光网状沉积技术修复激光DED的新方法

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100301

Thomas Girerd , Richard Adamson , Andres Gameros , Marco Simonelli , Andy Norton , Adam Thomas Clare

{"title":"A new approach to laser DED as a repair technology with laser mesh deposition","authors":"Thomas Girerd , Richard Adamson , Andres Gameros , Marco Simonelli , Andy Norton , Adam Thomas Clare","doi":"10.1016/j.addlet.2025.100301","DOIUrl":"10.1016/j.addlet.2025.100301","url":null,"abstract":"<div><div>Controlling the heat input and exploring alternate feedstocks for DED is necessary to improve the versatility of DED as a repair technique. In this research, a new DED method using metallic mesh feedstocks and laser beam oscillations. This method is shown to have good stability, repeatability and good bonding with the substrate comparable to other DED processes. The best depositions show a dilution above 40 % and a height of >1.2 mm. The deposits show similar results to wire DED and powder DED with low dilution levels producing dense clads with no large pores and some grain refinements at the edges of the tracks. This then manifests as a potentially viable repair process with the advantage of a more flexible material input facilitating the delivering of the feedstock material for hard to access repair operations.</div><div>Furthermore, this process has shown its capability to be used with various energy profiles and mesh density paving the way for a better control of the microstructure for complex repair operations. This new DED alternative method has shown its capability to run efficiently with various scan strategies and feedstocks. Hence, laser mesh deposition could be used to deposit material on inhomogeneous surfaces by using carefully designed scanning strategies and mesh density during the process increasing the repair capabilities of DED.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100301"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144653847","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

Superior mechanical properties of a high temperature Co-based superalloy fabricated by laser powder bed fusion 激光粉末床熔合制备的高温钴基高温合金具有优异的力学性能

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100311

Liuhao Miao , Huiliang Wei , Jiashun Yue , Rong Chen , Yuanhong Qian , Xiaopeng Li , Zhiguang Zhu , Tingting Liu , Wenhe Liao

{"title":"Superior mechanical properties of a high temperature Co-based superalloy fabricated by laser powder bed fusion","authors":"Liuhao Miao , Huiliang Wei , Jiashun Yue , Rong Chen , Yuanhong Qian , Xiaopeng Li , Zhiguang Zhu , Tingting Liu , Wenhe Liao","doi":"10.1016/j.addlet.2025.100311","DOIUrl":"10.1016/j.addlet.2025.100311","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) of high temperature superalloys with superior mechanical properties are highly desired. However, the correlations between the process, microstructure and ambient/high temperature mechanical properties for the typical Co-based superalloy Haynes 188 remain unclear. In this work, the process development, the ambient and high temperature mechanical properties for LPBF of Haynes 188 were systematically explored. Samples with relative density over 99.9 % were achieved. Unprecedented ambient temperature strength-ductility were obtained, with yield strength of 756 MPa, tensile strength of 1067 MPa, and elongation of 60.2 %, respectively. Moreover, high temperature mechanical properties such as the steady-state creep rate of 1.04×10<sup>−4</sup> s⁻¹ at 750 °C and 270 MPa were firstly reported. Additionally, the yield strength of Haynes 188 at 980 °C reached 276 MPa. Microstructural analysis revealed that nano-scale M<sub>6</sub>C/M<sub>23</sub>C<sub>6</sub> carbides pinned dislocations, while dense dislocation networks and refined sub-grains suppressed dynamic recovery. The obtained achievements can provide valuable insights for additive manufacturing of complex and high-performance Haynes 188 components.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100311"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144770757","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

Cross-modality transfer for DED-LB/M: AI-based prediction of schlieren phenomena from coaxial imaging d - lb /M的跨模态转移：基于人工智能的同轴成像纹影现象预测

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100298

Benedikt Brandau , João Sousa , Rico Hemschik , Frank Brueckner , Alexander F.H. Kaplan

{"title":"Cross-modality transfer for DED-LB/M: AI-based prediction of schlieren phenomena from coaxial imaging","authors":"Benedikt Brandau , João Sousa , Rico Hemschik , Frank Brueckner , Alexander F.H. Kaplan","doi":"10.1016/j.addlet.2025.100298","DOIUrl":"10.1016/j.addlet.2025.100298","url":null,"abstract":"<div><div>Real-time process monitoring is essential for ensuring stability and defect control in directed energy deposition - laser beam/metal (DED-LB/M). Schlieren imaging has proven to be a valuable tool for detecting refractive index variations in the process zone, providing insights into gas flow behaviour, shielding gas efficiency and process plume dynamics. However, schlieren imaging typically requires specialized optical setups, making integration into industrial systems challenging. This study explores an artificial intelligence-driven cross-modality transfer approach that enables the prediction of schlieren-induced refractive index variations from coaxial imaging data, eliminating the need for a dedicated schlieren setup. A background-oriented schlieren system was used to capture reference data, while a coaxial camera recorded the melt pool and surrounding process zone during DED-LB/M. A machine learning model was trained on the combined dataset, establishing correlations between schlieren activity and intensity variations in the coaxial images. The model successfully predicted schlieren-induced disturbances, allowing for the indirect detection of gas flow instabilities and shielding gas deficiencies. The results demonstrate that artificial intelligence-based analysis of coaxial imaging can provide schlieren-equivalent process information, making it possible to monitor refractive index variations, detect process deviations and improve defect prediction in real time. This approach enhances process monitoring capabilities in DED-LB/M, enabling cost-effective, scalable and easily integrable monitoring solutions for industrial applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100298"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144523170","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

Chamfer distance for non-linear registration of Triply Periodic Minimal Surface lattices 三周期极小曲面格非线性配准的倒角距离

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100299

Michela Lapenna , Francesco Faglioni , Keerthana Chand , Bardia Hejazi , Rita Fioresi , Giovanni Bruno

引用次数: 0