Additive manufacturing letters最新文献_第2页

An integrated hybrid wire-arc directed energy deposition, friction stir processing, and milling system for multi-track, multi-layer part manufacturing 用于多轨道、多层零件制造的线弧定向能沉积、摩擦搅拌加工和铣削综合混合系统

IF 4.2

Additive manufacturing letters Pub Date : 2024-10-11 DOI: 10.1016/j.addlet.2024.100247

Dinh Son Nguyen , Jie Song , Yao Fu , Albert C. To

{"title":"An integrated hybrid wire-arc directed energy deposition, friction stir processing, and milling system for multi-track, multi-layer part manufacturing","authors":"Dinh Son Nguyen , Jie Song , Yao Fu , Albert C. To","doi":"10.1016/j.addlet.2024.100247","DOIUrl":"10.1016/j.addlet.2024.100247","url":null,"abstract":"<div><div>Wire-based Directed Energy Deposition (DED) is a widely-used manufacturing method due to its high productivity and large part fabrication capability. Meanwhile, Friction Stir Processing (FSP) is a solid-state joining process that can modify microstructure and weld lightweight alloys. Additionally, wire-based DED printed parts need machining process to achieve the desired dimensional accuracy. To take advantage of all these three processes, this work proposes an integrated hybrid system by combining the wire-arc DED, FSP, and milling processes into a standalone system which can fabricate superior materials in a multi-track, multi-layer manner for the first time. The integrated system can improve dimensional accuracy and productivity by processing the workpiece without the need to move it between different systems. It is demonstrated that a 150 × 40 × 21 mm<sup>3</sup> block of aluminum alloy AA5183 can be fabricated using the hybrid wire-DED/FSP/milling process from wire feedstock. Material characterization shows that the hybrid process is able to refine the grain size by two orders of magnitude to sub-micron scale, while eliminating all the pores and microcracks produced by the DED process. These enhancements result in significantly improved mechanical properties including Young's modulus (15 %), yield strength (161 %), ultimate strength (33 %), and hardness (55 %) without compromising ductility.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100247"},"PeriodicalIF":4.2,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433430","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effect of laser power during laser powder bed fusion on microstructure of joining interface between Tungsten and AISI 316L steel 激光粉末床熔融过程中的激光功率对钨和 AISI 316L 钢连接界面微观结构的影响

IF 4.2

Additive manufacturing letters Pub Date : 2024-10-09 DOI: 10.1016/j.addlet.2024.100246

Seung-Hoon Lee , Ji-Hoe Koo , Omer Cakmak , Jung-Wook Cho

引用次数: 0

Preparation of continuous carbon fiber reinforced PA6 prepreg filaments with high fiber volume fraction 制备高纤维体积分数的连续碳纤维增强 PA6 预浸丝

IF 4.2

Additive manufacturing letters Pub Date : 2024-10-02 DOI: 10.1016/j.addlet.2024.100245

Ming Zhang , Zhonggang Sun , Yingbing Liang , Yanhua Guo , Guoqing Dai , Keyuan Wei , Ming Li , Xiping Li , Igor V. Alexandrov

{"title":"Preparation of continuous carbon fiber reinforced PA6 prepreg filaments with high fiber volume fraction","authors":"Ming Zhang , Zhonggang Sun , Yingbing Liang , Yanhua Guo , Guoqing Dai , Keyuan Wei , Ming Li , Xiping Li , Igor V. Alexandrov","doi":"10.1016/j.addlet.2024.100245","DOIUrl":"10.1016/j.addlet.2024.100245","url":null,"abstract":"<div><div>High-performance continuous carbon fiber prepreg filaments have been a research hotspot in the field of additive manufacturing in recent years, and are considered to be an effective option for improving the mechanical strength of thermoplastic composite parts. However, the effect of fiber volume fraction on the microstructure and tensile properties of 3D printed prepreg filaments remains miss. Therefore, this study selected suitable impregnation processes and materials to prepare prepreg filaments with different fiber volume fraction and investigated their mechanical properties and microscopic morphologies. The results show that the increase of fiber volume fraction effectively promoted the interface bonding between fiber and resin, and increased capacity for load transfer. When the fiber volume fraction was 54.0 %, the tensile strength of the prepreg filaments and specimens reached 1977 MPa and 334 MPa, respectively. This study can provide a process optimization strategy for the preparation of more types of continuous fiber prepreg filaments with high fiber volume fraction, as well as a data reference for the preparation of high-performance 3D-printed thermoplastic composites.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100245"},"PeriodicalIF":4.2,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142422867","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Deep learning for melt pool depth contour prediction from surface thermal images via vision transformers 通过视觉转换器进行深度学习，从表面热图像预测熔池深度轮廓

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-29 DOI: 10.1016/j.addlet.2024.100243

Francis Ogoke , Peter Pak , Alexander Myers , Guadalupe Quirarte , Jack Beuth , Jonathan Malen , Amir Barati Farimani

{"title":"Deep learning for melt pool depth contour prediction from surface thermal images via vision transformers","authors":"Francis Ogoke , Peter Pak , Alexander Myers , Guadalupe Quirarte , Jack Beuth , Jonathan Malen , Amir Barati Farimani","doi":"10.1016/j.addlet.2024.100243","DOIUrl":"10.1016/j.addlet.2024.100243","url":null,"abstract":"<div><div>Anomalous melt pools during metal additive manufacturing (AM) can lead to deteriorated mechanical and fatigue performance. In-situ monitoring of the melt pool subsurface morphology requires specialized equipment that may not be readily accessible or scalable. Therefore, we introduce a machine learning framework to correlate in-situ two-color thermal images observed via high-speed color imaging to the two-dimensional profile of the melt pool cross-section. We employ a hybrid CNN-Transformer architecture to establish a correlation between single bead off-axis thermal image sequences and melt pool cross-section contours measured via optical microscopy. Specifically, a ResNet model embeds the spatial information contained within the thermal images to a latent vector, while a Transformer model correlates the sequence of embedded vectors to extract temporal information. The performance of this model is evaluated through dimensional and geometric comparisons to the corresponding experimental no-powder melt pool observations. Our framework is able to model the curvature of the subsurface melt pool structure, with improved performance in high energy density regimes compared to analytical models. Additionally, the use of ratiometric temperature estimates improves the accuracy of the model predictions compared to monochromatic imaging. This work establishes a framework extensible towards powder-based AM builds.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100243"},"PeriodicalIF":4.2,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142422438","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effect of laser parameters and shielding gas flow on co-axial photodiode-based melt pool monitoring signals in laser powder bed fusion 激光参数和屏蔽气体流量对激光粉末床熔融中基于同轴光电二极管的熔池监测信号的影响

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-19 DOI: 10.1016/j.addlet.2024.100244

Joni Reijonen

{"title":"Effect of laser parameters and shielding gas flow on co-axial photodiode-based melt pool monitoring signals in laser powder bed fusion","authors":"Joni Reijonen","doi":"10.1016/j.addlet.2024.100244","DOIUrl":"10.1016/j.addlet.2024.100244","url":null,"abstract":"<div><div>Melt pool monitoring using co-axial photodiodes is increasingly used for online quality monitoring in PBF-LB AM. However, the fundamental correlations between different processing conditions and the co-axial photodiode signals are not well understood. In this study the impact of laser parameters and the shielding gas flow speed on co-axial photodiode-based melt pool monitoring signals is established. It is shown that laser power has positive linear correlation with the photodiode signal, while the correlation with scanning speed is non-linear in the form of <em>y</em>=ax<sup>–b</sup>. The focal point position, scanning orientation and shielding gas flow speed have highly non-linear response on the photodiode signal, depending on the combinatorial effects of the parameters. These underlying physical correlations should be carefully assessed and taken into consideration when trying to establish correlations between photodiode-based melt pool monitoring signal and defect formation in the PBF-LB process.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100244"},"PeriodicalIF":4.2,"publicationDate":"2024-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2772369024000525/pdfft?md5=cbf9c1ba3b0f65a2fea5968c1f650aaa&pid=1-s2.0-S2772369024000525-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142316051","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Additively manufactured Nb-Ti-Si based alloy: As-built and heat-treated conditions 以铌钛硅为基础的添加式制造合金：坯料和热处理条件

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-17 DOI: 10.1016/j.addlet.2024.100242

Runqi Gao , Hui Peng , Hongbo Guo , Bo Chen

{"title":"Additively manufactured Nb-Ti-Si based alloy: As-built and heat-treated conditions","authors":"Runqi Gao , Hui Peng , Hongbo Guo , Bo Chen","doi":"10.1016/j.addlet.2024.100242","DOIUrl":"10.1016/j.addlet.2024.100242","url":null,"abstract":"<div><p>This work aims to fully characterise the Nb-Ti-Si based alloy (Nb-26Ti-16Si-2.2Al-2Cr), processed by the electron-beam powder-bed-fusion in both as-built and heat-treated conditions, to elucidate the microstructure-property relationships. The as-built condition has [001]-oriented columnar grains of the Nb<sub>3</sub>Si phase with the Nbss phase dispersed throughout the microstructure. The microhardness is 645.2 ± 6.7 HV<sub>0.5</sub>, and the indentation fracture toughness shows distinct directionality: 7.7 MPa·m<sup>1/2</sup> in the horizontal direction compared to 5.3 MPa·m<sup>1/2</sup> in the vertical direction. Both properties are comparable to the cast version. The directionality is attributed to the underlying mechanisms such as crack bridging, arrest, and micro-crack formation. By contrast, in the heat-treated condition, the alloy exhibits a dual-phase microstructure (Nbss and Nb<sub>5</sub>Si<sub>3</sub> phases) with near-equiaxed grain shape due to the Nb<sub>3</sub>Si phase decomposition. The fracture toughness increases to 12.1 MPa·m<sup>1/2</sup>, at the expense of a reduced microhardness of 564.4 ± 15.0 HV<sub>0.5</sub>.</p></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100242"},"PeriodicalIF":4.2,"publicationDate":"2024-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2772369024000501/pdfft?md5=4e9a54c3bc27837b474f34dc47844f58&pid=1-s2.0-S2772369024000501-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142272232","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Jet on demand—A pneumatically driven molten metal jetting method for printing crack-free aluminum components 按需喷射--用于打印无裂纹铝制部件的气动驱动熔融金属喷射方法

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-17 DOI: 10.1016/j.addlet.2024.100240

Eric S. Elton, Kellen D. Traxel, Andrew J. Pascall, Jason R. Jeffries

{"title":"Jet on demand—A pneumatically driven molten metal jetting method for printing crack-free aluminum components","authors":"Eric S. Elton, Kellen D. Traxel, Andrew J. Pascall, Jason R. Jeffries","doi":"10.1016/j.addlet.2024.100240","DOIUrl":"10.1016/j.addlet.2024.100240","url":null,"abstract":"<div><div>Additive manufacturing (AM) of many traditional aluminum alloys is difficult due to hot cracking during cooling, which motivates investigating alternative AM methods that can mitigate this challenge. Here we demonstrate a new pneumatically driven molten metal jetting (MMJ) AM technique which uses a longer pressure pulse width to produce a jet of liquid metal that reaches the heated build plate. The “jet on demand” technique is utilized to build Al-6061 parts on heated build plates. Due to the large thermal mass contained in each jet, excellent adhesion is observed between droplets and layers while still maintaining dimensional control to produce parts with high relative densities (>98%). While as-printed parts exhibit different microstructure and hardness than traditional Al-6061, both microstructure and hardness are restored to traditionally processed values through a traditional T6 heat treatment. Microhardness values of 104 HV were obtained for printed Al-6061, which compares well to wrought properties. We observe that high build plate temperatures allow for lower solidification rates and eliminate hot cracking. These results point to a method for additively manufacturing traditional aluminum or other alloys that cannot currently be additively manufactured due to hot cracking.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100240"},"PeriodicalIF":4.2,"publicationDate":"2024-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2772369024000483/pdfft?md5=2d587638c9808e9d5184e4e2c4bcff5b&pid=1-s2.0-S2772369024000483-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142310901","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Deep learning based automated quantification of powders used in additive manufacturing 基于深度学习的增材制造所用粉末自动定量分析

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-14 DOI: 10.1016/j.addlet.2024.100241

K.V. Mani Krishna , A. Anantatamukala , Narendra B. Dahotre

引用次数: 0

In-situ characterization of defect formation and elimination dynamics during electron beam melting using high-speed X-ray imaging 利用高速 X 射线成像对电子束熔化过程中的缺陷形成和消除动态进行现场表征

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-05 DOI: 10.1016/j.addlet.2024.100239

Jiandong Yuan , Luis I. Escano , Samuel J. Clark , Junye Huang , Ali Nabaa , Qilin Guo , Minglei Qu , Kamel Fezzaa , Lianyi Chen

{"title":"In-situ characterization of defect formation and elimination dynamics during electron beam melting using high-speed X-ray imaging","authors":"Jiandong Yuan , Luis I. Escano , Samuel J. Clark , Junye Huang , Ali Nabaa , Qilin Guo , Minglei Qu , Kamel Fezzaa , Lianyi Chen","doi":"10.1016/j.addlet.2024.100239","DOIUrl":"10.1016/j.addlet.2024.100239","url":null,"abstract":"<div><p>Electron beam melting (EBM), also known as electron beam powder bed fusion (EB-PBF), is a metal additive manufacturing (AM) technology that can make metal parts that are difficult, inefficient, or unachievable through conventional manufacturing routes and other AM technologies. However, a comprehensive understanding of the dynamics of electron beam-matter interactions in EBM remains elusive, which is a barrier for the development and adoption of EBM technology. Here, we report the dynamics and mechanisms of pore formation, pore elimination, and crack elimination in EBM. Three mechanisms of pore formation are observed: (1) pore formation from feedstock powders, (2) pore formation from pre-existing defects, and (3) pore captured by solidification front. One pore elimination mechanism is discovered: pore elimination due to metal vapor condensation, which is unique to EBM. One crack elimination mechanism is uncovered: crack elimination through remelting. These results will enhance the understanding of defect formation and evolution mechanisms in EBM and may inspire the invention of effective approaches to mitigate and control defects (porosity and cracks) in EBM.</p></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100239"},"PeriodicalIF":4.2,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2772369024000471/pdfft?md5=4c8677c4726e2063dec2b6d8c31a7ae2&pid=1-s2.0-S2772369024000471-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142272233","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Laser additive manufacturing of a carbon-supersaturated β-Ti alloy for biomaterial application 用于生物材料应用的碳过饱和 β-Ti 合金激光快速成型技术

IF 4.2

Additive manufacturing letters Pub Date : 2024-09-04 DOI: 10.1016/j.addlet.2024.100233

Mingqi Dong , Yu Zhang , Weiwei Zhou , Peng Chen , Zhenxing Zhou , Hiroyasu Kanetaka , Takuya Ishimoto , Yuichiro Koizumi , Takayoshi Nakano , Naoyuki Nomura

{"title":"Laser additive manufacturing of a carbon-supersaturated β-Ti alloy for biomaterial application","authors":"Mingqi Dong , Yu Zhang , Weiwei Zhou , Peng Chen , Zhenxing Zhou , Hiroyasu Kanetaka , Takuya Ishimoto , Yuichiro Koizumi , Takayoshi Nakano , Naoyuki Nomura","doi":"10.1016/j.addlet.2024.100233","DOIUrl":"10.1016/j.addlet.2024.100233","url":null,"abstract":"<div><p>Developing high-performance β-Ti alloys is a persistent and long-term demand for the advancement of next-generation biomaterials. In this study, a strategy of leveraging the unique characteristics of laser powder bed fusion (L-PBF) technique and nanocarbon materials was proposed to design a novel carbon-supersaturated β-Ti alloy. Ultrathin graphene oxide (GO) sheets were closely covering onto spherical Ti-15Mo-5Zr-3Al (Ti1553) powders, enhancing laser absorptivity while maintaining good flowability. Consequently, the GO-added Ti1553 builds tended to be denser than the initial ones, indicating an improved additive manufacturability. During <span>L</span>-PBF, GO sheets were completely dissolved into the Ti1553 matrix, generating fully carbon-supersaturated β-Ti structures with a reduced grain size. Thanks to the exceptional strengthening effects of high-concentration solid-solution carbon (∼0.05 wt%), the GO/Ti1553 builds achieved a high ultimate tensile strength of 1166 MPa. Moreover, as revealed by the immunofluorescence staining experiments, the GO/Ti1553 builds demonstrated a retained cytocompatibility. This study provides new insight into composition and processing design of high-performance Ti components for biomedical applications.</p></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100233"},"PeriodicalIF":4.2,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2772369024000410/pdfft?md5=f91ca5affc8917d8cbab1f3b90e6769a&pid=1-s2.0-S2772369024000410-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142137012","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0