Additive manufacturing letters最新文献_第3页

Molten metal jetting for repairing aluminum components

IF 4.2

Additive manufacturing letters Pub Date : 2024-12-01 DOI: 10.1016/j.addlet.2024.100259

Benedikt Kirchebner , Kellen D. Traxel , Alexander E. Wilson-Heid , Eric S. Elton , Andrew J. Pascall , Jason R. Jeffries

{"title":"Molten metal jetting for repairing aluminum components","authors":"Benedikt Kirchebner , Kellen D. Traxel , Alexander E. Wilson-Heid , Eric S. Elton , Andrew J. Pascall , Jason R. Jeffries","doi":"10.1016/j.addlet.2024.100259","DOIUrl":"10.1016/j.addlet.2024.100259","url":null,"abstract":"<div><div>Molten metal jetting (MMJ) is an additive manufacturing (AM) method where droplets of molten metal are used to build parts. Like most AM technologies, MMJ is typically used to build stand-alone parts rather than add onto existing parts. However, the droplet-wise deposition method of MMJ is inherently compatible with the ability to build on existing parts. Here, we utilize MMJ to “repair” machined damage on cast aluminum parts. A commercial MMJ system was used to fill in varied but defined groove geometries to find optimal shapes amenable to repair with MMJ. Subsequently, grooves were cut into tensile specimens and back-filled (repaired) using MMJ. Tensile tests indicate that MMJ repair restores significant strength to samples despite the distinct microstructure and void structures present in the repaired section. Repaired samples demonstrated tensile strengths ∼72 % of the as-received material, compared to UTS of ∼33 % for damaged samples. These results indicate that MMJ is a viable method to repair parts where other repair methods may be impractical.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100259"},"PeriodicalIF":4.2,"publicationDate":"2024-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143148355","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

A spatial-temporal method for early prediction of fatigue crack region and orientation in metallic cellular materials using in-situ infrared thermography (IRT)

IF 4.2

Additive manufacturing letters Pub Date : 2024-12-01 DOI: 10.1016/j.addlet.2024.100258

Tyler D. Smith , Chad Westover , Matthew D'Souza , Shenghan Guo , Dhruv Bhate

引用次数: 0

A new process route for the additive manufacturing of a high nitrogen containing martensitic stainless steel - A feasibility study 高含氮马氏体不锈钢增材制造的新工艺路线 - 可行性研究

IF 4.2

Additive manufacturing letters Pub Date : 2024-11-19 DOI: 10.1016/j.addlet.2024.100257

L. Becker, P. König, J. Lentz, S. Weber

{"title":"A new process route for the additive manufacturing of a high nitrogen containing martensitic stainless steel - A feasibility study","authors":"L. Becker, P. König, J. Lentz, S. Weber","doi":"10.1016/j.addlet.2024.100257","DOIUrl":"10.1016/j.addlet.2024.100257","url":null,"abstract":"<div><div>High-nitrogen martensitic stainless steels, such as X30CrMoN15 (0.3 to 0.5 mass% nitrogen), exhibit an excellent combination of strength and corrosion resistance, making them well-suited for applications in the medical technology and aerospace industry. The qualification of these steels for additive manufacturing (AM) could generate new application areas where AM, due to its process-specific advantages, could offer added value compared to conventional manufacturing methods. However, the laser powder bed fusion (PBF-LB/M) of high-nitrogen alloyed steels is challenging due to the high tendency for gas pore formation, resulting from the limited nitrogen solubility in the steel melt. In this work, a new process route for AM of a high nitrogen containing X50CrMoV15 martensitic stainless steel is presented, which consists of a process combination of powder nitriding, PBF-LB/M and subsequent hot isostatic pressing (HIP) with integrated quenching. Gas nitriding is used to achieve a nitrogen content in the starting powder that exceeds the maximum solubility in the melt. Although the nitrogen content decreases during the PBF-LB/M process, the high solidification and cooling rates prevent the melt from reaching equilibrium nitrogen levels, resulting in a nitrogen content above the solubility limit in the final PBF-LB/M state. The pores formed during the process are closed through HIP, which also allows hardening via integrated gas quenching. With an additional cryogenic treatment, the process produces a fully dense steel with 75% martensitic structure and 0.246 mass% nitrogen. Further optimization opportunities have been identified and are discussed.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100257"},"PeriodicalIF":4.2,"publicationDate":"2024-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142702849","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

Additive manufacturing simulations: An approach based on space partitioning and dynamic 3D mesh adaptation 快速成型制造模拟：基于空间分割和动态 3D 网格适应的方法

IF 4.2

Additive manufacturing letters Pub Date : 2024-11-18 DOI: 10.1016/j.addlet.2024.100256

Panagis Foteinopoulos, Alexios Papacharalampopoulos, Panagiotis Stavropoulos

引用次数: 0

Understanding the effect of pre-sintering scanning strategy on the relative density of Zr-modified Al7075 processed by laser powder bed fusion 了解预烧结扫描策略对激光粉末床熔融技术加工的 Zr 改性 Al7075 相对密度的影响

IF 4.2

Additive manufacturing letters Pub Date : 2024-11-13 DOI: 10.1016/j.addlet.2024.100253

Nicolas Nothomb , Ignacio Rodriguez-Barber , María Teresa Pérez-Prado , Norberto Jimenez Mena , Grzegorz Pyka , Aude Simar

引用次数: 0

Mechanical performance of laser powder bed fused Ti-6Al-4V: The influence of filter condition and part location 激光粉末床熔融 Ti-6Al-4V 的机械性能：过滤条件和零件位置的影响

IF 4.2

Additive manufacturing letters Pub Date : 2024-11-08 DOI: 10.1016/j.addlet.2024.100255

Mohammad Salman Yasin , Kevin Stonaker , Shuai Shao , Nima Shamsaei

{"title":"Mechanical performance of laser powder bed fused Ti-6Al-4V: The influence of filter condition and part location","authors":"Mohammad Salman Yasin , Kevin Stonaker , Shuai Shao , Nima Shamsaei","doi":"10.1016/j.addlet.2024.100255","DOIUrl":"10.1016/j.addlet.2024.100255","url":null,"abstract":"<div><div>Deteriorated filter condition in laser powder bed fusion (L-PBF) systems may negatively impact shield gas flow, causing inadequate spatter particle/plume removal, leading to laser beam attenuation and reduction in melt pool depth, and potentially causing more frequent formation of volumetric defects. This work investigated the effects of filter condition and part location on the micro-/defect-structure and mechanical behavior, including tensile and fatigue, of Ti-6Al-4V parts fabricated by L-PBF. Interestingly, within the manufacturer recommended service intervals, no specific effect of filter condition could be observed on the micro-/defect-structure or the mechanical behavior of the fabricated parts. However, the parts’ defect-structures were affected by their location, with ones located near the center of the build plate having less porosity than the ones located away. Although these defects did not affect the tensile properties, they frequently observed to initiate fatigue cracks (the critical defects sizes were often in the range of a few tens of micrometers). Therefore, their sensitivity to location resulted in the location dependence of the fatigue behavior.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100255"},"PeriodicalIF":4.2,"publicationDate":"2024-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142656286","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

Area-based composition predictions of materials fabricated using simultaneous wire-powder-directed energy deposition 利用同步线-粉末定向能沉积法制造材料的基于面积的成分预测

IF 4.2

Additive manufacturing letters Pub Date : 2024-11-04 DOI: 10.1016/j.addlet.2024.100254

Scott C. Bozeman, O. Burkan Isgor, Julie D. Tucker

{"title":"Area-based composition predictions of materials fabricated using simultaneous wire-powder-directed energy deposition","authors":"Scott C. Bozeman, O. Burkan Isgor, Julie D. Tucker","doi":"10.1016/j.addlet.2024.100254","DOIUrl":"10.1016/j.addlet.2024.100254","url":null,"abstract":"<div><div>Functionally graded materials are an emergent method for designing components with programmable site-specific material properties. These materials are typically fabricated using metal additive manufacturing tools by simultaneously feeding multiple wire and/or powder feedstocks at various rates to achieve spatial composition change. The wire-powder-directed energy deposition (WP-DED) technique is of particular interest for many functionally graded material applications by balancing the low raw materials cost of wire with the high resolution of powder. However, feeding wire and powder are inherently different processes since all extruded wire enters the melt pool, while much of the blown powder is scattered, which makes determining the composition of the build challenging. In this study, we devise a simple area-based measurement method for estimating the composition of WP-DED structures. WP-DED single beads are printed using 309L stainless steel wire and commercially pure Fe powder at five wire feed rates (0.5, 0.75, 1.00, 1.25, 1.50 mm/mm) and five powder feed rates (2, 4, 6, 8, 10 rpm). Characteristic defects including interface gaps and macrosegregation (lack of mixing) tendencies are examined. High powder feed rates (8, 10 rpm) result in interface gaps at all wire feed rates, but smooth deposition and complete mixing is achieved at low powder feed rates, particularly with lower wire feed rates as well. The area-based composition measurement method is within ±20% of energy dispersive x-ray spectroscopy measurements for all samples, showing its effectiveness as a rapid composition estimate for WP-DED materials development.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100254"},"PeriodicalIF":4.2,"publicationDate":"2024-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142656285","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

Modelling process monitoring data in laser powder bed fusion: A pragmatic route to additive manufacturing quality assurance 激光粉末床熔融过程监控数据建模：快速成型制造质量保证的实用途径

IF 4.2

Additive manufacturing letters Pub Date : 2024-10-29 DOI: 10.1016/j.addlet.2024.100252

Luke N. Carter , Victor M. Villapún , James Andrews , Thomas R.B. Grandjean , John Dardis , Sophie C. Cox

{"title":"Modelling process monitoring data in laser powder bed fusion: A pragmatic route to additive manufacturing quality assurance","authors":"Luke N. Carter , Victor M. Villapún , James Andrews , Thomas R.B. Grandjean , John Dardis , Sophie C. Cox","doi":"10.1016/j.addlet.2024.100252","DOIUrl":"10.1016/j.addlet.2024.100252","url":null,"abstract":"<div><div>Quality assurance remains a significant challenge for laser powder bed fusion and metal additive manufacturing. Despite system manufacturers offering process monitoring as a possible solution, datasets are large and cumbersome with practical use limited without direct comparative data. Model datasets would enable individual build validation, highlight deviations, and facilitate intelligent build planning whereby challenging features or build strategies could be pre-emptively assessed.</div><div>Herein a pragmatic approach has been developed to model process monitoring data from a commercial system using a relatively simple algorithm. Using a heuristic method, the algorithm response has been fitted to an experimental dataset to derive governing constants and their relationship to key process parameters. Predictability of constants and model fit has been shown to improve with increasing line energy up to a maximum R<sup>2</sup>=0.8. Algorithm variable trends, supported by corresponding sensitivity analysis, identified two different behavioural regimes. Under low linear energy density (<0.2J/mm) the cumulative spacetime proximity time-weight variable shows a low sensitivity index, characterised by a flat model response reflected in the experimental data. At higher energies (≥0.2J/mm) algorithm variables become more predictable, reflected in stabilising sensitivity indices, as measurements adopt a form characteristic of the cumulative spacetime proximity function.</div><div>Effectiveness has been demonstrated through presentation of experimental and model data. Refining the methodology to accommodate noise, geometry, and systematic behaviours are identified as key steps to future development. This feasibility study has laid the groundwork for a generalised predictive tool, capable of realising the quality assurance ambitions promised by laser powder-bed fusion process monitoring.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100252"},"PeriodicalIF":4.2,"publicationDate":"2024-10-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142572438","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

Drop-on-demand 3D printing of programable magnetic composites for soft robotics 用于软机器人的可编程磁性复合材料的按需滴落三维打印技术

IF 4.2

Additive manufacturing letters Pub Date : 2024-10-28 DOI: 10.1016/j.addlet.2024.100250

Anil Bastola , Luke Parry , Robyn Worsley , Nisar Ahmed , Edward Lester , Richard Hague , Christopher Tuck

{"title":"Drop-on-demand 3D printing of programable magnetic composites for soft robotics","authors":"Anil Bastola , Luke Parry , Robyn Worsley , Nisar Ahmed , Edward Lester , Richard Hague , Christopher Tuck","doi":"10.1016/j.addlet.2024.100250","DOIUrl":"10.1016/j.addlet.2024.100250","url":null,"abstract":"<div><div>Soft robotics have become increasingly popular as a versatile alternative to traditional robotics. Magnetic composite materials, which respond to external magnetic fields, have attracted significant interest in this field due to their programmable two-way actuation and shape-morphing capabilities. Additive manufacturing (AM)/3D printing allows for the incorporation of different functional composite materials to create active components for soft robotics. However, current AM methods have limitations, especially when it comes to printing smart composite materials with high functional material content. This is a key requirement for enhancing responsiveness to external stimuli. Commonly used AM methods for smart magnetic composites, such as direct ink writing (DIW), confront challenges in achieving discontinuous printing, and enabling multi-material control at the voxel level, while some AM techniques are not suitable for producing composite materials. To address these limitations, we employed high-viscosity drop-on-demand (DoD) jetting and developed programmable magnetic composites filled with micron-sized hard magnetic particles. This method bridges the gap between conventional ink-jetting and DIW, which require printing inks with viscosities at opposite ends of the spectrum. This high-viscosity DoD jetting enables continuous, discontinuous, and non-contact printing, making it a versatile and effective method for 3D printing functional magnetic composites even with micron-sized fillers. Furthermore, we demonstrated stable magnetic domain programming and two-way shape-morphing actuations of printed structures for soft robotics. In summary, our work highlights high-viscosity DoD jetting as a promising method for printing functional magnetic composites and other similar materials for a wide range of applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100250"},"PeriodicalIF":4.2,"publicationDate":"2024-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142560560","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

In-situ heating TEM observation of solidification cell evolutions in an Al-Fe alloy built by laser-powder bed fusion 原位加热 TEM 观察激光粉末床熔融法制造的 Al-Fe 合金中凝固单元的演变过程

IF 4.2

Additive manufacturing letters Pub Date : 2024-10-28 DOI: 10.1016/j.addlet.2024.100251

Ji-Yun Wang , Verner Soh , Pei Wang , Tzu-Ching Tsao , Ming-Wen Chu , Ming-Hao Lee , Zhongji Sun , Shao-Pu Tsai

{"title":"In-situ heating TEM observation of solidification cell evolutions in an Al-Fe alloy built by laser-powder bed fusion","authors":"Ji-Yun Wang , Verner Soh , Pei Wang , Tzu-Ching Tsao , Ming-Wen Chu , Ming-Hao Lee , Zhongji Sun , Shao-Pu Tsai","doi":"10.1016/j.addlet.2024.100251","DOIUrl":"10.1016/j.addlet.2024.100251","url":null,"abstract":"<div><div>Cellular structures (i.e., solidification cells) are a unique feature within alloys fabricated through rapid solidification, such as laser-powder bed fusion (L-PBF). Ever since the report of these structures’ beneficial effects on the material's mechanical properties, numerous studies have been devoted to the understanding of their formation mechanisms. Yet, the integrity and stability of the cellular structures are often less investigated, despite their significance on property interpretation and evolution. In this work, a stepwise <em>in-situ</em> heating transmission electron microscopy (TEM) experiment was performed on the exemplary LPBF-fabricated AlFeSiMoZr alloy. A critical threshold of 325 °C was identified, beyond which the cellular structures start to decompose in conjunction with precipitate coarsening. Preferred precipitate nucleation sites and their subsequent coarsening kinetics were determined and presented. Nanometer-sized crystalline embryos (3.81 ± 0.66 nm) were discovered within the cellular structure boundaries in their as-built condition, offering new insights on the precipitate formation and evolution at elevated temperatures.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100251"},"PeriodicalIF":4.2,"publicationDate":"2024-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142578222","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