Additive manufacturing letters最新文献

{"title":"Thermo-mechanical response of aluminum alloy in the additive friction-stir deposition process","authors":"Chowdhury Sadid Alam ,&nbsp;Vahid Karami ,&nbsp;Shengmin Guo ,&nbsp;M Shafiqur Rahman","doi":"10.1016/j.addlet.2024.100263","DOIUrl":"10.1016/j.addlet.2024.100263","url":null,"abstract":"<div><div>Additive Friction Stir Deposition (AFSD) is an emerging solid-state additive manufacturing (AM) technique that creates fully dense metallic structures with equiaxed fine microstructures. The feedstock material is plasticized via frictional heating and deposited in the solid state. Due to the complex multi-physics nature of the process, an in-depth understanding of the interplay between material flow, temperature variations, and stress distribution within the deposited layers under various process parameters is crucial for achieving desired outcomes. This study focuses on the development of a plasticity-based computational model that employs a coupled Eulerian-Lagrangian (CEL) finite element methodology to analyze the thermo-mechanical response of the AA6061-T6 alloy in the AFSD process. By incorporating essential AFSD process variables namely, tool rotation speed, tool traverse speed, and material deposition rate, the model can accurately forecast the flow of material, temperature fluctuations, and stress distribution across different operational settings. For instance, an optimal solid-state deposition of AA 6061-T6 alloy is achieved with 380 RPM tool rotation speed, 0.9 mm/s tool traverse speed, and 0.3 mm/s material deposition rate for the geometry reported in this study. The CEL model is validated by comparing its results (e.g., peak temperature) with the experimental data and published computational results for the same combination of process parameters, giving the maximum errors of 8 % and 2.8 %, respectively. Through the utilization of this proposed model, a practical and efficient means of predicting process results is established, enabling a rapid and cost-effective optimization of the AFSD process parameters for different scale of the feed material, tool, and substrate. Ultimately, this advancement contributes to the progression of solid-state AM techniques and development of digital twins by streamlining the process with scalability, multifunctionality, and a variety of material selections.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"12 ","pages":"Article 100263"},"PeriodicalIF":4.2,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143181279","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}

{"title":"Microstructure-sensitive mechanical behavior of an additively manufactured psuedoelastic shape memory alloy","authors":"Patxi Fernandez-Zelaia ,&nbsp;Chris Ledford ,&nbsp;Chris M. Fancher ,&nbsp;Sarah Graham ,&nbsp;Taresh Guleria ,&nbsp;Brad Sampson ,&nbsp;Fred List III ,&nbsp;Jason Mayeur ,&nbsp;Chins Chinnasamy ,&nbsp;Mohammad Elahinia ,&nbsp;Michael M. Kirka","doi":"10.1016/j.addlet.2025.100270","DOIUrl":"10.1016/j.addlet.2025.100270","url":null,"abstract":"<div><div>The additive manufacturing of shape memory alloys into complex geometries enables fabrication of advanced functional systems across a variety of fields and domains. This work presents results focused on the mechanical behavior of additively manufactured shape memory pseudoelastic NiTi. The deformation induced solid state phase transformation from austenite to martensite allows this system to accommodate large recoverable strains. This deformation behavior is fundamentally driven by crystal-scale transformation physics. Laser powder bed fusion processing reveals that the resulting microstructure, both grain morphology and crystallographic texture, is strongly dependent on the manufacturing processing history. Exhaustive mechanical testing demonstrates that these microstructural factors strongly impact both tensile and cyclic stress–strain behavior. Cyclic dissipative behavior, however, is similar across all tested microstructures following an initial transient period. Remarkably, analysis of spatial strain fields during tensile loading reveals two distinctly different localization “modes”. The first is initiation of localized deformation bands which continuously propagate through the tensile bar during loading. In the second mode localization is observed but lacks propagation; instead additional localization cites nucleate during subsequent loading. The latter phenomena is suspected to be driven by grain-scale deformation physics as the localized band morphologies coincide with grain morphologies. These phenomena strongly impact the resulting aggregate stress–strain behavior. Hence, manufacturers and designers of psuedoelastic functional components must at the very least consider the potential variability in properties when considering additive manufacturing processing. More ideally the process–structure–property relations can be used to further tailor and optimize final functional performance.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100270"},"PeriodicalIF":4.2,"publicationDate":"2025-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143098480","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}

{"title":"Investigation on curing strategies for metal binder jetting with Ti-6Al-4V","authors":"Kevin Janzen ,&nbsp;Timo Rieß ,&nbsp;Claus Emmelmann","doi":"10.1016/j.addlet.2025.100272","DOIUrl":"10.1016/j.addlet.2025.100272","url":null,"abstract":"<div><div>Metal binder jetting is a promising manufacturing technology that holds the potential to be a future competition technology to classic laser based additive manufacturing processes. In contrast to these technologies, however, metal binder jetting is much less mature. While sintering and debinding are already well known due to the spread of metal injection molding and powder deposition by laser powder bed fusion and its related processes, the often-neglected curing step represents a major challenge in process control. This study was therefore the first comprehensive investigation into the curing of metal binder jetting green parts from Ti-6Al-4 V powder with a powder size distribution below 25 µm. It was shown that the curing step has only a minor effect on the green part quality (surface roughness and density), but at the same time has a decisive influence on the green strength. In addition, position-dependent effects for the green density were detected, which indicate insufficient curing in the outer areas of the print box.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100272"},"PeriodicalIF":4.2,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143098479","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}

{"title":"Study on metallurgical interface and grain refinement effect in AlMgSc alloy reinforced with HEAs particles formed by arc-direct energy deposition","authors":"Shihao Shi,&nbsp;Yingying Ren,&nbsp;Shihao Kang,&nbsp;Yongqin Liu,&nbsp;Chenyu Liu,&nbsp;Yaning He,&nbsp;Yinghui Zhou","doi":"10.1016/j.addlet.2025.100271","DOIUrl":"10.1016/j.addlet.2025.100271","url":null,"abstract":"<div><div>On the basis of the AlMgSc alloy formed by Arc-DED (Arc Directed Energy Deposition), we adopted a method of coaxially depositing powder and wire layer by layer to fabricate the AlMgSc alloy enhanced by (HEAs) High Entropy Alloys. The HEAs powder exhibited favorable metallurgical bonding with the α-Al matrix, and the elements such as Co, Fe, and Ni in the HEAs particles obviously diffused towards the matrix at the interface. The addition of HEAs powder significantly refined the microstructure. The average grain size of the AlMgSc alloy was 40.7 ± 13.9 μm, while that of the AlMgSc-HEAs alloy was 14.5 ± 4.9 μm, with a 64 % reduction in grain size. Compared with the AlMgSc alloy, the yield strength (YS) of the AlMgSc-HEAs alloy was increased by 9 %.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100271"},"PeriodicalIF":4.2,"publicationDate":"2025-01-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143098478","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}

{"title":"Effects of extreme deposition rate on the microstructure evolution of additive friction stir deposited AA6061 alloy","authors":"Lu Jiang,&nbsp;Ramesh Varma,&nbsp;Mahendra Ramajayam,&nbsp;Thomas Dorin,&nbsp;Matthew Robert Barnett,&nbsp;Daniel Fabijanic","doi":"10.1016/j.addlet.2025.100269","DOIUrl":"10.1016/j.addlet.2025.100269","url":null,"abstract":"<div><div>Additive manufacturing (AM) using additive friction stir deposition (AFSD) offers unique advantages over traditional liquid-solid state transitions, notably the ability to plasticise materials through frictional and deformation heat and build a bulk deposit via discrete layers without melting. Although inherently a large-scale and high deposition rate process, the boundaries of deposition rates have not been explored. In this work, we explored a deposition rate 4–29 times faster than typical for aluminium AFSD processing. The microstructure analyses of the deposited AA6061 alloys reveal a distinct grain structure and precipitation between the slow and fast depositions, attributed to the varied thermal and mechanical histories stemming from differences in tool velocity. The AFSD process also effectively refines the constituent intermetallic phases, resulting in more uniform sizes due to high temperatures and strains experienced during deposition. Energy consumption analysis revealed significant efficiency improvement associated with the fast deposition.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100269"},"PeriodicalIF":4.2,"publicationDate":"2025-01-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143098477","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}

{"title":"Fabrication of ultra-thin porous titanium alloys by electron beam selective melting: Porosity and mechanical properties","authors":"Jinhu Liu ,&nbsp;Feihong Wang ,&nbsp;Dong Lu ,&nbsp;Yongfeng Liang ,&nbsp;Junpin Lin","doi":"10.1016/j.addlet.2025.100268","DOIUrl":"10.1016/j.addlet.2025.100268","url":null,"abstract":"<div><div>Titanium alloys are widely regarded as ideal biomaterials due to their superior mechanical properties and resistance to corrosion. Additive manufacturing offers a novel approach for fabricating porous structures, enabling the production of titanium alloys with intricate geometries and varied dimensions. In this study, porous titanium alloys were produced using the Ti-6Al-2Zr-2V-1Mo alloy via electron beam selective melting (EBSM). Thin-wall structures with thicknesses ranging from 360 μm to 600 μm demonstrated exceptional mechanical performance near the forming threshold. An increase in porosity from 22 % to 32 % was observed, resulting in a reduction in tensile strength from 350 MPa to 250 MPa. Tensile testing and microstructural analyses revealed that precise control of the electron beam spot diameter facilitated effective metallurgical bonding between powder particles, with residual pores comparable in size to the original powder. This work highlights a promising strategy for fabricating titanium alloys tailored for biomedical applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100268"},"PeriodicalIF":4.2,"publicationDate":"2025-01-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143148820","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}

{"title":"Hot forming behavior of tungsten carbide reinforced Ni-Based superalloy 625 additively manufactured by laser directed energy deposition","authors":"Gökhan Ertugrul ,&nbsp;Aliakbar Emdadi ,&nbsp;Angelika Jedynak ,&nbsp;Sabine Weiß ,&nbsp;Sebastian Härtel","doi":"10.1016/j.addlet.2025.100267","DOIUrl":"10.1016/j.addlet.2025.100267","url":null,"abstract":"<div><div>The demands of high-performance industries such as aerospace, automotive, tool manufacturing, oil, and gas industries are driving the innovation in high-performance materials and their production methods. This study explores the impact of hybrid manufacturing, specifically the effect of the addition of tungsten carbide (WC/W2C) via Laser-Directed Energy Deposition (L-DED), on the hot workability, hardness, and microstructure of nickel-based superalloy Inconel 625 (IN625). IN625 is known for its high temperature and high corrosion resistance, and tungsten carbide for its high wear resistance and grain refinement effect. The integration of WC/W2C particles into the IN625 matrix, in addition to the use of the hybrid approach of additive manufacturing followed by a hot–forming process, significantly influences the microstructure and mechanical behavior of the material. Thus, while incorporation of the WC/W2C can strengthen the material and extend the mechanical limitations, its full impact, including any potential usages, should be thoroughly evaluated for the intended application of the materials. To understand the effect of WC/W2C, additive manufacturing of IN625 both with and without WC/W2C and isothermal hot compression was carried out. The objective is to analyze the differences in microstructure and properties between <span>L</span>-DED manufactured IN625, and WC-reinforced IN625, and their hot-forming behavior, focusing on the effects of WC addition and post-deformation on microstructure and mechanical properties. This work represents the first investigation into the effect of WC/W2C hard particles on the hot-forming process of additively manufactured Ni-based metal matrix composites.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100267"},"PeriodicalIF":4.2,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143098795","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}

{"title":"On the damping and fatigue characterization of additively manufactured Ti-6Al-4V","authors":"Peyton J. Wilson ,&nbsp;Elaheh Azizian-Farsani ,&nbsp;Mikyle Paul ,&nbsp;Michael M. Khonsari ,&nbsp;Shuai Shao ,&nbsp;Nima Shamsaei","doi":"10.1016/j.addlet.2024.100260","DOIUrl":"10.1016/j.addlet.2024.100260","url":null,"abstract":"<div><div>With the recent implementation of additively manufactured parts into industrial applications, there is a dire need for nondestructive evaluation methods to qualify if these components are fit for service due to their sensitivity to processing conditions. The Impulse Excitation Technique (IET) is applied to additively manufactured Ti-6Al-4V bending specimens to determine natural frequencies and damping properties in order to predict fatigue performance relative to specimens fabricated with different processing parameters. From the damping and natural frequency results, it was found that the specimens, fabricated with intentional underheating to induce lack of fusion defects, had the lowest damping value in the pristine condition and the highest natural frequency. For the three batches of specimens tested, it was determined that the underheated specimens had the best fully-reversed bending fatigue performance with the highest fatigue limit (297 MPa) and longest fatigue lives as compared to the other two batches, implying a relation of decreased fatigue life with increased material damping in the pristine condition. The theory of the IET related to materials is presented with damping and fatigue results, as well as microstructural analysis and fractography of three specimens batches fabricated with different processing parameters.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100260"},"PeriodicalIF":4.2,"publicationDate":"2024-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143148337","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}

{"title":"Molten metal jetting for repairing aluminum components","authors":"Benedikt Kirchebner ,&nbsp;Kellen D. Traxel ,&nbsp;Alexander E. Wilson-Heid ,&nbsp;Eric S. Elton ,&nbsp;Andrew J. Pascall ,&nbsp;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}

{"title":"A spatial-temporal method for early prediction of fatigue crack region and orientation in metallic cellular materials using in-situ infrared thermography (IRT)","authors":"Tyler D. Smith ,&nbsp;Chad Westover ,&nbsp;Matthew D'Souza ,&nbsp;Shenghan Guo ,&nbsp;Dhruv Bhate","doi":"10.1016/j.addlet.2024.100258","DOIUrl":"10.1016/j.addlet.2024.100258","url":null,"abstract":"<div><div>This study seeks an early prediction method of crack failure location and orientation due to low cycle fatigue in additively manufactured metallic cellular materials by leveraging experimentally observed accumulation of plastic deformation. To study this, a novel spatial-temporal approach for analyzing Infrared Thermographic (IRT) video was developed to detect heat generated by local plastic deformation. The method was validated experimentally by conducting fully reversed low cycle fatigue tests of Inconel 718 (IN718) honeycomb specimens manufactured using Laser Powder Bed Fusion (LPBF). Using the approach developed, results showed that localized heating due to plastic work could be detected and used for early prediction of the most probable path, and orientation of crack propagation. Furthermore, the method developed was found to be able to predict these results within the first 1.5 % of the total life of the specimen apriori to crack initiation.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"11 ","pages":"Article 100258"},"PeriodicalIF":4.2,"publicationDate":"2024-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143148338","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}