Additive manufacturing letters最新文献_第5页

Dimensionless process windows in laser-based powder bed fusion of AISI 316L using ring-shaped beam profiles 基于环形光束轮廓的aisi316l激光粉末床熔合无因次加工窗口

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-28 DOI: 10.1016/j.addlet.2025.100284

Jonas Grünewald, Katrin Wudy

{"title":"Dimensionless process windows in laser-based powder bed fusion of AISI 316L using ring-shaped beam profiles","authors":"Jonas Grünewald, Katrin Wudy","doi":"10.1016/j.addlet.2025.100284","DOIUrl":"10.1016/j.addlet.2025.100284","url":null,"abstract":"<div><div>The research trend to investigate the influence of alternative beam profiles on the process and component properties in laser-based powder bed fusion raises the question of how to compare the processes and process results generated with various beam profiles in different sizes. The current state of research mainly examines the process simplified on a single-track basis or addresses isolated aspects, such as the change in beam profile and size with constant absolute process parameters, which neglects the cross-effects of these parameters. Therefore, this paper presents a new approach to consider varied process parameters and their cross effects. The approach is based on a simple heat conduction model and allows the creation of beam shape and size-independent process maps. These dimensionless process maps are created by replacing the common dimensioned process parameters (laser power and scan speed) with combined dimensionless parameters (dimensionless enthalpy and Peclét number, each extended by a dimensionless hatch distance). This way, the parameters consider material and beam properties. Within the process maps, the process boundaries are predicted by simple geometric conditions of the calculated melt pools using the introduced heat conduction model. The model is experimentally validated by conducting a comprehensive parameter study using a multidimensional design of experiments with seven different beam profiles in various sizes and varying laser power, scanning speed, and hatch distance processing AISI 316L. The relative density and surface roughness are evaluated in the experiments. The predicted and experimentally determined process limits are in excellent agreement.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100284"},"PeriodicalIF":4.2,"publicationDate":"2025-04-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143906639","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

Columnar-to-equiaxed transitions in additively manufactured face-centered cubic multi-principal element alloys 增材制造面心立方多主元素合金的柱向等轴转变

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-14 DOI: 10.1016/j.addlet.2025.100283

Mengyao Zheng , Yu Liao , Zheng Zhou , Hao Zhang , Chuanwei Li , Zhong Long , Jianfeng Gu

{"title":"Columnar-to-equiaxed transitions in additively manufactured face-centered cubic multi-principal element alloys","authors":"Mengyao Zheng , Yu Liao , Zheng Zhou , Hao Zhang , Chuanwei Li , Zhong Long , Jianfeng Gu","doi":"10.1016/j.addlet.2025.100283","DOIUrl":"10.1016/j.addlet.2025.100283","url":null,"abstract":"<div><div>Columnar-to-equiaxed transition (CET) represents a critical microstructural characteristic in additively manufactured alloys. Precise control over CET is essential for achieving high-performance metallic components through additive manufacturing. In this study, two face-centered cubic multi-principal element alloys (MPEAs), namely CoCrNi and FeCoCrNi, were fabricated via laser directed energy deposition. The influence of process parameter and alloy composition on the CET of the two MPEAs was investigated. The results demonstrated that pronounced CET phenomena were observed in both MPEAs as the laser power increased and the scanning speed decreased. However, significant variations were noted in their CET parameters, equiaxed grain fraction, and crystallographic texture. Subsequently, the impact of process parameters on temperature gradient, solidification rate, and molten pool morphology was investigated via finite element modelling, revealing the formation mechanisms of the grain morphology and texture in additively manufactured CoCrNi and FeCoCrNi alloys. Additionally, the results of thermodynamic calculation revealed significant differences in the growth restriction factors between the two MPEAs, thereby explaining the distinct CET behaviors observed in the two MPEAs.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100283"},"PeriodicalIF":4.2,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859350","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

Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers 使用小型和大型基于颗粒的3d打印机对钕铁硼/SmFeN尼龙粘结磁铁进行综合压缩成型的材料挤压

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100282

Kaustubh Mungale , Vipin Kumar , Mariappan Parans Paranthaman , Brian C. Sales , Harshida Parmar , Ikenna C. Nlebedim , Brittany Rodriguez , Uday Kumar Vaidya

{"title":"Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers","authors":"Kaustubh Mungale , Vipin Kumar , Mariappan Parans Paranthaman , Brian C. Sales , Harshida Parmar , Ikenna C. Nlebedim , Brittany Rodriguez , Uday Kumar Vaidya","doi":"10.1016/j.addlet.2025.100282","DOIUrl":"10.1016/j.addlet.2025.100282","url":null,"abstract":"<div><div>High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fraction (65 % volume fraction) are used for the study. The mechanical properties (tensile strength and modulus), magnetic properties (maximum energy density, coercivity, remanence) are reported. Manufacturing parameters such as layer height, barrel temperatures, screw speed and gantry feed rate are optimized to obtain the highest possible density of the magnets using a small-scale desktop material extrusion printer. Large scale integrated additive manufacturing-compression molding (AM-CM) is then utilized to increase the density of the magnets by reducing porosity defects common in the material extrusion process. The density of as-printed magnets was 5.2 g/cm<sup>3</sup> with a <em>BH<sub>max</sub></em> value of 124.14 kJ/m<sup>3</sup>, tensile strength of 20 MPa and a modulus of 2 GPa. AM-CM increased the density of the compound by 5.5 % (5.49 g/cm<sup>3</sup>). The reduction in porosity was confirmed using X-ray tomography (XCT). Improvement in mechanical strength of the material was also observed, with an increase in tensile strength of 25 % (25.09 MPa) and increase in tensile modulus of 275 % (5.49 GPa). Scanning electron microscopy showed increased particle-matrix adhesion with the integrated AM-CM process.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100282"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143838686","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 cyber sabotage risks in automated manufacturing of advanced composites 先进复合材料自动化制造中的网络破坏风险研究

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100280

Saral Mittal , Hammond Pearce , Mark Yampolskiy , Ebrahim Oromiehie , B. Gangadhara Prusty

{"title":"On cyber sabotage risks in automated manufacturing of advanced composites","authors":"Saral Mittal , Hammond Pearce , Mark Yampolskiy , Ebrahim Oromiehie , B. Gangadhara Prusty","doi":"10.1016/j.addlet.2025.100280","DOIUrl":"10.1016/j.addlet.2025.100280","url":null,"abstract":"<div><div>Recent advancements in the manufacturing of layered composite structures have seen the deployment of automated control systems, with computers used for both design protocols and control of manufacturing processes. However, as digitisation and computerisation of composites manufacturing advances, so too grows the potential exposure to cyber-attacks. Given that large manufacturing companies, government organisations, and defence agencies are increasingly utilising parts made out of fibre-reinforced composite materials, this security exposure must be acknowledged and managed carefully.</div><div>From other computerised manufacturing domains, we know that adversaries may aim to steal technical data such as digital design files (for example, for espionage or to infringe on Intellectual Property, IP) or to sabotage manufactured parts. Both can have consequences reaching far beyond immediate financial or physical damage. While it can be assumed that the adversarial goals are similar for composites manufacturing, the attack methods have not been explored or studied yet. This paper seeks to address this gap in part, by providing the first holistic security analysis of potential sabotage attacks in automated composites manufacturing using modern equipment. This security analysis provides a framework for composite manufacturers to identify vulnerabilities in their production workflows that are susceptible to cyber-attacks, while also providing opportunity to design customised countermeasures to strengthen the security of their automated manufacturing processes.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100280"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143823526","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

Simultaneously improving strength and corrosion resistance of additively manufactured Mg-Gd-Zr alloy by in-situ alloying with Al 通过原位合金化铝，同时提高了增材制造Mg-Gd-Zr合金的强度和耐腐蚀性

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100279

Ziyi Liu, Qingchen Deng, Yiwen Ding, Ziyan Li, Jiacheng Wang, Liming Peng

{"title":"Simultaneously improving strength and corrosion resistance of additively manufactured Mg-Gd-Zr alloy by in-situ alloying with Al","authors":"Ziyi Liu, Qingchen Deng, Yiwen Ding, Ziyan Li, Jiacheng Wang, Liming Peng","doi":"10.1016/j.addlet.2025.100279","DOIUrl":"10.1016/j.addlet.2025.100279","url":null,"abstract":"<div><div>Additive manufacturing of magnesium (Mg) alloy components with intricate geometries via laser powder bed fusion (LPBF) offers significant advantages for lightweight engineering applications. However, as a commonly issue of Mg alloys, the corrosion resistance of LPBF-Mg alloys is even worse than their cast and deformed counterparts. In-situ alloying provides a rapid pathway for composition modification tailored for the LPBF process. In this study, aluminum (Al) is introduced through in-situ alloying to prepare Mg-10Gd-xAl-Zr (GA10xK, <em>x</em> = 0.5, 1, 2 wt. %) alloys using blended Mg-10Gd-Zr and Mg-15Al powders. By employing a lower scanning speed during LPBF, a uniform distribution of Al throughout the as-built components is achieved. The increase in Al content leads to the progressive enhancement in grain refinement and the transformation of secondary phases from Mg<sub>3</sub>Gd to Al<sub>2</sub>Gd with a significant reduction in size and a notable increase in number density. These microstructural transformations yield a synchronous enhancement in strength and corrosion resistance with increasing Al content. The yield strength and ultimate tensile strength of the GA102K alloy reach 328 MPa and 350 MPa, respectively, with a minimized corrosion rate of 0.787 mm/yr., surpassing the mechanical and corrosion performance of both LPBF and semi-continuous cast G10K alloys.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100279"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739518","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

Enhanced superelasticity and notable elastocaloric effect of Cu71Al17.5Mn11.5 shape memory alloys by laser-based powder bed fusion 激光粉末床熔合Cu71Al17.5Mn11.5形状记忆合金的超弹性增强和显著的弹热效应

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100281

Xiang Li , Zeming Fan , Qijie Zhai , Gang Wang , Xiang Lu , Hanyang Qian , Rui Cai , Daqiang Jiang , Jian Liu

{"title":"Enhanced superelasticity and notable elastocaloric effect of Cu71Al17.5Mn11.5 shape memory alloys by laser-based powder bed fusion","authors":"Xiang Li , Zeming Fan , Qijie Zhai , Gang Wang , Xiang Lu , Hanyang Qian , Rui Cai , Daqiang Jiang , Jian Liu","doi":"10.1016/j.addlet.2025.100281","DOIUrl":"10.1016/j.addlet.2025.100281","url":null,"abstract":"<div><div>Cu-based shape memory alloys (SMAs) with highly oriented columnar grains and high densities are promising candidates for solid-state refrigeration. In this work, the Cu<sub>71</sub>Al<sub>17.5</sub>Mn<sub>11.5</sub> alloys with a strong 〈001〉 texture columnar grains and a high relative density were fabricated using laser-based powder bed fusion of metals (PBF-LB/M) technique. The Cu<sub>71</sub>Al<sub>17.5</sub>Mn<sub>11.5</sub> alloys exhibited enhanced superelasticity, with a superelastic strain of 6.2 %. A maximum recoverable strain of 8.5 % was achieved under 9 % compressive loading, which includes both superelastic and elastic strain components. Additionally, a notable elastocaloric temperature change of 8.0 K was achieved upon fast unloading under adiabatic conditions. The phase transformation behavior has been systematically investigated by the digital image correlation (DIC) and the transmission wide-angle X-ray diffraction measurements. The current results suggest that the additive manufacturing could be a promising route for near-net-shape high-performance Cu-based elastocaloric refrigerants.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100281"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143828193","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

Enhancing dental model accuracy through optimized vat photopolymerization additive manufacturing parameters 通过优化大桶光聚合增材制造参数，提高牙科模型精度

IF 4.2

Additive manufacturing letters Pub Date : 2025-03-15 DOI: 10.1016/j.addlet.2025.100278

Clément Tien , Camille Jean , Lucas Poupaud , Floriane Laverne , Frédéric Segonds

引用次数: 0

Qualification of additively manufactured polymer fluid manifolds for life-detection instruments 生命检测仪器用增材制造聚合物流体歧管的鉴定

IF 4.2

Additive manufacturing letters Pub Date : 2025-03-04 DOI: 10.1016/j.addlet.2025.100277

Theresa Juarez, Nathan J. Oborny, Andrew Berg, Aaron C. Noell

{"title":"Qualification of additively manufactured polymer fluid manifolds for life-detection instruments","authors":"Theresa Juarez, Nathan J. Oborny, Andrew Berg, Aaron C. Noell","doi":"10.1016/j.addlet.2025.100277","DOIUrl":"10.1016/j.addlet.2025.100277","url":null,"abstract":"<div><div>The development of autonomous life detection instruments is being driven by the advancement of multiple space exploration missions to investigate the subsurface oceans of icy worlds, particularly Titan, Enceladus, and Europa. A fundamental feature of this type of instrument is a compact, reliable, and chemically inert internal liquid transport network. Additively manufactured (AM) custom liquid manifolds produced via vat photopolymerization (VPP) methods can meet these requirements. However, before these materials can be considered, basic spaceflight requirements, qualification for flight worthiness and functionality must be addressed. In this study, mechanical properties, outgassing behavior, polymeric characteristics, and chemical compatibility are assessed for select commercially available AM polymers. The results indicate basic materials qualification requirements are met, including sufficiently characterized mechanical properties, the identification of a bakeout protocol for reduced outgassing to meet NASA standards, and chemical compatibility with liquids and reagents used in candidate instrumentation under development for life detection missions.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100277"},"PeriodicalIF":4.2,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143706047","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 raster orientation on large-scale robotic 3D printing of short carbon fiber-reinforced PLA composites 栅格取向对短碳纤维增强PLA复合材料大规模机器人3D打印的影响

IF 4.2

Additive manufacturing letters Pub Date : 2025-02-18 DOI: 10.1016/j.addlet.2025.100276

E. Baharlou , J. Ma

{"title":"Effect of raster orientation on large-scale robotic 3D printing of short carbon fiber-reinforced PLA composites","authors":"E. Baharlou , J. Ma","doi":"10.1016/j.addlet.2025.100276","DOIUrl":"10.1016/j.addlet.2025.100276","url":null,"abstract":"<div><div>Additive manufacturing in building construction can be extended for mass customization of building components or even complex mold making. This study examines the process parameters of raster orientation of short carbon fiber-reinforced polylactic acid (SCF-PLA) and neat PLA in large-scale 3D printing. Three raster orientations—unidirectional, cross-ply, and quasi-isotropic layups—were printed using a pellet extruder assembled on an industrial robotic arm. Tensile and flexural tests were conducted to characterize the differences between SCF-PLA and neat PLA across all raster orientations. This study shows that neat PLA has higher tensile strength compared to SCF-PLA, and quasi-isotropic orientation can improve the week mechanical properties of both SCF-PLA and PLA. This research highlights the interface bonding challenges encountered with larger 3D printed filaments, which result in more significant pores. Furthermore, any factor that modifies rheological properties of the filament, such as carbon filling, can lead to a higher likelihood of material defects. To understand this discrepancy, microstructure analyses were conducted on intact and fractured 3D printed samples, including the analysis of micro voids, interlayer voids, and bonding between SCF and the PLA matrix. This suggests that the effects of quasi-isotropic layups can be applied to enhance 3D print large-scale polymer-based building components.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100276"},"PeriodicalIF":4.2,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143510071","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

Process screening in additive manufacturing: Detection of keyhole mode using surface topography and machine learning 增材制造中的工艺筛选：使用表面形貌和机器学习检测钥匙孔模式

IF 4.2

Additive manufacturing letters Pub Date : 2025-02-17 DOI: 10.1016/j.addlet.2025.100275

Mingzhang Yang, Ali Rezaei, Mihaela Vlasea

{"title":"Process screening in additive manufacturing: Detection of keyhole mode using surface topography and machine learning","authors":"Mingzhang Yang, Ali Rezaei, Mihaela Vlasea","doi":"10.1016/j.addlet.2025.100275","DOIUrl":"10.1016/j.addlet.2025.100275","url":null,"abstract":"<div><div>Screening of defective additive manufactured (AM) parts is crucial for ensuring process consistency and part reliability, yet common microstructural inspection methods can be time-consuming or destructive. This study explores how surface analysis combined with machine learning (ML) algorithms can effectively infer the microstructure of laser powder bed fusion (LPBF) parts. As a case study, non-spherical ZrH₂ nanoparticle-enhanced AA7075 aluminum powders was fabricated using 60 different LPBF recipes. ML classification models were then employed to link side-surface topographical features to keyhole melting occurring within the parts. Among the tested ML models, random forest (RF) achieving a testing accuracy of 95 % and an F1-score of 0.98, outperforming both the neural network (NN) and support vector machine (SVM) models. To enhance the interpretability of the ML model, the RF model was leveraged to identify the hierarchical importance of surface features associated with keyhole melting mode. This resulted in the development of keyhole-probability maps based on superficial surface parameters, providing engineers with an effective and easy-to-use tool for screening keyhole mode parts. While further validation is needed, the proposed strategy lays a foundation for leveraging surface topography to infer microstructural features and adapting the method to different material systems.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100275"},"PeriodicalIF":4.2,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143445387","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