Additive manufacturing letters最新文献

{"title":"Corrigendum to “Reassessing the Biodegradation Behavior of Pure Iron and Iron-Manganese Alloys Fabricated by Laser Powder Bed Fusion” [ADDLET, 15 (2025) 100321]\"","authors":"Fanshuo Wang , Qiyang Tan , Ting Liu , Jeffery Venezuela , Zhiming Shi , Sarah Hurley , Anh Ly , Chun Xu , Deniz U. Erbulut , Jun Yin , Yue Zhao , Mingxing Zhang","doi":"10.1016/j.addlet.2025.100341","DOIUrl":"10.1016/j.addlet.2025.100341","url":null,"abstract":"","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100341"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145736572","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}

{"title":"Bimetallic 17-4 PH/316 L stainless steel: Interfacial diffusion and mechanical response in multi-material MEX","authors":"Héctor García de la Torre,&nbsp;Giovanni Gómez-Gras,&nbsp;Marco A. Pérez","doi":"10.1016/j.addlet.2025.100332","DOIUrl":"10.1016/j.addlet.2025.100332","url":null,"abstract":"<div><div>Multi-material additive manufacturing enables the integration of distinct alloys with contrasting mechanical and microstructural properties, such as stainless steels 17–4 PH and AISI 316 L that are widely used in aerospace and tooling, within a single build; however, their combined performance in hybrid configurations remains underexplored. Here, we address key challenges related to densification, interfacial behavior and mechanical property control of metallic multi-material additive manufacturing structures. Near-full densification (98–99 %) was achieved with strong interfacial bonding and minimal deformation. Microstructural analysis revealed solid-state diffusion of Ni and Mo from 316 L into 17–4 PH, resulting in a chemically and structurally graded interface that affects local phase composition and fracture mechanics. Mechanical testing under tensile and flexural loading demonstrated that configurations with 17–4 PH as face material and 316 L as the core provided higher stiffness and strength while maintaining ductility, with flexural property metrics more than double to those of monolithic 316 L cores. Fractographic analysis confirmed that fractures initiated within the more brittle 17–4 PH material and often thereafter propagated along the interface, identifying it as a mechanically weaker zone serving as a crack pathway. These results highlight the potential hybrid stainless steel structures to achieve combined mechanical responses suitable for advanced engineering applications in a single manufacturing step, enabling the design of cost-efficient, multifunctional components for structural applications requiring hybrid mechanical behavior.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100332"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324331","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}

{"title":"In situ recrystallization of pure Cu during electron beam powder bed fusion","authors":"Alexandre Margueret ,&nbsp;Pierre Lhuissier ,&nbsp;Guilhem Martin","doi":"10.1016/j.addlet.2025.100329","DOIUrl":"10.1016/j.addlet.2025.100329","url":null,"abstract":"<div><div>Additively manufactured parts often exhibit an anisotropic microstructure characterized by columnar grains resulting from epitaxial growth from the underlying layers in the direction of the thermal gradient, i.e. parallel to the build direction. Herein we report that the columnar grains of pure Cu produced by electron beam powder bed fusion can be transformed into equiaxed grains by reducing the hatch spacing and increasing the scanning speed. Columnar grains are observed for hatch spacings ≥ 100 µm and a scanning speed = 100 mm/s, whereas equiaxed grains are observed when the hatch spacing is ≤ 60 µm and the scanning speed ≥ 150 mm/s. The underlying mechanism is discussed and identified on the basis of EBSD analyses. It is concluded that in situ recrystallization during electron beam powder bed fusion can be locally activated by varying the processing parameters. Further insight into the underlying mechanism is gained from the characterization of layered samples produced with varying processing parameters along the build direction. We show that in situ recrystallization offers an interesting pathway to produce site-specific microstructures in electron beam powder bed fusion.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100329"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145267142","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}

{"title":"Ultrasonic nanocrystal surface modification for post-processing of additively manufactured AISI 440C stainless steel","authors":"Milad Zohrevand ,&nbsp;Reza Jafari ,&nbsp;Venkata K. Nadimpalli ,&nbsp;Thomas Dahmen ,&nbsp;Sherzod Barlibayev ,&nbsp;Khasan Turkmenov ,&nbsp;Bakhadir Mirzaev ,&nbsp;Auezhan Amanov","doi":"10.1016/j.addlet.2025.100335","DOIUrl":"10.1016/j.addlet.2025.100335","url":null,"abstract":"<div><div>Laser-based powder bed fusion (L-PBF) method has been shown as a promising method in additive manufacturing (AM) of the AISI 440C stainless tool steel. Nevertheless, the as-printed material typically exhibits a soft austenitic structure, poor surface finish, and tensile residual stresses, all of which limit its mechanical performance. In this study, ultrasonic nanocrystal surface modification (UNSM) was applied as a post-processing treatment to improve the mechanical and surface properties of as-built AISI 440C <span>l</span>-PBF samples. The UNSM treatment resulted in a 26 % increase in surface hardness, a 50 % reduction in surface roughness, and a transition of tensile residual stress (57 MPa) into compressive residual stress (−364 MPa). Microstructural analysis revealed that nano-grain formation, increased dislocation density, strain-induced martensitic transformation, and carbide precipitation were the key mechanisms responsible for surface hardening. These findings demonstrate the potential of UNSM as an effective post-processing method for enhancing the performance of <span>l</span>-PBF-manufactured AISI 440C components.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100335"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145415568","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}

{"title":"Multi-scale mechanical characterization of an additively manufactured Fe-based glass-forming alloy","authors":"C. Garrote-Junco ,&nbsp;A. Ghavimi ,&nbsp;R. Busch ,&nbsp;M.T. Pérez-Prado ,&nbsp;M. Rodríguez-Sánchez","doi":"10.1016/j.addlet.2025.100345","DOIUrl":"10.1016/j.addlet.2025.100345","url":null,"abstract":"<div><div>This work aims to investigate the influence of specimen size and loading direction on the mechanical response of a laser-powder-bed-fused (LPBF) Fe-based metallic glass (Kuamet 6B2). Cuboidal specimens of sizes ranging from 4 to 8 mm were fabricated and then systematically characterized by a range of complementary techniques including optical microscopy, image analysis, differential scanning calorimetry and electron backscattered diffraction (EBSD). All builds exhibited three highly oriented defect families: elongated lack-of-fusion pores perpendicular to BD, oblique internal cracks and large surface cracks normal to BD. These defects, along with limited amorphous retention, dominate the bulk compliance and strength.</div><div>The mechanical behavior was assessed by room temperature uniaxial compression, both parallel and perpendicular to the build direction (BD), as well as by nanoindentation. A clear, direction-dependent size effect emerges. Under loading parallel to BD, strength and uniform strain diminish with increasing specimen size, consistent with defect closure and the correlation between density and mechanical response. In contrast, when loading is perpendicular to BD, strength and uniform strain increase with size, due to the reduction of normalized defect length scales relative to specimen width. The ensuing drop in stress-intensity at defect tips, suppressing crack propagation. Nanoindentation on defect-free regions revealed substantially higher local stiffness than bulk values, underscoring that the macroscopic response is defect-controlled rather than matrix-controlled.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100345"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145736571","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}

{"title":"Additively manufactured self-expandable stents from Zr-based bulk metallic glasses via laser powder bed fusion","authors":"Jan Wegner ,&nbsp;Lars Bruckhaus ,&nbsp;Daniel Leonardo Schwöppe ,&nbsp;Hanna Schönrath ,&nbsp;Stefan Kleszczynski","doi":"10.1016/j.addlet.2025.100325","DOIUrl":"10.1016/j.addlet.2025.100325","url":null,"abstract":"<div><div>Self-expandable stents are among the most implanted biomedical devices. We investigate the feasibility of additive manufacturing via laser powder bed fusion to fabricate Zr-based bulk metallic glasses into self-expandable stents to enable automated and customizable stent fabrication while implementing a novel class of materials with superior resilience compared to established alloys such as Nitinol. Three geometries are investigated with different cell dimensions. The additively manufactured stents are analyzed by µCT, SEM imaging and DSC. Overhanging geometry features show increasing crystalline defects in the amorphous matrix. However, with steep elevation angles, an amorphous fraction of up to 97.3 ± 1% is achieved in the struts. Three-point bending tests reveal large resilience of the structures, allowing for full compaction for diamond shaped cells with a height of 7 mm and an elevation angle of 77.5°, without fracture. Our findings offer preliminary evidence supporting the potential of additive manufacturing for Zr-based bulk metallic glass stents, while further studies are necessary to validate and optimize the process.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100325"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145105127","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}

{"title":"Physics-informed machine learning surrogate for scalable simulation of thermal histories during wire-arc directed energy deposition","authors":"Michael Ryan,&nbsp;Mohammad Hassan Baqershahi,&nbsp;Hessamoddin Moshayedi,&nbsp;Elyas Ghafoori","doi":"10.1016/j.addlet.2025.100327","DOIUrl":"10.1016/j.addlet.2025.100327","url":null,"abstract":"<div><div>Wire-arc directed energy deposition (DED) has emerged as a promising additive manufacturing (AM) technology for large-scale applications. However, the complex thermal dynamics inherent to the process present challenges in ensuring structural integrity and mechanical properties of fabricated components. Finite element method (FEM) simulations have been conventionally employed to predict thermal history during deposition. However, their high computational demand increase significantly with scale. Given the necessity of multiple repetitive simulations for heat management and the determination of optimal printing strategy, FEM simulation quickly becomes unfit. Instead, advancements have been made in using trained neural networks as surrogate models for rapid prediction. However, traditional data-driven approaches necessitate large amounts of relevant and verifiable external data, either from simulation, experimental, or analytical solutions, during the training and validation of the neural network. Regarding large-scale wire-arc DED, none of these data sources are readily available in quantities sufficient for an accurate surrogate. The introduction of physics-informed neural networks (PINNs) has opened up an alternative simulation strategy by leveraging the existing physical knowledge of the phenomena with advanced machine learning methods. However, the practical application of PINNs for real-world large-scale wire-arc DED has been rarely explored, particularly within the context of structural engineering. This study investigates one of the necessary steps for up-scaling PINN with a focus on advanced and effective sampling of collocation points — a critical factor controlling both the training time and the performance of the model. The results affirm the potential of PINNs to outperform FEM in terms of wall-clock times, while maintaining the desired accuracy and offering resolution-agnostic evaluation. Further discussion provides an outlook on the future steps for improving the PINNs for wire-arc DED simulations.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100327"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145267141","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}

{"title":"Isolating the influence of residual stress on tensile behaviour of laser-based powder bed fusion Ti alloys via mechanical stress relief","authors":"Zhiyi Zou ,&nbsp;Brandon McWilliams ,&nbsp;Brady Butler ,&nbsp;Alexander Butler ,&nbsp;Richard Hague ,&nbsp;Marco Simonelli","doi":"10.1016/j.addlet.2025.100336","DOIUrl":"10.1016/j.addlet.2025.100336","url":null,"abstract":"<div><div>This study proposes a mechanical stress relief (MSR) process to reduce the residual stress in PBF-LB materials. It involves progressive, slow cyclic loading in the material’s elastic region. Two Ti alloys, Ti-6Al-4V and Ti-7Cr-4Sn, were chosen as model alloys and underwent MSR accordingly. Results suggest that the proposed MSR helps reduce residual stress, and its effectiveness in relieving residual stress is similar across the two alloys. However, the influence of MSR on the tensile performance is different in the two alloys, which is affected by the initial residual stress level and the material’s deformation mechanism. Ti-6Al-4V possesses high residual stress, with deformation slip being the only deformation mechanism. In contrast, Ti-7Cr-4Sn possesses relatively low residual stress, and a unique deformation mechanism involves {332}&lt;113&gt; twinning and ω_iso precipitates. Such a unique deformation mechanism leads to crack initiation driven by twin-confined dislocation pile-up.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100336"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145415569","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}

{"title":"The efficacy of self-curing agents on enhanced internal curing and accelerated carbonation with CO2-steam integrated 3D concrete printing","authors":"Sean Gip Lim ,&nbsp;Junghyun Lee ,&nbsp;Nuran Khalid A. Bawarith ,&nbsp;Suvash Chandra Paul ,&nbsp;Jihye Jhun ,&nbsp;Issam T. Amr ,&nbsp;Bandar A. Fadhel ,&nbsp;Ming Jen Tan","doi":"10.1016/j.addlet.2025.100339","DOIUrl":"10.1016/j.addlet.2025.100339","url":null,"abstract":"<div><div>Construction industry, responsible for a substantial portion of global carbon emissions, faces an urgent demand to adopt sustainable practices. Traditional concrete manufacturing processes contribute significantly to these emissions, underscoring a pressing need for innovative technologies that not only reduce carbon footprint but also improve material performances. This study presents an extension of CO₂-steam integrated 3D construction printing by incorporating functional self-curing agents, specifically Polyethylene Glycol (PEG-6000), to enhance both early-age carbonation reactions and mechanical strength developments of 3D printed cementitious materials. The presented method aims to suppress moisture loss that delays hydration and carbonation activities during unconfined atmospheric curing, which would otherwise hinder strength developments. The combined usage of in-situ CO₂-steam printing with PEG-6000 demonstrated improvements in early-age carbon uptake up to 137 %, along with substantial developments in compressive, flexural, and interlayer bond strengths of up to 29.4 %, 51.9 %, and 36.5 %, respectively.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100339"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623555","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}

{"title":"Investigation and potentials of a novel resin-based additive manufacturing process","authors":"Leo Körber ,&nbsp;Thomas Wettemann ,&nbsp;Margarita Etchegaray Bello ,&nbsp;Isabell Petri ,&nbsp;Gabriel Rojas ,&nbsp;Daniela Schreil ,&nbsp;Klaus Drechsler ,&nbsp;Satoshi Enzaki ,&nbsp;Yuichiro Tsuda ,&nbsp;Jun Inagaki","doi":"10.1016/j.addlet.2025.100328","DOIUrl":"10.1016/j.addlet.2025.100328","url":null,"abstract":"<div><div>Polymer Additive Manufacturing (AM) processes are a means of producing complex parts in small numbers. Short fibers are frequently added to enhance the parts’ mechanical properties. Alignment along the extrusion path during printing results in highly anisotropic material behavior. In this study, a novel resin-based AM process (“Core-Shell Method”, developed by Toray Engineering) is investigated consisting of a vat photopolymerization printing of a non-reinforced mold (“shell”) that is subsequently filled with a short fiber filled thermally cured resin (“core”). Thermal and chemical analyses were performed and recommendations for process adjustments derived. Mechanical, microscopic and CT analyses were performed on samples produced using the Core-Shell Method and manual variants of the process as reference. The Core-Shell samples show an only slightly anisotropic material behavior. From these findings, potentials for the printing process are derived, including further modification of the fiber alignment towards either improving isotropy or selectively introducing load-path adjusted fiber orientation and reinforcement within a homogenous material mixture.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100328"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145362094","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}