Additive manufacturing letters最新文献_第8页

Influence of aging time to achieve tensile build direction heat treated T74 forging properties in lubricant free AFSD AA7050 时效时间对在无润滑油AFSD AA7050中实现拉伸构建方向热处理T74锻件性能的影响

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-06-23 DOI: 10.1016/j.addlet.2025.100296

I. Liu , J. Hoarston , N. Zhu , A. Birt , N. Palya , B.J. Phillips , D.Z. Avery , P.G. Allison , J.B. Jordon

{"title":"Influence of aging time to achieve tensile build direction heat treated T74 forging properties in lubricant free AFSD AA7050","authors":"I. Liu , J. Hoarston , N. Zhu , A. Birt , N. Palya , B.J. Phillips , D.Z. Avery , P.G. Allison , J.B. Jordon","doi":"10.1016/j.addlet.2025.100296","DOIUrl":"10.1016/j.addlet.2025.100296","url":null,"abstract":"<div><div>The need for long-lead time aluminum alloy casting and forging replacements requires innovative solutions such as Additive Friction Stir Deposition (AFSD), a solid-state additive manufacturing technique that uses frictional heat and severe plastic deformation to create metallurgical bonds through layer-by-layer deposition. While AFSD has demonstrated isotropic mechanical properties in the as-deposited condition, post-deposition heat treatment (PDHT) of precipitation hardened aluminum alloys processed by AFSD has led to poor ductility, particularly in the build direction. In this feasibility study, a lubricant-free twin rod AFSD (TR-AFSD) approach printed a 100 millimeter tall AA7050 build. Mechanical properties in the build direction were determined for a range of artificial aging times. Experimental results showed that a one hour aging time following a 24-hour solution treatment produced tensile yield, ultimate tensile strength, and strain to failure results of 360 ± 5.5 MPa, 463 ± 10.3 MPa, and 7.55 ± 2.00 %, respectively. Our feasibility study shows that forging-like tensile properties can be achieved in the build direction from TR-AFSD prints using a featureless tool coupled with a temperature control lubricant-free round feedstock approach and a custom PDHT schedule.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100296"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144535579","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 joining additive manufactured metals via friction welding technology: a comprehensive mechanical and microstructural study on 316 L stainless steel components 用摩擦焊技术连接增材制造金属：316l不锈钢构件力学和显微组织的综合研究

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-07-22 DOI: 10.1016/j.addlet.2025.100309

Fatma Nur Depboylu , Loïc Jegou , Luciana Tavares , Andrei-Alexandru Popa

{"title":"On joining additive manufactured metals via friction welding technology: a comprehensive mechanical and microstructural study on 316 L stainless steel components","authors":"Fatma Nur Depboylu , Loïc Jegou , Luciana Tavares , Andrei-Alexandru Popa","doi":"10.1016/j.addlet.2025.100309","DOIUrl":"10.1016/j.addlet.2025.100309","url":null,"abstract":"<div><div>Rotational Friction Welding (RFW) is a solid-state joining technique that enables the assembly of metallic components below their melting temperature, while also avoiding harmful gas emissions commonly associated with fusion-based methods. Despite their high mechanical strength, parts manufactured by RFW often struggle to meet the industrial demand for complex geometries beyond their typical cylindrical and disc shapes. Laser Powder Bed Fusion (PBF-LB/M) allows fabrication of geometrically intricate parts with high precision and mechanical reliability. However, it faces challenges such as high production costs and dimensional limitations. Combining PBF-LB/M with RFW enables the production of larger and complex metal parts. The purpose of this study is to demonstrate the feasibility and benefits of this hybrid approach for 316 L stainless steel (SS). To accomplish this, 316 L SS parts were initially fabricated using PBF-LB/M and then joined by RFW. The joints were analyzed to evaluate weld integrity, microstructural evolution, phase stability, and mechanical performance. The analysis reveals three distinct microstructural zones: the weld zone, the thermo-mechanically affected zone, and the base metal zone. Grain refinement is observed in the weld zone, whereas coarser grains appear toward the base metal zone. Phase analysis exhibits a fully austenitic structure without any detrimental secondary phases. Mechanical testing shows increased hardness in the weld zone associated with grain refinement. Tensile tests reveal that the fracture occurred outside the welding region, specifically in the base metal zone. These findings highlight a finer, defect-free weld zone without secondary phases in RFW joined PBF-LB/M 316 L SS components.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100309"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703767","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

Toward sustainable additive manufacturing of PEKK/Martian regolith composite for lightweight structural applications on Mars PEKK/火星风化层复合材料的可持续增材制造，用于火星上的轻型结构应用

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-06-20 DOI: 10.1016/j.addlet.2025.100297

Farshad Malekpour , Marjan Abdali , Mehdi Hojjati , Krzysztof Skonieczny

{"title":"Toward sustainable additive manufacturing of PEKK/Martian regolith composite for lightweight structural applications on Mars","authors":"Farshad Malekpour , Marjan Abdali , Mehdi Hojjati , Krzysztof Skonieczny","doi":"10.1016/j.addlet.2025.100297","DOIUrl":"10.1016/j.addlet.2025.100297","url":null,"abstract":"<div><div>Advances in sustainable resource utilization and innovative manufacturing techniques are driving efforts toward the prospect of human settlement on Mars, led by programs such as SpaceX’s Occupy Mars initiative. One promising approach involves the development of materials and processes that leverage in-situ Martian resources. In this study, we investigate the fabrication and characterization of a composite material consisting of Polyether-Ketone-Ketone (PEKK) incorporated with Martian Regolith Simulant (MRS), targeting sustainable applications in outer space. Amorphous PEKK was pulverized and mixed with sieved MRS particles, followed by extrusion through a twin-screw extruder to produce a filament with a consistent diameter suitable for Material Extrusion Additive Manufacturing (MEAM). A post-processing protocol, including annealing, was implemented to optimize the degree of crystallinity and improve mechanical properties. The filament quality and dispersion of regolith within the matrix were evaluated, and the composite was characterized through mechanical and thermomechanical analyses. Based on the material properties achieved, a conceptual Mars rover wheel featuring a lightweight graded structure was designed and successfully fabricated. These results demonstrate the early-stage feasibility of producing high-quality, mechanically robust 3D-printed components from regolith-based composites, highlighting the potential of integrating additive manufacturing with local resources as a step toward sustainable extraterrestrial exploration.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100297"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144579815","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

Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries 复杂几何形状的增材制造超高强度钢结构的裂缝预防和性能改进

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-07-20 DOI: 10.1016/j.addlet.2025.100307

Jun Wang , Mark Taylor , Chenglei Diao , Ed Pickering , Jian Qin , Yao Lu , Sonia Martins Meco , Jialuo Ding , Stewart Williams

{"title":"Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries","authors":"Jun Wang , Mark Taylor , Chenglei Diao , Ed Pickering , Jian Qin , Yao Lu , Sonia Martins Meco , Jialuo Ding , Stewart Williams","doi":"10.1016/j.addlet.2025.100307","DOIUrl":"10.1016/j.addlet.2025.100307","url":null,"abstract":"<div><div>Hybrid wire-arc directed energy deposition (WDED), in which complex features are deposited onto a forged base, offers a cost-effective solution for manufacturing geometrically complex ultra-high-strength steel components, particularly for aerospace applications. However, cracking at the base forging/build interface during post-build heat treatment limits its widespread application. This study investigates the underlying causes of interfacial cracking, highlighting microstructural inhomogeneity, elemental segregation and transformation stresses as likely key contributing factors. A modified three-step post-build heat treatment incorporating a normalisation step was developed to mitigate some of these issues. The optimised process successfully suppressed cracking by refining prior-austenite grains before the application of a conventional quenching step. This enhanced tensile performance beyond AMS6419K standards, supporting the industrial implementation of hybrid WDED in aerospace structures.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100307"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144686272","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

Processing of Thermoelectric Fe2VAl Heusler-compounds by laser powder bed fusion: From single scan tracks to bulk material 热电Fe2VAl heusler化合物的激光粉末床熔合加工：从单一扫描轨迹到块状材料

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-07-24 DOI: 10.1016/j.addlet.2025.100305

M. Delcroix, G. Roy, C. van der Rest, V. Marchal-Marchant, P.J. Jacques

{"title":"Processing of Thermoelectric Fe2VAl Heusler-compounds by laser powder bed fusion: From single scan tracks to bulk material","authors":"M. Delcroix, G. Roy, C. van der Rest, V. Marchal-Marchant, P.J. Jacques","doi":"10.1016/j.addlet.2025.100305","DOIUrl":"10.1016/j.addlet.2025.100305","url":null,"abstract":"<div><div>In the present study, the n-type Fe<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> VAl<sub>0.9</sub> Si<sub>0.1</sub> was printed by laser powder bed fusion (L-PBF) for the first time. This work highlights the complexity of processing non-metallic materials by L-PBF and the need for advanced optimization strategies. A Single Scan Tracks (SSTs) analysis was conducted as usually done for materials newly processed by L-PBF as well as a top-down approach based on printing parameters of stainless steel. Process parameter sets based on SST analysis led to overheating while the stainless-steel-based strategy successfully produced bulk samples. Printed samples transitioned rapidly from cold defects (i.e. lack-of-fusion) to overheating as the printing parameters were varied. Moreover, high density samples were printed with parameters that would produce insufficient melting in the case of SSTs. Successive parallel tracks were printed and revealed a transition from unmelting to balling to continuous densification, demonstrating the critical role of heat accumulation. The microstructure of printed samples was analyzed, and their thermoelectric properties were measured. Transverse cold cracks, perpendicular to the scanning direction were observed. Statistical analysis on SST demonstrated that these cracks were insensitive to laser parameter variations, significantly decreasing the thermoelectric performance of bulk samples.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100305"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144766968","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

Introduction of Cr steels to additive manufacturing using an innovative alloying approach - Challenges and Potentials 采用创新的合金化方法将Cr钢引入增材制造-挑战和潜力

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-05-03 DOI: 10.1016/j.addlet.2025.100287

Philip König, Sebastian Weber, Jonathan Lentz

{"title":"Introduction of Cr steels to additive manufacturing using an innovative alloying approach - Challenges and Potentials","authors":"Philip König, Sebastian Weber, Jonathan Lentz","doi":"10.1016/j.addlet.2025.100287","DOIUrl":"10.1016/j.addlet.2025.100287","url":null,"abstract":"<div><div>This study introduces martensitic Cr steels into additive manufacturing (AM) and provides first important findings for its PBF-LB/M processing. The comprehensive approach covers the entire process chain, including alloy modification, powder production, additive manufacturing, and microstructural characterization. Nitrogen (N), as an interstitial element soluble in iron, plays a central role in this strategy, offering economic and sustainability benefits during powder production while improving the PBF-LB/M-processability and performance of the final components. The atomizing gas N₂ was employed in vacuum induction gas atomization (VIGA) to facilitate direct alloying with N in the powder production process. A thermodynamic calculation-based alloying adjustment of the base alloy resulted in an increased N concentration of approximately 0.17 mass% in the powder. Consequently, electron backscatter diffraction (EBSD) and X-ray diffraction (XRD) studies demonstrate a notable increase in austenite content in the PBF-LB/M state. This finding aligns with thermodynamic predictions regarding the impact of N on austenite stability, reducing the propensity for cold cracking.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100287"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143912556","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

AdditiveLLM: Large language models predict defects in metals additive manufacturing AdditiveLLM：大型语言模型预测金属增材制造中的缺陷

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-06-11 DOI: 10.1016/j.addlet.2025.100292

Peter Pak , Amir Barati Farimani

引用次数: 0

Continuous carbon fiber 3D printing with interweaving deposition for enhanced mechanical performance in fused filament fabrication 连续碳纤维3D打印与交织沉积，以提高机械性能的熔丝制造

IF 4.2

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-05-09 DOI: 10.1016/j.addlet.2025.100289

A. ElSherbiny, A.J. Qureshi, P. Mertiny

{"title":"Continuous carbon fiber 3D printing with interweaving deposition for enhanced mechanical performance in fused filament fabrication","authors":"A. ElSherbiny, A.J. Qureshi, P. Mertiny","doi":"10.1016/j.addlet.2025.100289","DOIUrl":"10.1016/j.addlet.2025.100289","url":null,"abstract":"<div><div>Additive manufacturing (AM) has revolutionized modern manufacturing by enabling the rapid prototyping and production of complex geometries with minimal material waste. Among AM techniques, Fused Filament Fabrication (FFF) is widely used for polymer-based manufacturing but exhibits limitations in high-performance applications due to insufficient mechanical properties. To address these shortcomings, this study focuses on advancing a standard FFF system to integrate Continuous Carbon Fiber (CCF) and implement interweaving deposition patterns, with the goal of enhancing structural performance and integrity. Representative volume element modeling and finite element analysis were conducted to evaluate the mechanical behavior, with results validated through experimental mechanical testing. The results confirm that CCF reinforcement improves the mechanical performance of printed components, particularly in the raster direction, although variations in response highlight the influence of material imperfections and non-linearities. The study demonstrates the potential of advanced CCF 3D printing in addressing the limitations of traditional FFF and provides insights for further advancements in polymer composite AM.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100289"},"PeriodicalIF":4.2,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143943283","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

Rapid exploration of nanoparticle-modified alloys in metal additive manufacturing by combining inkjet printing and laser powder bed fusion 结合喷墨打印和激光粉末床熔接技术在金属增材制造中纳米颗粒改性合金的快速探索

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-08-07 DOI: 10.1016/j.addlet.2025.100315

Emre Tekoglu , Shuheng Liao , Zachary Kutschke , Alexander D. O’Brien , Bethany Lettiere , Ju Li , A. John Hart

{"title":"Rapid exploration of nanoparticle-modified alloys in metal additive manufacturing by combining inkjet printing and laser powder bed fusion","authors":"Emre Tekoglu , Shuheng Liao , Zachary Kutschke , Alexander D. O’Brien , Bethany Lettiere , Ju Li , A. John Hart","doi":"10.1016/j.addlet.2025.100315","DOIUrl":"10.1016/j.addlet.2025.100315","url":null,"abstract":"<div><div>The development of new metal alloys is key to the continued advances in critical technologies such as jet engines operating at higher temperatures, rocket engines with longer lifetime and reusability, and reactors for fusion and fission energy generation. While additive manufacturing (AM) is attractive for both prototyping and production of advanced alloys and components, the experimental screening and validation of new alloys typically requires costly synthesis of custom powder feedstocks. We present a technique for high-throughput screening of nanoparticle-enhanced alloys for AM, combining inkjet printing and laser powder bed fusion (LPBF). Alloyed specimens are prepared on metal substrates with shallow machined cavities; a nanoparticle-containing ink is printed into the cavities via inkjet deposition; powder is manually spread into the wells; and then the material is melted by scanning of a laser as in traditional LPBF. We exercise this workflow using Niobium as the base metal and with custom-formulated inks containing Si and/or Ti nanoparticles. The alloyed specimens exhibit locally defined composition, microstructure, and hardness. We demonstrate control of minority element composition of <1 % to >10 % over <1 mm distances, and along with the capability to create multi-material gradients exhibiting complex microstructural effects.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100315"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144827674","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

Towards fully 3D printed dielectric elastomer actuators—A mini review 迈向完全3D打印的介电弹性体致动器-一个小型回顾

IF 4.7

Additive manufacturing letters Pub Date : 2025-07-01 Epub Date: 2025-07-25 DOI: 10.1016/j.addlet.2025.100304

Rollo Pattinson , Nathan Ellmer , Mokarram Hossain , Rogelio Ortigosa , Jesús Martínez-Frutos , Antonio J. Gil , Anil Bastola

{"title":"Towards fully 3D printed dielectric elastomer actuators—A mini review","authors":"Rollo Pattinson , Nathan Ellmer , Mokarram Hossain , Rogelio Ortigosa , Jesús Martínez-Frutos , Antonio J. Gil , Anil Bastola","doi":"10.1016/j.addlet.2025.100304","DOIUrl":"10.1016/j.addlet.2025.100304","url":null,"abstract":"<div><div>Dielectric elastomer actuators (DEAs) have attracted the interest of researchers in soft robotics and biomimetics, due to their versatile capabilities, explored through numerical analysis and experimentation. Advances in computational simulation techniques have accelerated numerical studies on DEAs, enabling even design optimisation for improved performance. However, as computational models grow in sophistication, the fabrication methods required often exceed the capabilities of traditional manufacturing. Additive manufacturing, in particular 3D printing, offers a promising solution to the challenges of realising intricate multi-functional designs developed through topology optimisation. Its precision and ability to create complex geometries make it well-suited for translating computational designs into functional DEA devices. This mini-review examines recent progress in 3D printing for DEA fabrication, emphasising its role in bridging the gap between computational design and physical devices. It also highlights emerging technologies and key challenges that must be addressed to fully realise topologically optimised DEA designs.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100304"},"PeriodicalIF":4.7,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144722272","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