Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.031
Andreas Fezer , Stefan Weihe , Martin Werz
Click here and insert your abstract text.
Resistance spot welding (RSW) is one of the dominant joining processes in “body-in-white” of the automotive industry and is mainly used for steel materials. Currently, RSW is also increasingly being used for aluminum alloys. However, the welding results vary greatly when welding aluminum. As less research has been carried out into the welding of aluminum than steel, the causes of various aspects, including these variations, are not yet fully understood.
A partially automated robot welding cell was set up at MPA to address various industry-related issues and test them under laboratory conditions. Important welding parameters such as electrode force and welding current can be adjusted. The weld samples are examined using destructive testing for the size of the weld spot and the presence of defects. Since the spot diameter is considered the main quality criterion in industry, the study presented here also examines the spot diameter in more detail. This study demonstrated the influence of welding current, electrode force, adhesive and sheet thickness on the spot diameter.
{"title":"Influences of Various Parameters on the Weld Spot Diameter during Resistance Spot Welding of the Aluminum Alloy EN AW-6014","authors":"Andreas Fezer , Stefan Weihe , Martin Werz","doi":"10.1016/j.prostr.2026.01.031","DOIUrl":"10.1016/j.prostr.2026.01.031","url":null,"abstract":"<div><div>Click here and insert your abstract text.</div><div>Resistance spot welding (RSW) is one of the dominant joining processes in “body-in-white” of the automotive industry and is mainly used for steel materials. Currently, RSW is also increasingly being used for aluminum alloys. However, the welding results vary greatly when welding aluminum. As less research has been carried out into the welding of aluminum than steel, the causes of various aspects, including these variations, are not yet fully understood.</div><div>A partially automated robot welding cell was set up at MPA to address various industry-related issues and test them under laboratory conditions. Important welding parameters such as electrode force and welding current can be adjusted. The weld samples are examined using destructive testing for the size of the weld spot and the presence of defects. Since the spot diameter is considered the main quality criterion in industry, the study presented here also examines the spot diameter in more detail. This study demonstrated the influence of welding current, electrode force, adhesive and sheet thickness on the spot diameter.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 229-236"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102881","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.032
Roman Hofmann , Moritz Käß , Martin Werz , Stefan Weihe
Laser Powder Bed Fusion (LPBF) or Laser Powder Bed Fusion of Metals (PBF-LB/M) enables the production of complex geometries. However, not every production process is successful and the outcome of the material properties is sometimes uncertain. Conventional build strategies are often limited to parameter tuning and minor scan-path variations, leaving much of the process freedom unused. Thus the full potential of the method has not yet been fully exploited. In this work, the development of new scan strategies implemented in a custom Python-based slicer with full vector-level control are described and evaluated. Four approaches were investigated: Index Reorder, Time Reorder, Voronoi partitioning, and Pilger (back-step–inspired segmentation).
The scan strategies were applied to demonstrator parts, cantilever specimens, and fatigue specimens, produced from 316L stainless steel and the alloy Specialis® on different PBF-LB/M machines. Thermographic snapshots revealed pronounced heat accumulation in linear hatching, whereas the Voronoi strategy achieved more homogeneous exposure. Cantilever tests showed that Index Reorder and Pilger reduced residual stresses compared to the reference (measured by defection). Fatigue testing demonstrated that all novel strategies substantially reduced life scatter relative to the linear baseline, with Voronoi showing a slight additional improvement.
The results highlight that build strategies significantly influence thermal histories, residual stress, and fatigue performance, beyond what can be achieved by parameter optimization alone. While no strategy-specific parameter optimization was performed, the findings point toward the potential of tailored scan strategies to improve reliability and reproducibility in PBF-LB/M. Future work will focus on quantitative thermography, microstructural analysis, and refined Voronoi implementations for local property control.
{"title":"Optimization and Development of scanning strategies in PBF-LB/M - Influencing mechanical properties of additive manufactured parts","authors":"Roman Hofmann , Moritz Käß , Martin Werz , Stefan Weihe","doi":"10.1016/j.prostr.2026.01.032","DOIUrl":"10.1016/j.prostr.2026.01.032","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (LPBF) or Laser Powder Bed Fusion of Metals (PBF-LB/M) enables the production of complex geometries. However, not every production process is successful and the outcome of the material properties is sometimes uncertain. Conventional build strategies are often limited to parameter tuning and minor scan-path variations, leaving much of the process freedom unused. Thus the full potential of the method has not yet been fully exploited. In this work, the development of new scan strategies implemented in a custom Python-based slicer with full vector-level control are described and evaluated. Four approaches were investigated: Index Reorder, Time Reorder, Voronoi partitioning, and Pilger (back-step–inspired segmentation).</div><div>The scan strategies were applied to demonstrator parts, cantilever specimens, and fatigue specimens, produced from 316L stainless steel and the alloy Specialis® on different PBF-LB/M machines. Thermographic snapshots revealed pronounced heat accumulation in linear hatching, whereas the Voronoi strategy achieved more homogeneous exposure. Cantilever tests showed that Index Reorder and Pilger reduced residual stresses compared to the reference (measured by defection). Fatigue testing demonstrated that all novel strategies substantially reduced life scatter relative to the linear baseline, with Voronoi showing a slight additional improvement.</div><div>The results highlight that build strategies significantly influence thermal histories, residual stress, and fatigue performance, beyond what can be achieved by parameter optimization alone. While no strategy-specific parameter optimization was performed, the findings point toward the potential of tailored scan strategies to improve reliability and reproducibility in PBF-LB/M. Future work will focus on quantitative thermography, microstructural analysis, and refined Voronoi implementations for local property control.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 237-247"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102882","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.041
Boyu Li, Konstantinos P. Baxevanakis, Vadim V. Silberschmidt
Composite materials are widely used in marine environments, with hygrothermal ageing being the main factor affecting their structural integrity (Zhang et al., 2017). In additively manufactured (AM) composites, printing-induced voids are formed at the interfaces between printing beads as a result of the layer-by-layer deposition process, with void’s size dependent on printing parameters (Ivey et al., 2017). Such voids present additional paths for the water ingress into these materials. Kim and Seo (2023) demonstrated that outer-wall layers in 3D-printed composite specimens can significantly retard water diffusion. Therefore, the impact of printing patterns on water penetration into AM composites is a critical factor for the diffusion process, worth investigation. This study integrates experimental analysis with finite-element modelling to investigate water diffusion in AM composites. Polylactic-acid specimens with a line printing pattern were printed and aged in water, with the diffusion process monitored via weekly measurement of weight increments. Specimens were immersed in water with their printing orientations arranged either parallel or perpendicular to the water surface, allowing for the evaluation of the effect of printing patterns on moisture transport. Both experimental and modelling results demonstrate that printing orientation significantly affects water penetration. These findings highlight the necessity of reconstructing the internal structure of 3D-printed composites from G-code to accurately capture their diffusion behaviour.
复合材料在海洋环境中应用广泛，湿热老化是影响复合材料结构完整性的主要因素（Zhang et al., 2017）。在增材制造（AM）复合材料中，由于逐层沉积过程，在打印珠之间的界面上形成打印诱导空洞，空洞的大小取决于打印参数（Ivey等人，2017）。这些空隙为水进入这些材料提供了额外的途径。Kim和Seo（2023）证明，3d打印复合材料试件的外壁层可以显著延缓水的扩散。因此，印刷图案对水渗透到AM复合材料中的影响是影响扩散过程的关键因素，值得研究。本研究将实验分析与有限元模拟相结合，研究了水在AM复合材料中的扩散。将具有线形印刷图案的聚乳酸样品在水中印刷和老化，并通过每周测量重量增量来监测扩散过程。将标本浸入水中，使其印刷方向与水面平行或垂直，以便评估印刷图案对水分输送的影响。实验和模型结果均表明，打印方向对水渗透有显著影响。这些发现强调了从g代码重建3d打印复合材料内部结构以准确捕获其扩散行为的必要性。
{"title":"Diffusion of moisture from voids in additively manufactured composites: Effect of printing patterns","authors":"Boyu Li, Konstantinos P. Baxevanakis, Vadim V. Silberschmidt","doi":"10.1016/j.prostr.2026.01.041","DOIUrl":"10.1016/j.prostr.2026.01.041","url":null,"abstract":"<div><div>Composite materials are widely used in marine environments, with hygrothermal ageing being the main factor affecting their structural integrity (Zhang et al., 2017). In additively manufactured (AM) composites, printing-induced voids are formed at the interfaces between printing beads as a result of the layer-by-layer deposition process, with void’s size dependent on printing parameters (Ivey et al., 2017). Such voids present additional paths for the water ingress into these materials. Kim and Seo (2023) demonstrated that outer-wall layers in 3D-printed composite specimens can significantly retard water diffusion. Therefore, the impact of printing patterns on water penetration into AM composites is a critical factor for the diffusion process, worth investigation. This study integrates experimental analysis with finite-element modelling to investigate water diffusion in AM composites. Polylactic-acid specimens with a line printing pattern were printed and aged in water, with the diffusion process monitored via weekly measurement of weight increments. Specimens were immersed in water with their printing orientations arranged either parallel or perpendicular to the water surface, allowing for the evaluation of the effect of printing patterns on moisture transport. Both experimental and modelling results demonstrate that printing orientation significantly affects water penetration. These findings highlight the necessity of reconstructing the internal structure of 3D-printed composites from G-code to accurately capture their diffusion behaviour.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 316-322"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102892","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.011
Alessandro Zanarini
Airborne pressure fields, with their variable spectral content in the acoustic and frequency domains, can become a threatening dynamic distributed loading for many surfaces in industrial applications, thus leading to airborne fatigue. Part A of this research path retrieves the structural force spectrum, as induced by the modelled airborne pressure fields on the real thin plate tested, which becomes the dynamic excitation for the structural dynamics in this Part B, leading to cumulative damage and fatigue life considerations. Reliable and advanced full-field receptance testing – as substitution of any other numerical model about the mounted realisation of the specific components – can nowadays be made by means of optical measurements. The quality achieved in the receptance maps helps in numerically derive the strain FRFs on the sensed surfaces. With proper constitutive models, the experiment-based mapping of the equivalent stresses can be achieved. Fatigue spectral methods turn this knowledge into component’s life distributions with the unmatched mapping ability of contactless full-field techniques. Full-field optical receptance maps turn to be pivotal in accurately representing the structural dynamics when retrieving the induced force by airborne pressure fields in Part A, and when mapping the effective solicitations for the airborne fatigue life predictions of Part B.
{"title":"About airborne fatigue life predictions by means of full-field receptances. Part B: estimating the failure distribution with spectral methods.","authors":"Alessandro Zanarini","doi":"10.1016/j.prostr.2026.01.011","DOIUrl":"10.1016/j.prostr.2026.01.011","url":null,"abstract":"<div><div>Airborne pressure fields, with their variable spectral content in the acoustic and frequency domains, can become a threatening dynamic distributed loading for many surfaces in industrial applications, thus leading to airborne fatigue. Part A of this research path retrieves the structural force spectrum, as induced by the modelled airborne pressure fields on the real thin plate tested, which becomes the dynamic excitation for the structural dynamics in this Part B, leading to cumulative damage and fatigue life considerations. Reliable and advanced full-field receptance testing – as substitution of any other numerical model about the mounted realisation of the specific components – can nowadays be made by means of optical measurements. The quality achieved in the receptance maps helps in numerically derive the strain FRFs on the sensed surfaces. With proper constitutive models, the experiment-based mapping of the equivalent stresses can be achieved. Fatigue spectral methods turn this knowledge into component’s life distributions with the unmatched mapping ability of contactless full-field techniques. Full-field optical receptance maps turn to be pivotal in accurately representing the structural dynamics when retrieving the induced force by airborne pressure fields in Part A, and when mapping the effective solicitations for the airborne fatigue life predictions of Part B.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 71-78"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102424","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2025.12.289
Robin Motte , Matthieu Vander Linden , Kris Hectors , Anil Sudhakar , Wim De Waele
Apart from producing new components, Wire + Arc Additive Manufacturing (WAAM) enables the remanufacturing of worn metallic parts, supporting a circular economy. However, the as-built surface often shows significant waviness resulting from the layered bead deposition, leading to stress concentrations and thus reduced fatigue life. Finishing operations are typically performed to mitigate those effects, though omitting them could save processing time, energy consumption, and overall costs. This work investigates the fatigue performance of S355J2 steel components remanufactured by WAAM using EMK8 wire, retaining as-built surface waviness. A novel four-point bending specimen with a WAAM-filled groove was designed to replicate a surface repair. Two electric arc welding methods — conventional short-circuit and Cold Metal Transfer — were compared to assess the effect of a different heat input. The former process resulted in higher heat input during material deposition. Compared to reference curves for S355J2 and bulk WAAMed EMK8 specimens, the fatigue strength of the remanufactured specimens was seen to be reduced. The as-built surface resulted in steeper slopes of the S-N curves compared to the polished reference materials. Crack initiation was determined by infrared thermography and was seen to occur between 6 and 50% of the total fatigue life, indicating that the majority of the total fatigue life consisted of crack propagation. The fatigue cracks were monitored by digital image correlation and were seen to propagate into the S355J2 substrate material, which can be considered as dominant for the crack growth rate.
{"title":"Fatigue performance of steel components remanufactured by wire + arc additive manufacturing with as-built surface waviness","authors":"Robin Motte , Matthieu Vander Linden , Kris Hectors , Anil Sudhakar , Wim De Waele","doi":"10.1016/j.prostr.2025.12.289","DOIUrl":"10.1016/j.prostr.2025.12.289","url":null,"abstract":"<div><div>Apart from producing new components, Wire + Arc Additive Manufacturing (WAAM) enables the remanufacturing of worn metallic parts, supporting a circular economy. However, the as-built surface often shows significant waviness resulting from the layered bead deposition, leading to stress concentrations and thus reduced fatigue life. Finishing operations are typically performed to mitigate those effects, though omitting them could save processing time, energy consumption, and overall costs. This work investigates the fatigue performance of S355J2 steel components remanufactured by WAAM using EMK8 wire, retaining as-built surface waviness. A novel four-point bending specimen with a WAAM-filled groove was designed to replicate a surface repair. Two electric arc welding methods — conventional short-circuit and Cold Metal Transfer — were compared to assess the effect of a different heat input. The former process resulted in higher heat input during material deposition. Compared to reference curves for S355J2 and bulk WAAMed EMK8 specimens, the fatigue strength of the remanufactured specimens was seen to be reduced. The as-built surface resulted in steeper slopes of the S-N curves compared to the polished reference materials. Crack initiation was determined by infrared thermography and was seen to occur between 6 and 50% of the total fatigue life, indicating that the majority of the total fatigue life consisted of crack propagation. The fatigue cracks were monitored by digital image correlation and were seen to propagate into the S355J2 substrate material, which can be considered as dominant for the crack growth rate.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"76 ","pages":"Pages 74-81"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102544","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}
Industries such as aerospace and automotive prioritize safety, making impact resistance a crucial factor in structural performance. Dual-adhesive joints (DAJ), which combine a stiff adhesive in the central region with a more flexible adhesive at the edges, enhance stress distribution and improve joint durability, providing a more reliable and efficient bonding solution. This work aims to improve the DAJ impact behaviour with steel adherends by applying geometrical modifications (outer and inner chamfers, and adhesive fillets) and considering different adhesive combinations. A numerical study was conducted using cohesive zone modelling (CZM), encompassing an analysis of peel (sy) and shear (txy) stresses, maximum load (Pm), and dissipated energy (U). Validation with experimental data was successfully carried out. The strategic use of DAJ combinations and targeted geometric modifications can effectively enhance the impact behaviour of adhesively bonded joints.
{"title":"Impact strength optimization of dual-adhesive joints by cohesive zone modelling","authors":"L.A.S. Maia , R.D.S.G. Campilho , J.F.B. Martins , A.J.A. Vieira , D.C. Gonçalves , K. Madani","doi":"10.1016/j.prostr.2026.01.013","DOIUrl":"10.1016/j.prostr.2026.01.013","url":null,"abstract":"<div><div>Industries such as aerospace and automotive prioritize safety, making impact resistance a crucial factor in structural performance. Dual-adhesive joints (DAJ), which combine a stiff adhesive in the central region with a more flexible adhesive at the edges, enhance stress distribution and improve joint durability, providing a more reliable and efficient bonding solution. This work aims to improve the DAJ impact behaviour with steel adherends by applying geometrical modifications (outer and inner chamfers, and adhesive fillets) and considering different adhesive combinations. A numerical study was conducted using cohesive zone modelling (CZM), encompassing an analysis of peel (<em>s</em><sub>y</sub>) and shear (<em>t</em><sub>xy</sub>) stresses, maximum load (<em>P</em><sub>m</sub>), and dissipated energy (<em>U</em>). Validation with experimental data was successfully carried out. The strategic use of DAJ combinations and targeted geometric modifications can effectively enhance the impact behaviour of adhesively bonded joints.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 87-94"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102592","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.078
Christian J. Silva , Rogério F.F. Lopes , Alexandre M. Löw , Vasco B. Gomes , Nuno V. Ramos , Pedro M.G.J. Moreira , João S. Silva , Rodrigo S. Andrade
Railway vehicle structures must comply with strict safety regulations to ensure integrity and passive safety. A key requirement is a crashworthiness analysis under EN 15227, as collisions pose significant risks to passengers. This study evaluates the structural behaviour of a railway coach in head-on collisions, following EN 15227 criteria. Finite Element Method (FEM) simulations with a dynamic explicit model were performed, enabling virtual testing that reduces development time and costs while maintaining high standards. The analysis identifies vulnerable areas in current structures, aiming to enhance passenger safety and regulatory compliance. A modified structure was also studied, and both designs were compared in terms of survival space and structural deceleration. The findings provide insights into how structural changes influence crashworthiness performance.
{"title":"Evaluation of a railway coach crashworthiness for the purpose of certification","authors":"Christian J. Silva , Rogério F.F. Lopes , Alexandre M. Löw , Vasco B. Gomes , Nuno V. Ramos , Pedro M.G.J. Moreira , João S. Silva , Rodrigo S. Andrade","doi":"10.1016/j.prostr.2026.01.078","DOIUrl":"10.1016/j.prostr.2026.01.078","url":null,"abstract":"<div><div>Railway vehicle structures must comply with strict safety regulations to ensure integrity and passive safety. A key requirement is a crashworthiness analysis under EN 15227, as collisions pose significant risks to passengers. This study evaluates the structural behaviour of a railway coach in head-on collisions, following EN 15227 criteria. Finite Element Method (FEM) simulations with a dynamic explicit model were performed, enabling virtual testing that reduces development time and costs while maintaining high standards. The analysis identifies vulnerable areas in current structures, aiming to enhance passenger safety and regulatory compliance. A modified structure was also studied, and both designs were compared in terms of survival space and structural deceleration. The findings provide insights into how structural changes influence crashworthiness performance.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 631-638"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102671","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.079
Y. Bakir , I. Zetková
Laser Powder Bed Fusion (LPBF) is governed by intricate interactions between laser settings and material characteristics, which collectively influence melt pool formation, energy absorption, and defect generation. Key parameters such as laser power, scanning speed, beam size, and layer thickness play a critical role in determining the energy absorption behavior and the resulting melting mechanisms. Absorptivity and melt pool depth are especially responsive near the transition between conduction and keyhole melting modes, where thermal properties and energy input become closely linked.
The geometry of the melt pool is also affected by the chosen scan strategy and powder properties. Finer and more uniformly distributed powders typically improve energy absorption and promote more stable melt pool formation. This results in higher part density and deeper melt pools across various alloy systems, including titanium, aluminum, and copper.
Real-time monitoring technologies, such as infrared pyrometry may allow for dynamic classification of melting regimes during the build process. Furthermore, adjustments in scan strategy can refine thermal behavior and improve part quality. The impact of these parameters varies with material type, highlighting the importance of tailoring process conditions to specific powder characteristics to achieve optimal performance.
{"title":"In situ process monitoring with respect to mechanical properties of additively manufactured parts","authors":"Y. Bakir , I. Zetková","doi":"10.1016/j.prostr.2026.01.079","DOIUrl":"10.1016/j.prostr.2026.01.079","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (LPBF) is governed by intricate interactions between laser settings and material characteristics, which collectively influence melt pool formation, energy absorption, and defect generation. Key parameters such as laser power, scanning speed, beam size, and layer thickness play a critical role in determining the energy absorption behavior and the resulting melting mechanisms. Absorptivity and melt pool depth are especially responsive near the transition between conduction and keyhole melting modes, where thermal properties and energy input become closely linked.</div><div>The geometry of the melt pool is also affected by the chosen scan strategy and powder properties. Finer and more uniformly distributed powders typically improve energy absorption and promote more stable melt pool formation. This results in higher part density and deeper melt pools across various alloy systems, including titanium, aluminum, and copper.</div><div>Real-time monitoring technologies, such as infrared pyrometry may allow for dynamic classification of melting regimes during the build process. Furthermore, adjustments in scan strategy can refine thermal behavior and improve part quality. The impact of these parameters varies with material type, highlighting the importance of tailoring process conditions to specific powder characteristics to achieve optimal performance.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 639-648"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102672","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.068
M. Turhan , I. Zetková , M. Zetek , J. Hruška
This paper deals with 3D printed parts which are being investigated in the printability and mechanical properties of Hastelloy X (HX) powder by Laser Powder Bed Fusion (L-PBF) technology. HX material is widely used in the industry, which is required for oxidation resistance, fabricability, and high-temperature strength applications. The objective of the research is to print the unit of the heat exchanger by doing experimental prints through manipulating scanning strategies and altering the support structures. There are many samples printed for mechanical tests such as tensile, creep, and fatigue to be exposed to supercritical water environment, in nitrogen, and in air environment at different temperatures and different durations. Each print is evaluated, and outcomes are applied on the next print. By doing this, to achieve more stable prints and verifying and comparing the mechanical properties with industrial applications. Some issues such as support structures (especially block support), and residual stresses are addressed to be worked on the further research for HX material at the end of the research.
{"title":"Investigation of printability and mechanical properties of Hastelloy X (HX) manufactured by Laser Powder Bed Fusion (L-PBF)","authors":"M. Turhan , I. Zetková , M. Zetek , J. Hruška","doi":"10.1016/j.prostr.2026.01.068","DOIUrl":"10.1016/j.prostr.2026.01.068","url":null,"abstract":"<div><div>This paper deals with 3D printed parts which are being investigated in the printability and mechanical properties of Hastelloy X (HX) powder by Laser Powder Bed Fusion (L-PBF) technology. HX material is widely used in the industry, which is required for oxidation resistance, fabricability, and high-temperature strength applications. The objective of the research is to print the unit of the heat exchanger by doing experimental prints through manipulating scanning strategies and altering the support structures. There are many samples printed for mechanical tests such as tensile, creep, and fatigue to be exposed to supercritical water environment, in nitrogen, and in air environment at different temperatures and different durations. Each print is evaluated, and outcomes are applied on the next print. By doing this, to achieve more stable prints and verifying and comparing the mechanical properties with industrial applications. Some issues such as support structures (especially block support), and residual stresses are addressed to be worked on the further research for HX material at the end of the research.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 543-549"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102726","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}
Pub Date : 2026-01-01DOI: 10.1016/j.prostr.2026.01.072
Carolina Francisco , Hugo Mesquita Vasconcelos , Susana Dias , Pedro J.S.C.P. Sousa , Paulo J. Tavares , Pedro M.G.J. Moreira , Tiago T.M. Soares , António da S. Guedes
Stamping presses are essential in manufacturing due to their ability to produce components with high speed, precision and repeatability. However, unplanned downtime due to equipment failure can disrupt production and raise costs. While preventive maintenance schedules, commonly used by manufacturers, help reduce these risks, their time-based nature can lead to unnecessary stoppages and may miss emerging faults that develop between inspections. Condition-based systems capable of estimating the current condition of a press and detecting potential component faults offer significant advantages, as it can lead to energy and cost savings, as well as increased productivity and product quality.
To address this need, a monitoring system was developed alongside the manufacturing of a new servo motorized stamping press. The system utilizes multi-sensor data collected from strategically placed sensors on the press. Sensor signals are filtered by dedicated modules and transmitted to a computer, where algorithms analyze the data to evaluate the press’s condition. The results of the estimated condition, along with the sensor data, are displayed on a dashboard also operating as an interface to manage data processing. The system’s modular architecture enables flexible integration or removal of sensors according to evolving requirements.
This paper describes the early stage of developing the monitoring system, including the design of the system architecture and the definition of the sensing plan. To support the development and validation of the processing algorithms, data were collected from a stamping presses ensuring representative signal characteristics for press operation.
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