Pub Date : 2024-08-13DOI: 10.1108/rpj-12-2023-0430
V. Vendittoli, Wilma Polini, Michael S. J. Walter, Jakob P.C. Stacheder
Purpose This study aims to address challenges in the Laser Powder Bed Fusion process of polymers, focusing on the considerable amount of unsintered powder left post-printing. The objective is to understand the altered properties of this powder and find solutions to improve the process, reduce waste and explore reusing reprocessed powder. Design/methodology/approach A novel methodology is used to generate reprocessed powder without traditional printing, reducing time, cost and waste. The approach mimics the ageing effects during the printing process, providing insights into particle size distribution and thermal behaviour. Findings Results reveal insights into artificial ageing, showing an 8.2% decrease in particle size (60.256–69.183 µm) and a 9.1% increase in particle size (17.378–19.953 µm) compared to unsintered powder. Thermal behaviour closely mirrors used powders, with variations in enthalpy of fusion (−0.55% to 2.69%) and degree of crystallinity (0.19% to 2.64%). The proposed methodology produces results that differ from those due to printing under 3% from a thermal point of view. The new process reduces the time needed for aged powder, contributing to cost savings and waste reduction. Originality/value The study introduces a novel method for reprocessed powder generation, deviating from traditional printing. The originality lies in artificially ageing powders, providing comparable results to actual printing. This approach offers efficiency, time savings and waste reduction in the Laser Powder Bed Fusion process, presenting a valuable avenue for further research.
{"title":"A novel approach on artificial aging of nylon 12 powder for laser powder bed fusion","authors":"V. Vendittoli, Wilma Polini, Michael S. J. Walter, Jakob P.C. Stacheder","doi":"10.1108/rpj-12-2023-0430","DOIUrl":"https://doi.org/10.1108/rpj-12-2023-0430","url":null,"abstract":"\u0000Purpose\u0000This study aims to address challenges in the Laser Powder Bed Fusion process of polymers, focusing on the considerable amount of unsintered powder left post-printing. The objective is to understand the altered properties of this powder and find solutions to improve the process, reduce waste and explore reusing reprocessed powder.\u0000\u0000\u0000Design/methodology/approach\u0000A novel methodology is used to generate reprocessed powder without traditional printing, reducing time, cost and waste. The approach mimics the ageing effects during the printing process, providing insights into particle size distribution and thermal behaviour.\u0000\u0000\u0000Findings\u0000Results reveal insights into artificial ageing, showing an 8.2% decrease in particle size (60.256–69.183 µm) and a 9.1% increase in particle size (17.378–19.953 µm) compared to unsintered powder. Thermal behaviour closely mirrors used powders, with variations in enthalpy of fusion (−0.55% to 2.69%) and degree of crystallinity (0.19% to 2.64%). The proposed methodology produces results that differ from those due to printing under 3% from a thermal point of view. The new process reduces the time needed for aged powder, contributing to cost savings and waste reduction.\u0000\u0000\u0000Originality/value\u0000The study introduces a novel method for reprocessed powder generation, deviating from traditional printing. The originality lies in artificially ageing powders, providing comparable results to actual printing. This approach offers efficiency, time savings and waste reduction in the Laser Powder Bed Fusion process, presenting a valuable avenue for further research.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141919654","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-13DOI: 10.1108/rpj-12-2023-0430
V. Vendittoli, Wilma Polini, Michael S. J. Walter, Jakob P.C. Stacheder
Purpose This study aims to address challenges in the Laser Powder Bed Fusion process of polymers, focusing on the considerable amount of unsintered powder left post-printing. The objective is to understand the altered properties of this powder and find solutions to improve the process, reduce waste and explore reusing reprocessed powder. Design/methodology/approach A novel methodology is used to generate reprocessed powder without traditional printing, reducing time, cost and waste. The approach mimics the ageing effects during the printing process, providing insights into particle size distribution and thermal behaviour. Findings Results reveal insights into artificial ageing, showing an 8.2% decrease in particle size (60.256–69.183 µm) and a 9.1% increase in particle size (17.378–19.953 µm) compared to unsintered powder. Thermal behaviour closely mirrors used powders, with variations in enthalpy of fusion (−0.55% to 2.69%) and degree of crystallinity (0.19% to 2.64%). The proposed methodology produces results that differ from those due to printing under 3% from a thermal point of view. The new process reduces the time needed for aged powder, contributing to cost savings and waste reduction. Originality/value The study introduces a novel method for reprocessed powder generation, deviating from traditional printing. The originality lies in artificially ageing powders, providing comparable results to actual printing. This approach offers efficiency, time savings and waste reduction in the Laser Powder Bed Fusion process, presenting a valuable avenue for further research.
{"title":"A novel approach on artificial aging of nylon 12 powder for laser powder bed fusion","authors":"V. Vendittoli, Wilma Polini, Michael S. J. Walter, Jakob P.C. Stacheder","doi":"10.1108/rpj-12-2023-0430","DOIUrl":"https://doi.org/10.1108/rpj-12-2023-0430","url":null,"abstract":"\u0000Purpose\u0000This study aims to address challenges in the Laser Powder Bed Fusion process of polymers, focusing on the considerable amount of unsintered powder left post-printing. The objective is to understand the altered properties of this powder and find solutions to improve the process, reduce waste and explore reusing reprocessed powder.\u0000\u0000\u0000Design/methodology/approach\u0000A novel methodology is used to generate reprocessed powder without traditional printing, reducing time, cost and waste. The approach mimics the ageing effects during the printing process, providing insights into particle size distribution and thermal behaviour.\u0000\u0000\u0000Findings\u0000Results reveal insights into artificial ageing, showing an 8.2% decrease in particle size (60.256–69.183 µm) and a 9.1% increase in particle size (17.378–19.953 µm) compared to unsintered powder. Thermal behaviour closely mirrors used powders, with variations in enthalpy of fusion (−0.55% to 2.69%) and degree of crystallinity (0.19% to 2.64%). The proposed methodology produces results that differ from those due to printing under 3% from a thermal point of view. The new process reduces the time needed for aged powder, contributing to cost savings and waste reduction.\u0000\u0000\u0000Originality/value\u0000The study introduces a novel method for reprocessed powder generation, deviating from traditional printing. The originality lies in artificially ageing powders, providing comparable results to actual printing. This approach offers efficiency, time savings and waste reduction in the Laser Powder Bed Fusion process, presenting a valuable avenue for further research.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141918995","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-09DOI: 10.1108/rpj-01-2024-0057
M. A. Mahmood, Marwan Khraisheh, Andrei C. Popescu, Frank Liou
Purpose This study aims to develop a holistic method that integrates finite element modeling, machine learning, and experimental validation to propose processing windows for optimizing the laser powder bed fusion (LPBF) process specific to the Al-357 alloy. Design/methodology/approach Validation of a 3D heat transfer simulation model was conducted to forecast melt pool dimensions, involving variations in laser power, laser scanning speed, powder bed thickness (PBT) and powder bed pre-heating (PHB). Using the validated model, a data set was compiled to establish a back-propagation-based machine learning capable of predicting melt pool dimensional ratios indicative of printing defects. Findings The study revealed that, apart from process parameters, PBT and PHB significantly influenced defect formation. Elevated PHBs were identified as contributors to increased lack of fusion and keyhole defects. Optimal combinations were pinpointed, such as 30.0 µm PBT with 90.0 and 120.0 °C PHBs and 50.0 µm PBT with 120.0 °C PHB. Originality/value The integrated process mapping approach showcased the potential to expedite the qualification of LPBF parameters for Al-357 alloy by minimizing the need for iterative physical testing.
{"title":"Processing windows for Al-357 by LPBF process: a novel framework integrating FEM simulation and machine learning with empirical testing","authors":"M. A. Mahmood, Marwan Khraisheh, Andrei C. Popescu, Frank Liou","doi":"10.1108/rpj-01-2024-0057","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0057","url":null,"abstract":"\u0000Purpose\u0000This study aims to develop a holistic method that integrates finite element modeling, machine learning, and experimental validation to propose processing windows for optimizing the laser powder bed fusion (LPBF) process specific to the Al-357 alloy.\u0000\u0000\u0000Design/methodology/approach\u0000Validation of a 3D heat transfer simulation model was conducted to forecast melt pool dimensions, involving variations in laser power, laser scanning speed, powder bed thickness (PBT) and powder bed pre-heating (PHB). Using the validated model, a data set was compiled to establish a back-propagation-based machine learning capable of predicting melt pool dimensional ratios indicative of printing defects.\u0000\u0000\u0000Findings\u0000The study revealed that, apart from process parameters, PBT and PHB significantly influenced defect formation. Elevated PHBs were identified as contributors to increased lack of fusion and keyhole defects. Optimal combinations were pinpointed, such as 30.0 µm PBT with 90.0 and 120.0 °C PHBs and 50.0 µm PBT with 120.0 °C PHB.\u0000\u0000\u0000Originality/value\u0000The integrated process mapping approach showcased the potential to expedite the qualification of LPBF parameters for Al-357 alloy by minimizing the need for iterative physical testing.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141923921","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Purpose The purpose of this study is to optimize and improve conventional welding using EMF assisted technology. Current industrial production has put forward higher requirements for welding technology, so the optimization and improvement of traditional welding methods become urgent needs. Design/methodology/approach External magnetic field assisted welding is an emerging technology in recent years, acting in a non-contact manner on the welding. The action of electromagnetic forces on the arc plasma leads to significant changes in the arc behavior, which affects the droplet transfer and molten pool formation and ultimately improve the weld seam formation and joint quality. Findings In this paper, different types of external magnetic fields are analyzed and summarized, which mainly include external transverse magnetic field, external longitudinal magnetic field and external cusp magnetic field. The research progress of welding behavior under the effect of external magnetic field is described, including the effect of external magnetic field on arc morphology, droplet transfer and weld seam formation law. Originality/value However, due to the extremely complex physical processes under the action of the external magnetic field, the mechanism of physical fields such as heat, force and electromagnetism in the welding has not been thoroughly analyzed, in-depth theoretical and numerical studies become urgent.
{"title":"Magnetic controlled arc welding technology: a review","authors":"Juanyan Miao, Yiwen Li, Siyu Zhang, Honglei Zhao, W. Zou, Chen-Hsuan Chang, Yunlong Chang","doi":"10.1108/rpj-06-2023-0201","DOIUrl":"https://doi.org/10.1108/rpj-06-2023-0201","url":null,"abstract":"Purpose\u0000The purpose of this study is to optimize and improve conventional welding using EMF assisted technology. Current industrial production has put forward higher requirements for welding technology, so the optimization and improvement of traditional welding methods become urgent needs.\u0000\u0000Design/methodology/approach\u0000External magnetic field assisted welding is an emerging technology in recent years, acting in a non-contact manner on the welding. The action of electromagnetic forces on the arc plasma leads to significant changes in the arc behavior, which affects the droplet transfer and molten pool formation and ultimately improve the weld seam formation and joint quality.\u0000\u0000Findings\u0000In this paper, different types of external magnetic fields are analyzed and summarized, which mainly include external transverse magnetic field, external longitudinal magnetic field and external cusp magnetic field. The research progress of welding behavior under the effect of external magnetic field is described, including the effect of external magnetic field on arc morphology, droplet transfer and weld seam formation law.\u0000\u0000Originality/value\u0000However, due to the extremely complex physical processes under the action of the external magnetic field, the mechanism of physical fields such as heat, force and electromagnetism in the welding has not been thoroughly analyzed, in-depth theoretical and numerical studies become urgent.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141925301","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-09DOI: 10.1108/rpj-10-2023-0345
Mathias Silmbroth, Norbert Enzinger, Sascha Senck, Karl Radlmayr, Thomas Klein
Purpose This study aims to investigate an intersecting single-walled structure fabricated using wire-arc directed energy deposition (waDED). Because of the highly complex geometrical features of this structure, characterisation is used to identify potential weak points and provide a benchmark for future complex components. Design/methodology/approach A structural component with a process-specific design is built using additive manufacturing of an Al-Mg alloy and analysed using micro-computed tomography. Scans are carried out at different resolutions and subsequently compared to microsections. The chemical composition and hardness are also examined. These investigations provide an enhanced understanding of defects and overall quality of the manufactured parts. Findings The results show that very high-quality parts can be achieved using ER5183 alloy, even in intersecting areas. Defects in these regions are primarily caused by converging and diverging waDED paths and discontinuous waDED operations. Originality/value In addition to demonstrating the feasibility of complex structures using waDED, this study provides an overview of problem areas and potential improvements in waDED manufacturing.
{"title":"Investigation of complex single-walled intersecting structures fabricated by wire-arc directed energy deposition","authors":"Mathias Silmbroth, Norbert Enzinger, Sascha Senck, Karl Radlmayr, Thomas Klein","doi":"10.1108/rpj-10-2023-0345","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0345","url":null,"abstract":"\u0000Purpose\u0000This study aims to investigate an intersecting single-walled structure fabricated using wire-arc directed energy deposition (waDED). Because of the highly complex geometrical features of this structure, characterisation is used to identify potential weak points and provide a benchmark for future complex components.\u0000\u0000\u0000Design/methodology/approach\u0000A structural component with a process-specific design is built using additive manufacturing of an Al-Mg alloy and analysed using micro-computed tomography. Scans are carried out at different resolutions and subsequently compared to microsections. The chemical composition and hardness are also examined. These investigations provide an enhanced understanding of defects and overall quality of the manufactured parts.\u0000\u0000\u0000Findings\u0000The results show that very high-quality parts can be achieved using ER5183 alloy, even in intersecting areas. Defects in these regions are primarily caused by converging and diverging waDED paths and discontinuous waDED operations.\u0000\u0000\u0000Originality/value\u0000In addition to demonstrating the feasibility of complex structures using waDED, this study provides an overview of problem areas and potential improvements in waDED manufacturing.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141922466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-08DOI: 10.1108/rpj-02-2024-0098
Siwei Bi, Jinkui Pi, Haohan Chen, Yannan Zhou, Ruiqi Liu, Yuanyuan Chen, Qianli Che, Wei Li, Jun Gu, Yi Zhang
Purpose Three-dimensional (3D) food printing is an innovative technology used to customize food products through the integration of digital technology and food ingredients. The purpose of this study is to assess the current state of research in the field of 3D food printing, identify trending topics and identify promising future research directions. Design/methodology/approach This bibliometric review systematically evaluates the field of 3D food printing using data from published literature in the Web of Science database. After reference screening, 812 articles were included in the analysis. Findings The result reveals that research in 3D food printing primarily focuses on the optimization and characterization of mechanical and rheological properties of food inks and that post-printing processing, such as laser treatment, has emerged recently as an important consideration in 3D food printing. However, extant works lack animal and human studies that demonstrate the functionality of 3D-printed food. Originality/value This sophisticated bibliometric analysis uncovered the most studied current research topics and the leading figures in the area of 3D food printing, providing promising future research directions.
目的三维（3D）食品打印是一项创新技术，通过将数字技术与食品配料相结合来定制食品。本研究的目的是评估三维食品打印领域的研究现状，确定趋势性课题，并确定未来有前景的研究方向。本文献计量学综述利用科学网数据库中已发表文献中的数据，对三维食品打印领域进行了系统评估。研究结果表明，3D 食品打印的研究主要集中在食品油墨的机械和流变特性的优化和表征上，而打印后处理（如激光处理）最近已成为 3D 食品打印的一个重要考虑因素。原创性/价值这项复杂的文献计量学分析揭示了当前研究最多的 3D 食品打印领域的研究课题和领军人物，为未来的研究方向提供了希望。
{"title":"Research landscape and trending topics on 3D food printing – a bibliometric review","authors":"Siwei Bi, Jinkui Pi, Haohan Chen, Yannan Zhou, Ruiqi Liu, Yuanyuan Chen, Qianli Che, Wei Li, Jun Gu, Yi Zhang","doi":"10.1108/rpj-02-2024-0098","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0098","url":null,"abstract":"\u0000Purpose\u0000Three-dimensional (3D) food printing is an innovative technology used to customize food products through the integration of digital technology and food ingredients. The purpose of this study is to assess the current state of research in the field of 3D food printing, identify trending topics and identify promising future research directions.\u0000\u0000\u0000Design/methodology/approach\u0000This bibliometric review systematically evaluates the field of 3D food printing using data from published literature in the Web of Science database. After reference screening, 812 articles were included in the analysis.\u0000\u0000\u0000Findings\u0000The result reveals that research in 3D food printing primarily focuses on the optimization and characterization of mechanical and rheological properties of food inks and that post-printing processing, such as laser treatment, has emerged recently as an important consideration in 3D food printing. However, extant works lack animal and human studies that demonstrate the functionality of 3D-printed food.\u0000\u0000\u0000Originality/value\u0000This sophisticated bibliometric analysis uncovered the most studied current research topics and the leading figures in the area of 3D food printing, providing promising future research directions.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141928782","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-08DOI: 10.1108/rpj-11-2023-0390
Yogesh Patil, Ashik Kumar Patel, G. Gote, Y. Mittal, Avinash Kumar Mehta, Sahil Devendra Singh, K. P. Karunakaran, M. Akarte
Purpose This study aims to improve the acceleration in the additive manufacturing (AM) process. AM tools, such as extrusion heads, jets, electric arcs, lasers and electron beams (EB), experience negligible forces. However, their speeds are limited by the positioning systems. In addition, a thin tool must travel several kilometers in tiny motions with several turns while realizing the AM part. Hence, acceleration is a more significant limiting factor than the velocity or precision for all except EB. Design/methodology/approach The sawtooth (ST) scanning strategy presented in this paper minimizes the time by combining three motion features: zigzag scan, 45º or 135º rotation for successive layers in G00 to avoid the CNC interpolation, and modifying these movements along 45º or 135º into sawtooth to halve the turns. Findings Sawtooth effectiveness is tested using an in-house developed Sand AM (SaAM) apparatus based on the laser–powder bed fusion AM technique. For a simple rectangle layer, the sawtooth achieved a path length reduction of 0.19%–1.49% and reduced the overall time by 3.508–4.889 times, proving that sawtooth uses increased acceleration more effectively than the other three scans. The complex layer study reduced calculated time by 69.80%–139.96% and manufacturing time by 47.35%–86.85%. Sawtooth samples also exhibited less dimensional variation (0.88%) than zigzag 45° (12.94%) along the build direction. Research limitations/implications Sawtooth is limited to flying optics AM process. Originality/value Development of scanning strategy for flying optics AM process to reduce the warpage by improving the acceleration.
{"title":"Sawtooth scanning strategy for additive manufacturing","authors":"Yogesh Patil, Ashik Kumar Patel, G. Gote, Y. Mittal, Avinash Kumar Mehta, Sahil Devendra Singh, K. P. Karunakaran, M. Akarte","doi":"10.1108/rpj-11-2023-0390","DOIUrl":"https://doi.org/10.1108/rpj-11-2023-0390","url":null,"abstract":"\u0000Purpose\u0000This study aims to improve the acceleration in the additive manufacturing (AM) process. AM tools, such as extrusion heads, jets, electric arcs, lasers and electron beams (EB), experience negligible forces. However, their speeds are limited by the positioning systems. In addition, a thin tool must travel several kilometers in tiny motions with several turns while realizing the AM part. Hence, acceleration is a more significant limiting factor than the velocity or precision for all except EB.\u0000\u0000\u0000Design/methodology/approach\u0000The sawtooth (ST) scanning strategy presented in this paper minimizes the time by combining three motion features: zigzag scan, 45º or 135º rotation for successive layers in G00 to avoid the CNC interpolation, and modifying these movements along 45º or 135º into sawtooth to halve the turns.\u0000\u0000\u0000Findings\u0000Sawtooth effectiveness is tested using an in-house developed Sand AM (SaAM) apparatus based on the laser–powder bed fusion AM technique. For a simple rectangle layer, the sawtooth achieved a path length reduction of 0.19%–1.49% and reduced the overall time by 3.508–4.889 times, proving that sawtooth uses increased acceleration more effectively than the other three scans. The complex layer study reduced calculated time by 69.80%–139.96% and manufacturing time by 47.35%–86.85%. Sawtooth samples also exhibited less dimensional variation (0.88%) than zigzag 45° (12.94%) along the build direction.\u0000\u0000\u0000Research limitations/implications\u0000Sawtooth is limited to flying optics AM process.\u0000\u0000\u0000Originality/value\u0000Development of scanning strategy for flying optics AM process to reduce the warpage by improving the acceleration.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-08-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141927321","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-30DOI: 10.1108/rpj-01-2024-0049
Shu Wang, Nathan B. Crane
Purpose Powder bed density is a key parameter in powder bed additive manufacturing (AM) processes but is not easily monitored. This research evaluates the possibility of non-invasively estimating the density of an AM powder bed via its thermal properties measured using flash thermography (FT). Design/methodology/approach The thermal diffusivity and conductivity of the samples were found by fitting an analytical model to the measured surface temperature after flash of the powder on a polymer substrate, enabling the estimation of the powder bed density. Findings FT estimated powder bed was within 8% of weight-based density measurements and the inferred thermal properties are consistent with literature findings. However, multiple flashes were necessary to ensure precise measurements due to noise in the experimental data and the similarity of thermal properties between the powder and substrate. Originality/value This paper emphasizes the capability of Flash Thermography (FT) for non-contact measurement of SS 316 L powder bed density, offering a pathway to in-situ monitoring for powder bed AM methods including binder jetting (BJ) and powder bed fusion. Despite the limitations of the current approach, the density knowledge and thermal properties measurements have the potential to enhance process development and thermal modeling powder bed AM processes, aiding in understanding the powder packing and thermal behavior.
目的粉末床密度是粉末床增材制造（AM）工艺中的一个关键参数，但不易监测。本研究评估了通过使用闪光热成像技术（FT）测量粉末床的热特性，以非侵入方式估算粉末床密度的可能性。研究结果FT 估算的粉末床密度在基于重量的密度测量值的 8% 以内，推断的热特性与文献结论一致。然而，由于实验数据中的噪声以及粉末和基底之间热特性的相似性，需要多次闪光才能确保精确测量。 本文强调了闪光热成像 (FT) 非接触式测量 SS 316 L 粉末床密度的能力，为粉末床 AM 方法（包括粘合剂喷射 (BJ) 和粉末床融合）的原位监测提供了途径。尽管目前的方法有其局限性，但密度知识和热特性测量有可能加强工艺开发和粉末床 AM 工艺的热建模，帮助了解粉末填料和热行为。
{"title":"Noncontact measurement of density and thermal properties of SS 316L powder bed through flash thermography","authors":"Shu Wang, Nathan B. Crane","doi":"10.1108/rpj-01-2024-0049","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0049","url":null,"abstract":"\u0000Purpose\u0000Powder bed density is a key parameter in powder bed additive manufacturing (AM) processes but is not easily monitored. This research evaluates the possibility of non-invasively estimating the density of an AM powder bed via its thermal properties measured using flash thermography (FT).\u0000\u0000\u0000Design/methodology/approach\u0000The thermal diffusivity and conductivity of the samples were found by fitting an analytical model to the measured surface temperature after flash of the powder on a polymer substrate, enabling the estimation of the powder bed density.\u0000\u0000\u0000Findings\u0000FT estimated powder bed was within 8% of weight-based density measurements and the inferred thermal properties are consistent with literature findings. However, multiple flashes were necessary to ensure precise measurements due to noise in the experimental data and the similarity of thermal properties between the powder and substrate.\u0000\u0000\u0000Originality/value\u0000This paper emphasizes the capability of Flash Thermography (FT) for non-contact measurement of SS 316 L powder bed density, offering a pathway to in-situ monitoring for powder bed AM methods including binder jetting (BJ) and powder bed fusion. Despite the limitations of the current approach, the density knowledge and thermal properties measurements have the potential to enhance process development and thermal modeling powder bed AM processes, aiding in understanding the powder packing and thermal behavior.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141796108","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-30DOI: 10.1108/rpj-05-2023-0164
Oğulcan Eren, H. Kürşad Sezer, N. Yüksel, Ahmad Reshad Bakhtari, O. Canyurt
Purpose This study aims to address the limited understanding of the complex correlations among strut size, structural orientation and process parameters in selective laser melting (SLM)-fabricated lattice structures. By investigating the effects of crucial process parameters, strut diameter and angle on the microstructure and mechanical performance of AlSi10Mg struts, the research seeks to enhance the surface morphologies, microstructures and mechanical properties of AM lattice structures, enabling their application in various engineering fields, including medical science and space technologies. Design/methodology/approach This comprehensive study investigates SLM-fabricated AlSi10Mg strut structures, examining the effects of process parameters, strut diameter and angle on densification behavior and microstructural characteristics. By analyzing microstructure, geometrical properties, melt pool morphology and mechanical properties using optical microscopy, scanning electron microscope, energy dispersive X-ray spectroscopy and microhardness tests, the research addresses existing gaps in knowledge on fine lattice strut elements and their impact on surface morphology and microstructure. Findings The study revealed that laser energy, power density and strut inclination angle significantly impact the microstructure, geometrical properties and mechanical performance of SLM-produced AlSi10Mg struts. Findings insight enable the optimization of SLM process parameters to produce lattice structures with enhanced surface morphologies, microstructures and mechanical properties, paving the way for applications in medical science and space technologies. Originality/value This study uniquely investigates the effects of processing parameters, strut diameter and inclination angle on SLM-fabricated AlSi10Mg struts, focusing on fine lattice strut elements with diameters as small as 200 µm. Unlike existing literature, it delves into the complex correlations among strut size, structural orientation and process parameters to understand their impact on microstructure, geometrical imperfections and mechanical properties. The study provides novel insights that contribute to the optimization of SLM process parameters, moving beyond the typically recommended guidelines from powder or machine suppliers.
{"title":"Investigation on selective laser-melted AlSi10Mg micro-struts: influence of processing parameters on dimensional accuracy, molten pool morphology and microhardness","authors":"Oğulcan Eren, H. Kürşad Sezer, N. Yüksel, Ahmad Reshad Bakhtari, O. Canyurt","doi":"10.1108/rpj-05-2023-0164","DOIUrl":"https://doi.org/10.1108/rpj-05-2023-0164","url":null,"abstract":"\u0000Purpose\u0000This study aims to address the limited understanding of the complex correlations among strut size, structural orientation and process parameters in selective laser melting (SLM)-fabricated lattice structures. By investigating the effects of crucial process parameters, strut diameter and angle on the microstructure and mechanical performance of AlSi10Mg struts, the research seeks to enhance the surface morphologies, microstructures and mechanical properties of AM lattice structures, enabling their application in various engineering fields, including medical science and space technologies.\u0000\u0000\u0000Design/methodology/approach\u0000This comprehensive study investigates SLM-fabricated AlSi10Mg strut structures, examining the effects of process parameters, strut diameter and angle on densification behavior and microstructural characteristics. By analyzing microstructure, geometrical properties, melt pool morphology and mechanical properties using optical microscopy, scanning electron microscope, energy dispersive X-ray spectroscopy and microhardness tests, the research addresses existing gaps in knowledge on fine lattice strut elements and their impact on surface morphology and microstructure.\u0000\u0000\u0000Findings\u0000The study revealed that laser energy, power density and strut inclination angle significantly impact the microstructure, geometrical properties and mechanical performance of SLM-produced AlSi10Mg struts. Findings insight enable the optimization of SLM process parameters to produce lattice structures with enhanced surface morphologies, microstructures and mechanical properties, paving the way for applications in medical science and space technologies.\u0000\u0000\u0000Originality/value\u0000This study uniquely investigates the effects of processing parameters, strut diameter and inclination angle on SLM-fabricated AlSi10Mg struts, focusing on fine lattice strut elements with diameters as small as 200 µm. Unlike existing literature, it delves into the complex correlations among strut size, structural orientation and process parameters to understand their impact on microstructure, geometrical imperfections and mechanical properties. The study provides novel insights that contribute to the optimization of SLM process parameters, moving beyond the typically recommended guidelines from powder or machine suppliers.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141796251","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-25DOI: 10.1108/rpj-02-2024-0078
Tianyu Zhang, Lang Yuan
Purpose Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel. Design/methodology/approach A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy. Findings The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm3) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation. Originality/value This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.
{"title":"Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion","authors":"Tianyu Zhang, Lang Yuan","doi":"10.1108/rpj-02-2024-0078","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0078","url":null,"abstract":"\u0000Purpose\u0000Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel.\u0000\u0000\u0000Design/methodology/approach\u0000A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy.\u0000\u0000\u0000Findings\u0000The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm3) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation.\u0000\u0000\u0000Originality/value\u0000This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141803164","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：