Pub Date : 2023-12-29DOI: 10.1108/rpj-08-2023-0276
Noah Ray, Il Yong Kim
Purpose Fiber reinforced additive manufacturing (FRAM) is an emerging technology that combines additive manufacturing and composite materials. As a result, design freedom offered by the manufacturing process can be leveraged in design optimization. The purpose of the study is to propose a novel method that improves structural performance by optimizing 3D print orientation of FRAM components. Design/methodology/approach This work proposes a two-part design optimization method that optimizes 3D global print orientation and topology of a component to improve a structural objective function. The method considers two classes of design variables: (1) print orientation design variables and (2) density-based topology design variables. Print orientation design variables determine a unique 3D print orientation to influence anisotropic material properties. Topology optimization determines an optimal distribution of material within the optimized print orientation. Findings Two academic examples are used to demonstrate basic behavior of the method in tension and shear. Print orientation and sequential topology optimization improve structural compliance by 90% and 58%, respectively. An industry-level example, an aerospace component, is optimized. The proposed method is used to achieve an 11% and 15% reduction of structural compliance compared to alternative FRAM designs. In addition, compliance is reduced by 43% compared to an equal-mass aluminum design. Originality/value Current research surrounding FRAM focuses on the manufacturing process and neglects opportunities to leverage design freedom provided by FRAM. Previous FRAM optimization methods only optimize fiber orientation within a 2D plane and do not establish an optimized 3D print orientation, neglecting exploration of the entire orientation design space.
目的 纤维增强增材制造（FRAM）是一项新兴技术，它将增材制造与复合材料相结合。因此，制造工艺提供的设计自由度可用于优化设计。本研究旨在提出一种新方法，通过优化 FRAM 组件的 3D 打印方向来提高结构性能。 设计/方法/途径 这项工作提出了一种由两部分组成的设计优化方法，可优化部件的三维全局打印方向和拓扑结构，以改善结构目标函数。该方法考虑了两类设计变量：(1) 打印方向设计变量和 (2) 基于密度的拓扑设计变量。打印方向设计变量确定独特的三维打印方向，以影响各向异性的材料特性。拓扑优化决定了材料在优化打印方向上的最佳分布。 研究结果 通过两个学术范例展示了该方法在拉伸和剪切时的基本行为。打印方向和顺序拓扑优化分别将结构顺应性提高了 90% 和 58%。优化了一个工业级实例，即一个航空航天部件。与其他 FRAM 设计相比，所提出的方法使结构顺应性分别降低了 11% 和 15%。此外，与等质量铝设计相比，结构顺应性降低了 43%。 原创性/价值 目前围绕 FRAM 的研究主要集中在制造工艺上，忽略了利用 FRAM 提供的设计自由度的机会。以前的 FRAM 优化方法只能优化二维平面内的纤维取向，不能建立优化的三维打印取向，从而忽略了对整个取向设计空间的探索。
{"title":"Fiber reinforced additive manufacturing: structurally motivated print orientation and sequential topology optimization of anisotropic material","authors":"Noah Ray, Il Yong Kim","doi":"10.1108/rpj-08-2023-0276","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0276","url":null,"abstract":"Purpose Fiber reinforced additive manufacturing (FRAM) is an emerging technology that combines additive manufacturing and composite materials. As a result, design freedom offered by the manufacturing process can be leveraged in design optimization. The purpose of the study is to propose a novel method that improves structural performance by optimizing 3D print orientation of FRAM components. Design/methodology/approach This work proposes a two-part design optimization method that optimizes 3D global print orientation and topology of a component to improve a structural objective function. The method considers two classes of design variables: (1) print orientation design variables and (2) density-based topology design variables. Print orientation design variables determine a unique 3D print orientation to influence anisotropic material properties. Topology optimization determines an optimal distribution of material within the optimized print orientation. Findings Two academic examples are used to demonstrate basic behavior of the method in tension and shear. Print orientation and sequential topology optimization improve structural compliance by 90% and 58%, respectively. An industry-level example, an aerospace component, is optimized. The proposed method is used to achieve an 11% and 15% reduction of structural compliance compared to alternative FRAM designs. In addition, compliance is reduced by 43% compared to an equal-mass aluminum design. Originality/value Current research surrounding FRAM focuses on the manufacturing process and neglects opportunities to leverage design freedom provided by FRAM. Previous FRAM optimization methods only optimize fiber orientation within a 2D plane and do not establish an optimized 3D print orientation, neglecting exploration of the entire orientation design space.","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139142768","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 : 2023-12-26DOI: 10.1108/rpj-02-2023-0068
Raghad Ahmed Alaloosi, O. Çomaklı, Mustafa Yazıcı, Ziad A. Taha
Purpose This paper aims to investigate the influence of scan speed on the corrosion and tribocorrosion features of the CoCrMoW samples fabricated via the selective laser melting (SLM) process. Design/methodology/approach CoCrMoW samples were produced by SLM at different scan speeds. Produced samples were made via structural surveys (X-ray diffraction examinations and scanning electron microscopic analyses), hardness measurements and electrochemical and tribocorrosion experiments. Findings Outcomes displayed that the corrosion and tribocorrosion properties of CoCrMoW alloy were significantly influenced by scanning speeds. Also, these properties of the alloy increased with increasing scanning speeds. CoCrMoW samples produced at a laser scan speed of 1,000 mm/s showed the best resistance to corrosion and tribocorrosion. This could be related to the high hardness and low grain structure of the fabricated samples. Originality/value This paper may be a practical reference and offers insight into the effect of scanning speeds on the increase of hardness, tribological and corrosion performance of CoCrMoW alloys. This study can help in the further advancement of cobalt-chromium alloy in situ produced by SLM for both electrochemical and tribocorrosion behavior for biomedical applications.
{"title":"Effect of scan speed on corrosion and tribocorrosion properties of cobalt-chromium alloy in situ produced by selective laser melting","authors":"Raghad Ahmed Alaloosi, O. Çomaklı, Mustafa Yazıcı, Ziad A. Taha","doi":"10.1108/rpj-02-2023-0068","DOIUrl":"https://doi.org/10.1108/rpj-02-2023-0068","url":null,"abstract":"Purpose This paper aims to investigate the influence of scan speed on the corrosion and tribocorrosion features of the CoCrMoW samples fabricated via the selective laser melting (SLM) process. Design/methodology/approach CoCrMoW samples were produced by SLM at different scan speeds. Produced samples were made via structural surveys (X-ray diffraction examinations and scanning electron microscopic analyses), hardness measurements and electrochemical and tribocorrosion experiments. Findings Outcomes displayed that the corrosion and tribocorrosion properties of CoCrMoW alloy were significantly influenced by scanning speeds. Also, these properties of the alloy increased with increasing scanning speeds. CoCrMoW samples produced at a laser scan speed of 1,000 mm/s showed the best resistance to corrosion and tribocorrosion. This could be related to the high hardness and low grain structure of the fabricated samples. Originality/value This paper may be a practical reference and offers insight into the effect of scanning speeds on the increase of hardness, tribological and corrosion performance of CoCrMoW alloys. This study can help in the further advancement of cobalt-chromium alloy in situ produced by SLM for both electrochemical and tribocorrosion behavior for biomedical applications.","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139155251","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 : 2023-12-21DOI: 10.1108/rpj-05-2023-0165
M. Ghasempour-Mouziraji, Daniel Afonso, Saman Hosseinzadeh, Constantinos Goulas, Mojtaba Najafizadeh, Morteza Hosseinzadeh, D.D. Ganji, Ricardo Alves de Sousa
Purpose The purpose of this paper is to assess the feasibility of analytical models, specifically the radial basis function method, Akbari–Ganji method and Gaussian method, in conjunction with the finite element method. The aim is to examine the impact of processing parameters on temperature history. Design/methodology/approach Through analytical investigation and finite element simulation, this research examines the influence of processing parameters on temperature history. Simufact software with a thermomechanical approach was used for finite element simulation, while radial basis function, Akbari–Ganji and Gaussian methods were used for analytical modeling to solve the heat transfer differential equation. Findings The accuracy of both finite element and analytical methods was validated with about 90%. The findings revealed direct relationships between thermal conductivity (from 100 to 200), laser power (from 400 to 800 W), heat source depth (from 0.35 to 0.75) and power absorption coefficient (from 0.4 to 0.8). Increasing the values of these parameters led to higher temperature history. On the other hand, density (from 7,600 to 8,200), emission coefficient (from 0.5 to 0.7) and convective heat transfer (from 35 to 90) exhibited an inverse relationship with temperature history. Originality/value The application of analytical modeling, particularly the utilization of the Akbari–Ganji, radial basis functions and Gaussian methods, showcases an innovative approach to studying directed energy deposition. This analytical investigation offers an alternative to relying solely on experimental procedures, potentially saving time and resources in the optimization of DED processes.
{"title":"Modeling the effect of processing parameters on temperature history in Directed Energy Deposition: an analytical and finite element approach","authors":"M. Ghasempour-Mouziraji, Daniel Afonso, Saman Hosseinzadeh, Constantinos Goulas, Mojtaba Najafizadeh, Morteza Hosseinzadeh, D.D. Ganji, Ricardo Alves de Sousa","doi":"10.1108/rpj-05-2023-0165","DOIUrl":"https://doi.org/10.1108/rpj-05-2023-0165","url":null,"abstract":"\u0000Purpose\u0000The purpose of this paper is to assess the feasibility of analytical models, specifically the radial basis function method, Akbari–Ganji method and Gaussian method, in conjunction with the finite element method. The aim is to examine the impact of processing parameters on temperature history.\u0000\u0000\u0000Design/methodology/approach\u0000Through analytical investigation and finite element simulation, this research examines the influence of processing parameters on temperature history. Simufact software with a thermomechanical approach was used for finite element simulation, while radial basis function, Akbari–Ganji and Gaussian methods were used for analytical modeling to solve the heat transfer differential equation.\u0000\u0000\u0000Findings\u0000The accuracy of both finite element and analytical methods was validated with about 90%. The findings revealed direct relationships between thermal conductivity (from 100 to 200), laser power (from 400 to 800 W), heat source depth (from 0.35 to 0.75) and power absorption coefficient (from 0.4 to 0.8). Increasing the values of these parameters led to higher temperature history. On the other hand, density (from 7,600 to 8,200), emission coefficient (from 0.5 to 0.7) and convective heat transfer (from 35 to 90) exhibited an inverse relationship with temperature history.\u0000\u0000\u0000Originality/value\u0000The application of analytical modeling, particularly the utilization of the Akbari–Ganji, radial basis functions and Gaussian methods, showcases an innovative approach to studying directed energy deposition. This analytical investigation offers an alternative to relying solely on experimental procedures, potentially saving time and resources in the optimization of DED processes.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138952634","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 : 2023-12-21DOI: 10.1108/rpj-12-2022-0413
Rafael Pereira Ferreira, L. Vilarinho, A. Scotti
Purpose This study aims to propose and evaluate the progress in the basic-pixel (a strategy to generate continuous trajectories that fill out the entire surface) algorithm towards performance gain. The objective is also to investigate the operational efficiency and effectiveness of an enhanced version compared with conventional strategies. Design/methodology/approach For the first objective, the proposed methodology is to apply the improvements proposed in the basic-pixel strategy, test it on three demonstrative parts and statistically evaluate the performance using the distance trajectory criterion. For the second objective, the enhanced-pixel strategy is compared with conventional strategies in terms of trajectory distance, build time and the number of arcs starts and stops (operational efficiency) and targeting the nominal geometry of a part (operational effectiveness). Findings The results showed that the improvements proposed to the basic-pixel strategy could generate continuous trajectories with shorter distances and comparable building times (operational efficiency). Regarding operational effectiveness, the parts built by the enhanced-pixel strategy presented lower dimensional deviation than the other strategies studied. Therefore, the enhanced-pixel strategy appears to be a good candidate for building more complex printable parts and delivering operational efficiency and effectiveness. Originality/value This paper presents an evolution of the basic-pixel strategy (a space-filling strategy) with the introduction of new elements in the algorithm and proves the improvement of the strategy’s performance with this. An interesting comparison is also presented in terms of operational efficiency and effectiveness between the enhanced-pixel strategy and conventional strategies.
{"title":"Enhanced-pixel strategy for wire arc additive manufacturing trajectory planning: operational efficiency and effectiveness analyses","authors":"Rafael Pereira Ferreira, L. Vilarinho, A. Scotti","doi":"10.1108/rpj-12-2022-0413","DOIUrl":"https://doi.org/10.1108/rpj-12-2022-0413","url":null,"abstract":"\u0000Purpose\u0000This study aims to propose and evaluate the progress in the basic-pixel (a strategy to generate continuous trajectories that fill out the entire surface) algorithm towards performance gain. The objective is also to investigate the operational efficiency and effectiveness of an enhanced version compared with conventional strategies.\u0000\u0000\u0000Design/methodology/approach\u0000For the first objective, the proposed methodology is to apply the improvements proposed in the basic-pixel strategy, test it on three demonstrative parts and statistically evaluate the performance using the distance trajectory criterion. For the second objective, the enhanced-pixel strategy is compared with conventional strategies in terms of trajectory distance, build time and the number of arcs starts and stops (operational efficiency) and targeting the nominal geometry of a part (operational effectiveness).\u0000\u0000\u0000Findings\u0000The results showed that the improvements proposed to the basic-pixel strategy could generate continuous trajectories with shorter distances and comparable building times (operational efficiency). Regarding operational effectiveness, the parts built by the enhanced-pixel strategy presented lower dimensional deviation than the other strategies studied. Therefore, the enhanced-pixel strategy appears to be a good candidate for building more complex printable parts and delivering operational efficiency and effectiveness.\u0000\u0000\u0000Originality/value\u0000This paper presents an evolution of the basic-pixel strategy (a space-filling strategy) with the introduction of new elements in the algorithm and proves the improvement of the strategy’s performance with this. An interesting comparison is also presented in terms of operational efficiency and effectiveness between the enhanced-pixel strategy and conventional strategies.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138952908","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 : 2023-12-20DOI: 10.1108/rpj-04-2023-0150
Prashant Anerao, A. Kulkarni, Y. Munde
Purpose This paper aims to investigate the current state of biocomposites used in fused deposition modelling (FDM) with a focus on their mechanical characteristics. Design/methodology/approach The study presents a variety of biocomposite materials that have been used in filaments for 3D printing by different researchers. The process of making filaments is then described, followed by a discussion of the process parameters associated with the FDM. Findings To achieve better mechanical properties of 3D-printed parts, it is essential to optimize the process parameters of FDM while considering the characteristics of the biocomposite material. Polylactic acid is considered the most promising matrix material due to its biodegradability and lower cost. Moreover, the use of natural fibres like hemp, flax and sugarcane bagasse as reinforcement to the polymer in FDM filaments improves the mechanical performance of printed parts. Originality/value The paper discusses the influence of critical process parameters of FDM like raster angle, layer thickness, infill density, infill pattern and extruder temperature on the mechanical properties of 3D-printed biocomposite.
{"title":"A review on exploration of the mechanical characteristics of 3D-printed biocomposites fabricated by fused deposition modelling (FDM)","authors":"Prashant Anerao, A. Kulkarni, Y. Munde","doi":"10.1108/rpj-04-2023-0150","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0150","url":null,"abstract":"\u0000Purpose\u0000This paper aims to investigate the current state of biocomposites used in fused deposition modelling (FDM) with a focus on their mechanical characteristics.\u0000\u0000\u0000Design/methodology/approach\u0000The study presents a variety of biocomposite materials that have been used in filaments for 3D printing by different researchers. The process of making filaments is then described, followed by a discussion of the process parameters associated with the FDM.\u0000\u0000\u0000Findings\u0000To achieve better mechanical properties of 3D-printed parts, it is essential to optimize the process parameters of FDM while considering the characteristics of the biocomposite material. Polylactic acid is considered the most promising matrix material due to its biodegradability and lower cost. Moreover, the use of natural fibres like hemp, flax and sugarcane bagasse as reinforcement to the polymer in FDM filaments improves the mechanical performance of printed parts.\u0000\u0000\u0000Originality/value\u0000The paper discusses the influence of critical process parameters of FDM like raster angle, layer thickness, infill density, infill pattern and extruder temperature on the mechanical properties of 3D-printed biocomposite.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138956920","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 : 2023-12-20DOI: 10.1108/rpj-01-2023-0027
İ. T. Gülenç, Mingwen Bai, Ria L. Mitchell, Iain Todd, B. Inkson
Purpose Current methods for the preparation of composite powder feedstock for selective laser melting (SLM) rely on costly nanoparticles or yield inconsistent powder morphology. This study aims to develop a cost-effective Ti6Al4V-carbon feedstock, which preserves the parent Ti6Al4V particle’s flowability, and produces in situ TiC-reinforced Ti6Al4V composites with superior traits. Design/methodology/approach Ti6Al4V particles were directly mixed with graphite flakes in a planetary ball mill. This composite powder feedstock was used to manufacture in situ TiC-Ti6Al4V composites using various energy densities. Relative porosity, microstructure and hardness of the composites were evaluated for different SLM processing parameters. Findings Homogeneously carbon-coated Ti6Al4V particles were produced by direct mixing. After SLM processing, in situ grown 100–500 nm size TiC nanoparticles were distributed within the α-martensite Ti6Al4V matrix. The formation of TiC particles refines the Ti6Al4V β grain size. Relative density varied between 96.4% and 99.5% depending on the processing parameters. Hatch distance, exposure time and point distance were all effective on relative porosity change, whereas only exposure time and point distance were effective on hardness change. Originality/value This work introduces a novel, cost-effective powder feedstock preparation method for SLM manufacture of Ti6Al4V-TiC composites. The in situ SLM composites achieved in this study have high relative density values, well-dispersed TiC nanoparticles and increased hardness. In addition, the feedstock preparation method can be readily adapted for various matrix and reinforcement materials in future studies.
{"title":"In situ TiC reinforced Ti6Al4V matrix composites manufactured via selective laser melting","authors":"İ. T. Gülenç, Mingwen Bai, Ria L. Mitchell, Iain Todd, B. Inkson","doi":"10.1108/rpj-01-2023-0027","DOIUrl":"https://doi.org/10.1108/rpj-01-2023-0027","url":null,"abstract":"\u0000Purpose\u0000Current methods for the preparation of composite powder feedstock for selective laser melting (SLM) rely on costly nanoparticles or yield inconsistent powder morphology. This study aims to develop a cost-effective Ti6Al4V-carbon feedstock, which preserves the parent Ti6Al4V particle’s flowability, and produces in situ TiC-reinforced Ti6Al4V composites with superior traits.\u0000\u0000\u0000Design/methodology/approach\u0000Ti6Al4V particles were directly mixed with graphite flakes in a planetary ball mill. This composite powder feedstock was used to manufacture in situ TiC-Ti6Al4V composites using various energy densities. Relative porosity, microstructure and hardness of the composites were evaluated for different SLM processing parameters.\u0000\u0000\u0000Findings\u0000Homogeneously carbon-coated Ti6Al4V particles were produced by direct mixing. After SLM processing, in situ grown 100–500 nm size TiC nanoparticles were distributed within the α-martensite Ti6Al4V matrix. The formation of TiC particles refines the Ti6Al4V β grain size. Relative density varied between 96.4% and 99.5% depending on the processing parameters. Hatch distance, exposure time and point distance were all effective on relative porosity change, whereas only exposure time and point distance were effective on hardness change.\u0000\u0000\u0000Originality/value\u0000This work introduces a novel, cost-effective powder feedstock preparation method for SLM manufacture of Ti6Al4V-TiC composites. The in situ SLM composites achieved in this study have high relative density values, well-dispersed TiC nanoparticles and increased hardness. In addition, the feedstock preparation method can be readily adapted for various matrix and reinforcement materials in future studies.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138953654","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 : 2023-12-20DOI: 10.1108/rpj-04-2023-0149
Jibing Chen, Shisen Huang, Nan Chen, Chengze Yu, Shanji Yu, Bowen Liu, Maohui Hu, Ruidi Li
Purpose This paper aims to identify the optimal forming angle for the selective laser melting (SLM) process and evaluate the mechanical properties of the SLM-formed GH3536 alloy in the aero-engine field. Design/methodology/approach Forming the samples with optimized parameters and analyzing the microstructure and properties of the block samples in different forming angles with scanning electron microscope, XRD, etc. so as to analyze and reveal the laws and mechanism of the block samples in different forming angles by SLM. Findings There are few cracks on the construction surface of SLM formed samples, and the microstructure shows columnar subgrains and cellular subgrains. The segregation of metal elements was not observed in the microstructure. The pattern shows strong texture strength on the (111) crystal plane. In the sample, the tensile strength of 60° sample is the highest, the plasticity of 90° forming sample is the best, the comprehensive property of 45° sample is the best and the fracture mode is plastic fracture. The comprehensive performance of the part is the best under the forming angle of 45°. To ensure the part size, performance and support structure processing, additional dimensions are added to the part structure. Originality/value In this paper, how to make samples with different forming angles is described. Combined with the standard of forged GH3536 alloy, the microstructure and properties of the samples are analyzed, and the optimal forming angle is obtained.
{"title":"Effect of forming angle on the microstructure and properties of GH3536 nickel-based superalloy formed by SLM","authors":"Jibing Chen, Shisen Huang, Nan Chen, Chengze Yu, Shanji Yu, Bowen Liu, Maohui Hu, Ruidi Li","doi":"10.1108/rpj-04-2023-0149","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0149","url":null,"abstract":"\u0000Purpose\u0000This paper aims to identify the optimal forming angle for the selective laser melting (SLM) process and evaluate the mechanical properties of the SLM-formed GH3536 alloy in the aero-engine field.\u0000\u0000\u0000Design/methodology/approach\u0000Forming the samples with optimized parameters and analyzing the microstructure and properties of the block samples in different forming angles with scanning electron microscope, XRD, etc. so as to analyze and reveal the laws and mechanism of the block samples in different forming angles by SLM.\u0000\u0000\u0000Findings\u0000There are few cracks on the construction surface of SLM formed samples, and the microstructure shows columnar subgrains and cellular subgrains. The segregation of metal elements was not observed in the microstructure. The pattern shows strong texture strength on the (111) crystal plane. In the sample, the tensile strength of 60° sample is the highest, the plasticity of 90° forming sample is the best, the comprehensive property of 45° sample is the best and the fracture mode is plastic fracture. The comprehensive performance of the part is the best under the forming angle of 45°. To ensure the part size, performance and support structure processing, additional dimensions are added to the part structure.\u0000\u0000\u0000Originality/value\u0000In this paper, how to make samples with different forming angles is described. Combined with the standard of forged GH3536 alloy, the microstructure and properties of the samples are analyzed, and the optimal forming angle is obtained.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138953881","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 : 2023-12-15DOI: 10.1108/rpj-03-2023-0114
M. A. Mahmood, Chioibasu Diana, Uzair Sajjad, S. Mihai, Ion Tiseanu, Andrei C. Popescu
Purpose Porosity is a commonly analyzed defect in the laser-based additive manufacturing processes owing to the enormous thermal gradient caused by repeated melting and solidification. Currently, the porosity estimation is limited to powder bed fusion. The porosity estimation needs to be explored in the laser melting deposition (LMD) process, particularly analytical models that provide cost- and time-effective solutions compared to finite element analysis. For this purpose, this study aims to formulate two mathematical models for deposited layer dimensions and corresponding porosity in the LMD process. Design/methodology/approach In this study, analytical models have been proposed. Initially, deposited layer dimensions, including layer height, width and depth, were calculated based on the operating parameters. These outputs were introduced in the second model to estimate the part porosity. The models were validated with experimental data for Ti6Al4V depositions on Ti6Al4V substrate. A calibration curve (CC) was also developed for Ti6Al4V material and characterized using X-ray computed tomography. The models were also validated with the experimental results adopted from literature. The validated models were linked with the deep neural network (DNN) for its training and testing using a total of 6,703 computations with 1,500 iterations. Here, laser power, laser scanning speed and powder feeding rate were selected inputs, whereas porosity was set as an output. Findings The computations indicate that owing to the simultaneous inclusion of powder particulates, the powder elements use a substantial percentage of the laser beam energy for their melting, resulting in laser beam energy attenuation and reducing thermal value at the substrate. The primary operating parameters are directly correlated with the number of layers and total height in CC. Through X-ray computed tomography analyses, the number of layers showed a straightforward correlation with mean sphericity, while a converse relation was identified with the number, mean volume and mean diameter of pores. DNN and analytical models showed 2%–3% and 7%–9% mean absolute deviations, respectively, compared to the experimental results. Originality/value This research provides a unique solution for LMD porosity estimation by linking the developed analytical computational models with artificial neural networking. The presented framework predicts the porosity in the LMD-ed parts efficiently.
目的由于反复熔化和凝固造成的巨大热梯度，气孔是激光增材制造工艺中常见的缺陷。目前，孔隙率估算仅限于粉末床熔融。在激光熔融沉积（LMD）过程中，需要对孔隙率估算进行探索，特别是与有限元分析相比，分析模型能提供成本和时间效益高的解决方案。为此，本研究旨在为激光熔融沉积过程中的沉积层尺寸和相应的孔隙率制定两个数学模型。首先，根据操作参数计算沉积层尺寸，包括层高、宽度和深度。这些输出结果被引入第二个模型，以估算零件的孔隙率。这些模型与 Ti6Al4V 基底上 Ti6Al4V 沉积的实验数据进行了验证。还为 Ti6Al4V 材料开发了校准曲线 (CC)，并使用 X 射线计算机断层扫描进行了表征。模型还与文献中采用的实验结果进行了验证。经过验证的模型与深度神经网络（DNN）相连接，通过 1,500 次迭代共 6,703 次计算对其进行训练和测试。计算结果表明，由于同时加入了粉末颗粒，粉末元素在熔化过程中消耗了很大比例的激光束能量，导致激光束能量衰减，降低了基底的热值。主要运行参数与 CC 的层数和总高度直接相关。通过 X 射线计算机断层扫描分析，层数与平均球度直接相关，而与孔的数量、平均体积和平均直径的关系则相反。与实验结果相比，DNN 和分析模型分别显示出 2%-3% 和 7%-9% 的平均绝对偏差。 原创性/价值 这项研究通过将开发的分析计算模型与人工神经网络联系起来，为 LMD 孔隙度估算提供了独特的解决方案。所提出的框架可有效预测 LMD 零件中的孔隙率。
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Pub Date : 2023-12-15DOI: 10.1108/rpj-08-2023-0266
Mohamed Ahmed Omrane, Raphaël Côté, Vincent Demers
Purpose The purpose of this study is to determine the material extrusion (MEX) printability envelope of a new kind of low-viscosity powder-binder feedstocks using rheological properties. Design/methodology/approach Formulation of 13 feedstocks (variation of solid loading 60–67 Vol.% and thickening agent proportion 3–15 Vol.%) that were characterized and printed at different temperatures. Findings Three rheological models were successfully used to define the viscosity envelope, producing stable and defect-free printing. At a shear deformation rate experienced by the feedstock in the nozzle ranging from 100 to 300 s–1, it was confirmed that metal injection molding (MIM) feedstocks exhibiting a low viscosity between 100 and 150 Pa s could be printed using an extrusion temperature as low as 85 °C. Practical implications MEX can be used in synergy with MIM to accelerate mold development for a new injected part or simply as a replacement for MIM when the cost of the mold becomes too high for very small production volumes. Originality/value Correlation between the rheological properties of this new generation of low-viscosity feedstocks and MEX printability has been demonstrated for the first time.
本研究的目的是利用流变特性确定新型低粘度粉末粘合剂原料的材料挤压（MEX）印刷适性包络线。设计/方法/方法配制了 13 种原料（固体含量变化范围为 60-67 Vol.%，增稠剂比例变化范围为 3-15 Vol.%），并在不同温度下进行了表征和印刷。当原料在喷嘴中的剪切变形率在 100 到 300 s-1 之间时，可以确认粘度在 100 到 150 Pa s 之间的金属注射成型（MIM）原料可以在低至 85 °C 的挤出温度下进行印刷。原创性/价值首次证明了新一代低粘度原料的流变特性与 MEX 印刷能力之间的相关性。
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Pub Date : 2023-12-12DOI: 10.1108/rpj-06-2023-0185
Austin R. Colon, David O. Kazmer, Amy M. Peterson, Jonathan E. Seppala
Purpose A main cause of defects within material extrusion (MatEx) additive manufacturing is the nonisothermal condition in the hot end, which causes inconsistent extrusion and polymer welding. This paper aims to validate a custom hot end design intended to heat the thermoplastic to form a melt prior to the nozzle and to reduce variability in melt temperature. A full 3D temperature verification methodology for hot ends is also presented. Design/methodology/approach Infrared (IR) thermography of steady-state extrusion for varying volumetric flow rates, hot end temperature setpoints and nozzle orifice diameters provides data for model validation. A finite-element model is used to predict the temperature of the extrudate. Model tuning demonstrates the effects of different model assumptions on the simulated melt temperature. Findings The experimental results show that the measured temperature and variance are functions of volumetric flow rate, temperature setpoint and the nozzle orifice diameter. Convection to the surrounding air is a primary heat transfer mechanism. The custom hot end brings the melt to its setpoint temperature prior to entering the nozzle. Originality/value This work provides a full set of steady-state IR thermography data for various parameter settings. It also provides insight into the performance of a custom hot end designed to improve the robustness of melting in MatEx. Finally, it proposes a strategy for modeling such systems that incorporates the metal components and the air around the system.
{"title":"Steady melting in material extrusion additive manufacturing","authors":"Austin R. Colon, David O. Kazmer, Amy M. Peterson, Jonathan E. Seppala","doi":"10.1108/rpj-06-2023-0185","DOIUrl":"https://doi.org/10.1108/rpj-06-2023-0185","url":null,"abstract":"\u0000Purpose\u0000A main cause of defects within material extrusion (MatEx) additive manufacturing is the nonisothermal condition in the hot end, which causes inconsistent extrusion and polymer welding. This paper aims to validate a custom hot end design intended to heat the thermoplastic to form a melt prior to the nozzle and to reduce variability in melt temperature. A full 3D temperature verification methodology for hot ends is also presented.\u0000\u0000\u0000Design/methodology/approach\u0000Infrared (IR) thermography of steady-state extrusion for varying volumetric flow rates, hot end temperature setpoints and nozzle orifice diameters provides data for model validation. A finite-element model is used to predict the temperature of the extrudate. Model tuning demonstrates the effects of different model assumptions on the simulated melt temperature.\u0000\u0000\u0000Findings\u0000The experimental results show that the measured temperature and variance are functions of volumetric flow rate, temperature setpoint and the nozzle orifice diameter. Convection to the surrounding air is a primary heat transfer mechanism. The custom hot end brings the melt to its setpoint temperature prior to entering the nozzle.\u0000\u0000\u0000Originality/value\u0000This work provides a full set of steady-state IR thermography data for various parameter settings. It also provides insight into the performance of a custom hot end designed to improve the robustness of melting in MatEx. Finally, it proposes a strategy for modeling such systems that incorporates the metal components and the air around the system.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2023-12-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138633217","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}
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