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Effect of recycled powder and gear profile into the functionality of additive manufacturing polymer gears 回收粉末和齿轮轮廓对增材制造聚合物齿轮功能的影响
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-12-08 DOI: 10.1108/rpj-06-2023-0199
F. Calignano, Alessandro Bove, Vincenza Mercurio, G. Marchiandi
PurposePolymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.Design/methodology/approachTechnological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.FindingsResults show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.Originality/valueIn the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.
聚合物激光粉末床熔融(PBF-LB/P)是一种可持续的增材制造技术,因为它可以多次回收粉末,并且可以在没有支撑结构和后续组装的情况下制造齿轮。然而,与其他添加剂技术(如材料挤压生产齿轮)相比,在工艺中有一些限制因素对其采用产生负面影响。本研究的目的是为了证明,它是有可能克服的问题,由于物理过程产生准确的机制。设计/方法/方法技术方面,如方向,轮轴厚度和粉末回收程度进行了检查。此外,还将齿形的演化作为设计参数,以提供基于齿轮的机构的可制造性图。结果表明,齿轮的功能取决于所使用的粉末类型,100%初榨或50%初榨,50%再循环五个周期。在齿轮上的槽的应用与100%的原始粉末生产允许该机构很容易地解锁,无论方向和轮轴厚度。应用特定的演化剖面独立于参考圆的直径上的垂直定向齿轮保证了旋转连续性,同时保留了组装机构的功能。文献中对PBF-LB/P工艺中材料时效和再利用的研究较多,主要集中在粉末劣化机理、粉末流动性、零件的微观结构和力学性能以及工艺参数等方面。相反,这项研究的重点是齿轮的功能,这代表了该技术可以取得巨大成功的应用之一,通过分析可能损害它的两个主要影响:回收粉末和施工期间的垂直方向。
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引用次数: 0
The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts 加法和减法制造的中心内部特征对 inconel-718 零件微观结构和机械性能的影响
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-12-07 DOI: 10.1108/rpj-12-2022-0420
Murat Isik, Isa Emami Tabrizi, Raja Muhammad Awais Khan, Mehmet Yildiz, E. Aydogan, B. Koc
PurposeIn recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and machinery industries. Most complex or assembled parts require internal features (IF) such as holes, channels, slots, or guides for locational and mating requirements. Therefore, it is critical to understand and compare the structural and mechanical properties of additively manufactured and conventionally machined IFs.Design/methodology/approachIn this study, mechanical and microstructural properties of Inconel 718 (Inc718) alloy internal features, manufactured either as-built with AM or machining of additively manufactured (AMed) part thereafter were investigated.FindingsThe results showed that the average ultimate tensile strength (UTS) of additively manufactured center internal feature (AM-IF) is almost analogous to the machined internal feature (M-IF). However, the yield strength of M-IF is greater than that of AM-IF due the greater surface roughness of the internal feature in AM-IF, which is deemed to surpass the effect of microstructure on the mechanical performance. The results of digital image correlation (DIC) analysis suggest that AM-IF and M-IF conditions have similar strain values under the same stress levels but the specimens with as built IF have a more locally ductile region around their IF, which is confirmed by hardness test results. But this does not change global elongation behavior. The microstructural evolution starting from as-built (AB) and heat-treated (HT) samples to specimens with IF are examined. The microstructure of HT specimens has bimodal grain structure with d phase while the AB specimens display a very fine dendritic microstructure with the presence of carbides. Although they both have close values, machined specimens have a higher frequency of finer grains based on SEM images.Originality/valueIt was shown that the concurrent creation of the IF during AM can provide a final part with a preserved ultimate tensile strength and elongation but a decreased yield strength. The variation in UTS of AM-IF increases due to the surface roughness near the internal feature as compared to smooth internal surfaces in M-IF. Hence, the outcomes of this study are believed to be valuable for the industry in terms of determining the appropriate production strategy of parts with IF using AM and postprocessing processes.
近年来,增材制造(AM)已开始用于制造航空航天、汽车和机械行业的关键应用的实际功能部件和组件。大多数复杂或组装的部件需要内部特征(IF),如孔、通道、槽或导向,以满足定位和配合要求。因此,了解和比较增材制造和常规加工的if的结构和力学性能是至关重要的。设计/方法/方法在本研究中,研究了用增材制造制造或增材制造(AMed)零件加工的Inconel 718 (Inc718)合金内部特征的机械和显微组织性能。结果表明:增材制造中心内特征(AM-IF)的平均极限抗拉强度(UTS)与加工中心内特征(M-IF)的平均极限抗拉强度基本相似;然而,由于AM-IF内部特征的表面粗糙度更大,M-IF的屈服强度大于AM-IF,这被认为超过了微观结构对力学性能的影响。数字图像相关分析(DIC)结果表明,在相同的应力水平下,AM-IF和M-IF条件下的应变值相似,但相同IF条件下的试样在IF周围有一个更局部的延展性区域,这一点得到了硬度测试结果的证实。但这不会改变整体延伸行为。研究了从建成(AB)和热处理(HT)试样到IF试样的显微组织演变。高温合金的显微组织为双峰型d相晶粒组织,而高温合金的显微组织为极细的枝晶组织,并伴有碳化物的存在。虽然两者的数值相近,但根据SEM图像,加工后的试样具有更高的细晶粒频率。独创性/价值研究表明,在AM过程中同时创建IF可以提供最终零件,保留极限抗拉强度和伸长率,但降低屈服强度。与M-IF的光滑内表面相比,AM-IF的UTS变化增加是由于内部特征附近的表面粗糙度。因此,本研究的结果被认为是有价值的行业在确定适当的生产策略与IF使用增材制造和后处理过程。
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引用次数: 0
Study on the mechanism and performance of 3D-printed PLA/epoxy composite for stab resistance 研究 3D 打印聚乳酸/环氧树脂复合材料的抗稳定机理和性能
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-12-01 DOI: 10.1108/rpj-05-2023-0172
Zhe Du, Changjie Chen, Xinhou Wang
PurposeStab-resistant body armor (SRBA) is used to protect the body from sharp knives. However, most SRBA materials currently have the disadvantages of large weight and thickness. This paper aims to prepare lightweight and high-performance SRBA by 3D printing truss structure and resin-filling method.Design/methodology/approachThe stab resistance truss structure was prepared by the fused deposition modeling method, and the composite structure was formed after filling with resin for dynamic and quasi-static stab tests. The optimized structural plate can meet the standard GA68-2019. Digital image correlation technology was used to analyze the local strain changes during puncture. The puncture failure mode was summarized by the final failure morphologies. The explicit dynamics module in ANSYS Workbench was used to analyze the design of the overlapped structure stab resistance process in this paper.FindingsThe stab resistance performance of the 3D-printed structural plate is affected by the internal filling pattern. The stab resistance performance of 3D-printed structural parts was significantly improved after resin filling. The 50%-diamond-PLA-epoxy, with a thickness of only 5 mm was able to meet the stab resistance standard. Resins are used to increase the strength and hardness of the material but also to increase crack propagation and reduce the toughness of the material. The overlapping semicircular structure was inspired by the exoskeleton structure of the demon iron beetle, which improved the stab resistance between gaps. The truss structure can effectively disperse stress for toughening. The filled resin was reinforced by absorbing impact energy.Originality/valueThe 3D-printed resin-filled truss structure can be used to prepare high-performance stab resistance structural plates, which balance the toughness and strength of the overall structure and ultimately reduce the thickness and weight of the SRBA.
目的抗刺防弹衣(SRBA)用于保护身体免受锋利刀具的伤害。然而,目前大多数SRBA材料都存在重量大、厚度大的缺点。采用3D打印桁架结构和树脂填充法制备轻质高性能SRBA材料。设计/方法/方法采用熔融沉积建模方法制备抗刺桁架结构,填充树脂后形成复合结构,进行动态和准静态刺刺试验。优化后的结构板满足GA68-2019标准。采用数字图像相关技术对穿刺过程中局部应变变化进行分析。通过最终的失效形态总结了穿刺失效模式。本文利用ANSYS Workbench中的显式动力学模块对叠置结构的抗刺过程设计进行了分析。发现3d打印结构板的抗刺性能受内部填充模式的影响。树脂填充后3d打印结构件的抗刺伤性能明显提高。50%金刚石- pla -环氧树脂的厚度仅为5mm,能够满足抗刺伤标准。树脂用于增加材料的强度和硬度,但也用于增加裂纹扩展和降低材料的韧性。重叠的半圆形结构的灵感来自于恶魔铁甲虫的外骨骼结构,它提高了间隙之间的抗刺性。桁架结构能有效分散应力增韧。填充树脂通过吸收冲击能进行增强。3d打印树脂填充桁架结构可用于制备高性能抗刺结构板,平衡整体结构的韧性和强度,最终降低SRBA的厚度和重量。
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引用次数: 0
Powder bed defect classification methods: deep learning vs traditional machine learning 粉末床缺陷分类方法:深度学习与传统机器学习
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-12-01 DOI: 10.1108/rpj-07-2023-0243
Francois Du Rand, André Francois van der Merwe, Malan van Tonder
PurposeThis paper aims to discuss the development of a defect classification system that can be used to detect and classify powder bed surface defects from captured layer images without the need for specialised computational hardware. The idea is to develop this system by making use of more traditional machine learning (ML) models instead of using computationally intensive deep learning (DL) models.Design/methodology/approachThe approach that is used by this study is to use traditional image processing and classification techniques that can be applied to captured layer images to detect and classify defects without the need for DL algorithms.FindingsThe study proved that a defect classification algorithm could be developed by making use of traditional ML models with a high degree of accuracy and the images could be processed at higher speeds than typically reported in literature when making use of DL models.Originality/valueThis paper addresses a need that has been identified for a high-speed defect classification algorithm that can detect and classify defects without the need for specialised hardware that is typically used when making use of DL technologies. This is because when developing closed-loop feedback systems for these additive manufacturing machines, it is important to detect and classify defects without inducing additional delays to the control system.
本文旨在讨论缺陷分类系统的开发,该系统可用于从捕获的层图像中检测和分类粉末床表面缺陷,而无需专门的计算硬件。这个想法是通过使用更传统的机器学习(ML)模型来开发这个系统,而不是使用计算密集型的深度学习(DL)模型。设计/方法/方法本研究使用的方法是使用传统的图像处理和分类技术,这些技术可以应用于捕获的层图像来检测和分类缺陷,而不需要DL算法。研究结果证明,利用传统ML模型可以开发出一种精度较高的缺陷分类算法,并且使用DL模型处理图像的速度比文献中通常报道的要快。原创性/价值本文解决了对高速缺陷分类算法的需求,该算法可以检测和分类缺陷,而不需要在使用DL技术时通常使用的专门硬件。这是因为在为这些增材制造机器开发闭环反馈系统时,重要的是在不给控制系统带来额外延迟的情况下检测和分类缺陷。
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引用次数: 0
Predictive modeling for online in-plane shape deviation inspection and compensation of additive manufacturing 用于在线平面形状偏差检测和增材制造补偿的预测模型
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-12-01 DOI: 10.1108/rpj-03-2023-0076
Hao Wang, Hamzeh Al Shraida, Yu Jin
PurposeLimited geometric accuracy is one of the major challenges that hinder the wider application of additive manufacturing (AM). This paper aims to predict in-plane shape deviation for online inspection and compensation to prevent error accumulation and improve shape fidelity in AM.Design/methodology/approachA sequence-to-sequence model with an attention mechanism (Seq2Seq+Attention) is proposed and implemented to predict subsequent layers or the occluded toolpath deviations after the multiresolution alignment. A shape compensation plan can be performed for the large deviation predicted.FindingsThe proposed Seq2Seq+Attention model is able to provide consistent prediction accuracy. The compensation plan proposed based on the predicted deviation can significantly improve the printing fidelity for those layers detected with large deviations.Practical implicationsBased on the experiments conducted on the knee joint samples, the proposed method outperforms the other three machine learning methods for both subsequent layer and occluded toolpath deviation prediction.Originality/valueThis work fills a research gap for predicting in-plane deviation not only for subsequent layers but also for occluded paths due to the missing scanning measurements. It is also combined with the multiresolution alignment and change point detection to determine the necessity of a compensation plan with updated G-code.
有限的几何精度是阻碍增材制造(AM)广泛应用的主要挑战之一。本文旨在预测平面内形状偏差,用于在线检测和补偿,以防止误差积累,提高增材制造的形状保真度。设计/方法/方法提出并实现了一种具有注意机制的序列到序列模型(Seq2Seq+ attention),用于预测多分辨率对准后的后续层或被遮挡的刀具轨迹偏差。对于预测的较大偏差,可以执行形状补偿方案。结果提出的Seq2Seq+Attention模型能够提供一致的预测精度。对于检测到的偏差较大的层,提出的基于预测偏差的补偿方案可以显著提高打印保真度。基于膝关节样本的实验,该方法在后续层和闭塞刀具轨迹偏差预测方面都优于其他三种机器学习方法。独创性/价值这项工作填补了预测平面内偏差的研究空白,不仅对后续层,而且对由于缺少扫描测量而遮挡的路径。它还与多分辨率对准和变化点检测相结合,以确定更新g代码的补偿计划的必要性。
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引用次数: 0
On 3D printed intelligent diaphragmatic hernia sensor 关于 3D 打印智能膈疝传感器
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-11-29 DOI: 10.1108/rpj-05-2023-0179
Rupinder Singh, Gurwinder Singh, Arun Anand
Purpose The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an Internet of Things (IOT)-based solution. Design/methodology/approach The approach used in this study is based on a bibliographic analysis for the re-occurrence of DH in the bovine after surgery. Using SolidWorks and ANSYS, the computer-aided design model of the implant was 3D printed based on literature and discussions on surgical techniques with a veterinarian. To ensure the error-proof design, load test and strain–stress rate analyses with boundary distortion have been carried out for the implant sub-assembly. Findings An innovative IOT-based additive manufacturing solution has been presented for the construction of a mesh-type sensor (for the health monitoring of bovine after surgery). Originality/value An innovative mesh-type sensor has been fabricated by integration of metal and polymer 3D printing (comprising 17–4 precipitate hardened stainless steel and polyvinylidene fluoride-hydroxyapatite-chitosan) without sacrificing strength and specific absorption ratio value.
目的 本文旨在设计和制造一种智能 3D 打印传感器,作为基于物联网(IOT)的解决方案,用于监测牛膈膜疝(DH;手术后)的再次发生。 设计/方法/途径 本研究采用的方法基于对牛手术后 DH 复发的文献分析。使用 SolidWorks 和 ANSYS,根据文献和与兽医讨论的手术技术,三维打印了植入物的计算机辅助设计模型。为确保设计无误,还对植入体子组件进行了载荷测试和边界变形应变应力率分析。 研究结果 提出了一种创新的基于物联网的增材制造解决方案,用于制造网状传感器(用于手术后牛的健康监测)。 原创性/价值 在不牺牲强度和比吸收比值的情况下,通过整合金属和聚合物三维打印技术(由 17-4 沉淀硬化不锈钢和聚偏氟乙烯-羟基磷灰石-壳聚糖组成),制造出了创新型网状传感器。
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引用次数: 0
Fabrication of continuous woven E-glass fiber composite using vat photopolymerization additive manufacturing process 使用大桶光聚合增材制造工艺制造连续编织 E 玻璃纤维复合材料
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-11-20 DOI: 10.1108/rpj-02-2023-0062
Annada Prasad Moharana, Ratnesh Raj, A. Dixit
Purpose The industrial application of continuous glass fabric-reinforced polymer composites (GFRPCs) is growing; however, the manufacturing boundedness of complex structures and the high cost of molds restrict their use. This research proposes a three-dimensional (3 D) printing process for GFRPCs that allows low-cost and rapid fabrication of complex composite parts. Design/methodology/approach The composite is manufactured using a digital light processing (DLP) based Vat-photopolymerization (VPP) process. For the composites, suitable resin material and glass fabrics are chosen based on their strength, stiffness, and printability. Jacob's working curve characterizes the curing parameters for adequate adhesion between the matrix and fabrics. The tensile and flexural properties were examined using UTM. The fabric distribution and compactness of the cured resin were analyzed in scanning electron microscopy. Findings The result showed that the object could print at a glass fabric content of 40 volume%. In DLP-based VPP printing technology, the adequate exposure time was found to be 30 seconds for making a GFRPC. The tensile strength and Young's modulus values were increased by 5.54 and 8.81 times, respectively than non-reinforced cured specimens. The flexural strength and modulus were also effectively increased to 2.8 and 3 times more than the neat specimens. In addition, the process is found to help fabricate the functional component. Originality/value The experimental procedure to fabricate GFRPC specimens through DLP-based AM is a spectacular experimental approach.
目的 连续玻璃纤维增强聚合物复合材料(GFRPCs)的工业应用正在不断增长;然而,复杂结构的制造限制和模具的高成本限制了其应用。本研究提出了玻璃纤维增强聚合物复合材料的三维(3 D)打印工艺,可低成本、快速地制造复杂的复合材料部件。 设计/方法/途径 采用基于数字光处理(DLP)的蒸镀-光聚合(VPP)工艺制造复合材料。根据强度、刚度和可印刷性,为复合材料选择合适的树脂材料和玻璃纤维织物。雅各布工作曲线表征了基体和织物之间充分粘合的固化参数。使用 UTM 对拉伸和弯曲性能进行了检测。用扫描电子显微镜分析了固化树脂的织物分布和致密性。 结果表明,玻璃纤维织物含量为 40% 时,物体可以进行打印。在基于 DLP 的 VPP 印刷技术中,发现制作 GFRPC 的适当曝光时间为 30 秒。拉伸强度和杨氏模量值分别比非增强固化试样提高了 5.54 倍和 8.81 倍。抗弯强度和模量也分别比未加固的试样有效提高了 2.8 倍和 3 倍。此外,该工艺还有助于制造功能部件。 独创性/价值 通过基于 DLP 的 AM 制作 GFRPC 试样的实验程序是一种引人注目的实验方法。
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引用次数: 0
Direct-print thermally responsive 4D textiles by depositing PLA on prestretched fabrics 通过在预拉伸织物上沉积聚乳酸,直接打印热响应 4D 纺织品
IF 3.9 4区 工程技术 Q1 Engineering Pub Date : 2023-11-17 DOI: 10.1108/rpj-04-2023-0125
Jinyu Zhang, Danni Shen, yuxiang Yu, Defu Bao, Chao Li, Jiapei Qin
Purpose This study aims to develop a four-dimensional (4D) textile composite that self-forms upon thermal stimulation while eliminating thermomechanical programming steps by using fused deposition modeling (FDM) 3D printing technology, and tries to refine the product development path for this composite. Design/methodology/approach Polylactic acid (PLA) printing filaments were deposited on prestretched Lycra-knitted fabric using desktop-level FDM 3D printing technology to construct a three-layer structure of thermally responsive 4D textiles. Subsequently, the effects of different PLA thicknesses and Lycra knit fabric relative elongation on the permanent shape of thermally responsive 4D textiles were studied. Finally, a simulation program was written, and a case in this study demonstrates the usage of thermally responsive 4D textiles and the simulation program to design a wrist support product. Findings The constructed three-layer structure of PLA and Lycra knitted fabric can self-form under thermal stimulation. The material can also achieve reversible transformation between a permanent shape and multiple temporary shapes. Thinner PLA deposition and higher relative elongation of the Lycra-knitted fabric result in the greater curvature of the permanent shape of the thermally responsive 4D textile. The simulation program accurately predicted the permanent form of multiple basic shapes. Originality/value The proposed method enables 4D textiles to directly self-form upon thermal, which helps to improve the manufacturing efficiency of 4D textiles. The thermal responsiveness of the composite also contributes to building an intelligent human–material–environment interaction system.
目的 本研究旨在利用熔融沉积建模(FDM)三维打印技术开发一种四维(4D)纺织复合材料,该复合材料在热刺激下可自行成型,同时省去了热机械编程步骤,并尝试完善该复合材料的产品开发路径。 设计/方法/途径 利用桌面级 FDM 三维打印技术,将聚乳酸(PLA)打印长丝沉积在预拉伸莱卡针织面料上,构建三层结构的热响应 4D 纺织品。随后,研究了不同聚乳酸厚度和莱卡针织物相对伸长率对热响应 4D 纺织品永久形状的影响。最后,编写了一个仿真程序,并在本研究中通过一个案例演示了如何利用热响应 4D 纺织品和仿真程序设计手腕支撑产品。 研究结果 由聚乳酸和莱卡针织物构成的三层结构在热刺激下可自行成型。该材料还能在一个永久形状和多个临时形状之间实现可逆转换。更薄的聚乳酸沉积层和莱卡针织织物更高的相对伸长率使得热响应 4D 纺织品的永久形状具有更大的弧度。模拟程序准确预测了多种基本形状的永久形态。 原创性/价值 所提出的方法可使 4D 纺织品在受热后直接自成型,有助于提高 4D 纺织品的制造效率。复合材料的热响应性还有助于构建智能的人-材料-环境交互系统。
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引用次数: 0
Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method 使用透射/反射线方法对材料进行电磁特性表征的加材制造矩形波导
4区 工程技术 Q1 Engineering Pub Date : 2023-11-10 DOI: 10.1108/rpj-06-2023-0197
Connor Shane Smith, Alanna Julius, Christian Arbeeny, John Davenport Stevens
Purpose Radio frequency (RF) technology relies on the electromagnetic properties of the materials used, which includes their complex permittivities and loss tangents. To measure these properties, techniques for material characterization such as the transmission/reflection method are used in conjunction with conversion techniques to calculate these values from scattering parameters. Unfortunately, these techniques rely on relatively expensive rectangular waveguide adaptors and components, especially if testing over large frequency ranges. This paper aims to overcome this challenge by developing a more affordable test equipment solution based on additively manufactured waveguide sections. Design/methodology/approach To evaluate the effectiveness of using additively manufactured waveguides to perform electromagnetic characterization with the transmission/reflection method, samples of PLA Tough with varying infill percentages and samples made from several Formlabs photopolymer resins are fabricated and analyzed. Findings Results show that the method yielded permittivity and loss tangent values for the measured materials that generally agree with those found in the literature, supporting its credibility. Originality/value The accessibility of this measurement technique will ideally allow for more electromagnetic material characterization to occur and expand the possible use of additive manufacturing in future RF designs. This work also provides characterization of several Formlabs photopolymer resins, which have not been widely analyzed in the current literature.
射频(RF)技术依赖于所用材料的电磁特性,包括其复杂的介电常数和损耗切线。为了测量这些特性,材料表征技术(如透射/反射法)与转换技术结合使用,从散射参数计算这些值。不幸的是,这些技术依赖于相对昂贵的矩形波导适配器和组件,特别是在大频率范围内进行测试时。本文旨在通过开发一种基于增材制造波导截面的更经济实惠的测试设备解决方案来克服这一挑战。为了评估使用增材制造波导进行透射/反射法电磁表征的有效性,制作并分析了不同填充百分比的PLA Tough样品和几种Formlabs光聚合物树脂制成的样品。结果表明,该方法得到的测量材料的介电常数和损耗正切值与文献中发现的值基本一致,支持其可信度。这种测量技术的可访问性将理想地允许更多的电磁材料特性发生,并扩大增材制造在未来RF设计中的可能使用。这项工作还提供了几种Formlabs光聚合物树脂的表征,这些树脂在当前文献中尚未得到广泛分析。
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引用次数: 0
Numerical and experimental investigation on the heat transfer and mass transport in LPBF in-situ alloying of Al/Cu alloy Al/Cu合金LPBF原位合金化传热传质的数值与实验研究
4区 工程技术 Q1 Engineering Pub Date : 2023-11-08 DOI: 10.1108/rpj-01-2023-0015
Yang Zhou, Zhong Li, Yuhe Huang, Xiaohan Chen, Xinggang Li, Xiaogang Hu, Qiang Zhu
Purpose Laser powder bed fusion (LPBF) in-situ alloying is a recently developed technology that provides a facile approach to optimizing the microstructural and compositional characteristics of the components for high performance goals. However, the complex mass and heat transfer behavior of the molten pool results in an inhomogeneous composition distribution within the samples fabricated by LPBF in-situ alloying. The study aims to investigate the heat and mass transfer behavior of an in-situ alloyed molten pool by developing a three-dimensional transient thermal-flow model that couples the metallurgical behavior of the alloy, thereby revealing the formation mechanism of composition inhomogeneity. Design/methodology/approach A multispecies multiphase computational fluid dynamic model was developed with thermodynamic factors derived from the phase diagram of the selected alloy system. The characteristics of the Al/Cu powder bed in-situ alloying process were investigated as a benchmark. The metallurgical behaviors including powder melting, thermal-flow, element transfer and solidification were investigated. Findings The Peclet number indicates that the mass transfer in the molten pool is dominated by convection. The large variation in material properties and temperature results in the presence of partially melted Cu-powder and pre-solidified particles in the molten pool, which further hinder the convection mixing. The study of simulation and experiment indicates that optimizing the laser energy input is beneficial for element homogenization. The effective time and driving force of the convection stirring can be improved by increasing the volume energy density. Originality/value This study provides an in-depth understanding of the formation mechanism of composition inhomogeneity in alloy fabricated by LPBF in-situ alloying.
激光粉末床原位合金化(LPBF)是近年来发展起来的一项新技术,它提供了一种简便的方法来优化部件的显微组织和成分特征,以达到高性能的目标。然而,由于熔池复杂的传质传热行为,导致LPBF原位合金化制备的样品中成分分布不均匀。本研究旨在通过建立耦合合金冶金行为的三维瞬态热流模型,研究原位合金熔池的传热传质行为,从而揭示成分不均匀性的形成机制。设计/方法/方法基于所选合金体系相图的热力学因素,建立了多组分多相流体力学计算模型。以Al/Cu粉末床原位合金化工艺为基准,研究了原位合金化工艺的特点。研究了粉末熔化、热流、元素传递和凝固等冶金行为。发现Peclet数表明熔池内的传质以对流为主。由于材料性能和温度的较大变化,导致熔池中存在部分熔化的铜粉和预固化颗粒,进一步阻碍了对流混合。仿真和实验研究表明,优化激光能量输入有利于元件均匀化。增大体积能量密度可以提高对流搅拌的有效时间和驱动力。本研究为LPBF原位合金化制备的合金中成分不均匀性的形成机制提供了深入的认识。
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Rapid Prototyping Journal
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