Pub Date : 2025-11-27DOI: 10.1080/17452759.2025.2589472
Siqian Wu, Rong Wang, Liuchao Jin, Xingjian Huang, Wuzhao Li, Kun Zhou, Qi Ge
Digital light processing (DLP) enables high-resolution and efficient ceramic additive manufacturing, yet the fabrication of large-scale, crack-free ceramic parts remains severely constrained by critical defects arising during debinding and sintering. To address this challenge, we propose an approach leveraging honeycomb sandwich structures with perforated sidewalls to mitigate crack formation. Key structural parameters, including the outer wall thickness (a) and honeycomb cell characteristics such as sidewall height (h), length (l), thickness (t), and perforation diameter (d), are systematically investigated to evaluate their effects on manufacturability and mechanical performance. The characterisations of sintered ceramic parts further elucidate the mechanism of crack formation and validate the approach in this work. Through a comprehensive consideration of fabrication limits, slurry discharge efficiency and mechanical behaviour, the honeycomb sandwich structure with optimised structural parameters exhibits superior mechanical properties after sintering, achieving more than twice the specific modulus and specific strength of the solid references with the same overall dimensions in three-point bending tests. This work provides valuable guidelines for the structural design and fabrication of honeycomb sandwich ceramic structures to achieve large-scale crack-free ceramic parts, demonstrating great promise for lightweight applications.
{"title":"Digital light processing 3D printing of large-scale and crack-free ceramics with perforated internal honeycomb structures","authors":"Siqian Wu, Rong Wang, Liuchao Jin, Xingjian Huang, Wuzhao Li, Kun Zhou, Qi Ge","doi":"10.1080/17452759.2025.2589472","DOIUrl":"https://doi.org/10.1080/17452759.2025.2589472","url":null,"abstract":"Digital light processing (DLP) enables high-resolution and efficient ceramic additive manufacturing, yet the fabrication of large-scale, crack-free ceramic parts remains severely constrained by critical defects arising during debinding and sintering. To address this challenge, we propose an approach leveraging honeycomb sandwich structures with perforated sidewalls to mitigate crack formation. Key structural parameters, including the outer wall thickness (a) and honeycomb cell characteristics such as sidewall height (h), length (l), thickness (t), and perforation diameter (d), are systematically investigated to evaluate their effects on manufacturability and mechanical performance. The characterisations of sintered ceramic parts further elucidate the mechanism of crack formation and validate the approach in this work. Through a comprehensive consideration of fabrication limits, slurry discharge efficiency and mechanical behaviour, the honeycomb sandwich structure with optimised structural parameters exhibits superior mechanical properties after sintering, achieving more than twice the specific modulus and specific strength of the solid references with the same overall dimensions in three-point bending tests. This work provides valuable guidelines for the structural design and fabrication of honeycomb sandwich ceramic structures to achieve large-scale crack-free ceramic parts, demonstrating great promise for lightweight applications.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"20 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147334022","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Multi-material objects enable the integration of diverse properties and functionalities through precise three-dimensional material arrangement. Recent research highlights additive manufacturing as a pioneering approach for fabricating these complex structures, offering unprecedented control over spatial material distribution. However, it faces significant limitations when producing multi-material objects in the traditional layer-by-layer manner, as the approach requires frequent material switching, making the process prohibitively time-consuming. In this work, we present a two-step multi-material additive manufacturing strategy which achieves the fabrication of multi-material objects by capillary-driving the materials into the pre-printed framework and curing them with external energy sources. This strategy fundamentally eliminates the frequent material switching that occurs in traditional multi-material printing, thereby significantly enhancing the manufacturing efficiency of multi-material objects. Moreover, this strategy accommodates materials previously incompatible with conventional 3D printing. Tailored mechanical properties of multi-material structures can be achieved by adjusting the porosity and position of the framework. By adding stimulus-responsive materials into the multi-material structure, the strategy also enables 4D printing. This strategy opens a new avenue for the development of multi-material additive manufacturing.
{"title":"Toward high-efficiency multi-material additive manufacturing: a two-step hybrid fabrication strategy","authors":"Zhengda Chen, Da‐Wei Fu, Xiang‐Jun Zha, Huan Qi, Jigang Huang","doi":"10.1080/17452759.2025.2534466","DOIUrl":"https://doi.org/10.1080/17452759.2025.2534466","url":null,"abstract":"Multi-material objects enable the integration of diverse properties and functionalities through precise three-dimensional material arrangement. Recent research highlights additive manufacturing as a pioneering approach for fabricating these complex structures, offering unprecedented control over spatial material distribution. However, it faces significant limitations when producing multi-material objects in the traditional layer-by-layer manner, as the approach requires frequent material switching, making the process prohibitively time-consuming. In this work, we present a two-step multi-material additive manufacturing strategy which achieves the fabrication of multi-material objects by capillary-driving the materials into the pre-printed framework and curing them with external energy sources. This strategy fundamentally eliminates the frequent material switching that occurs in traditional multi-material printing, thereby significantly enhancing the manufacturing efficiency of multi-material objects. Moreover, this strategy accommodates materials previously incompatible with conventional 3D printing. Tailored mechanical properties of multi-material structures can be achieved by adjusting the porosity and position of the framework. By adding stimulus-responsive materials into the multi-material structure, the strategy also enables 4D printing. This strategy opens a new avenue for the development of multi-material additive manufacturing.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"20 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147334133","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-07-18eCollection Date: 2025-01-01DOI: 10.1080/17452759.2025.2530732
Moslem Mohammadi, Abbas Z Kouzani, Mahdi Bodaghi, Ali Zolfagharian
Traditional design and analysis of mechanical metamaterials are complex and time-consuming, owing to their nonlinear characteristics. This paper proposes a computationally efficient inverse design framework to predict the nonlinear strain-stress response considering the buckling behaviour under a tensile load. Design and simulation processes of the structures are based on the reduced order model (ROM) of flexible structures, all within a single software environment, MATLAB/Simscape, using the flexible beam blocks. The physical-enhanced neural network (PENN) design is implemented in MATLAB, utilising the results of the ROM model for training and testing. The ROM model takes 4.5 min on average on a 12-core CPU, whereas the trained PENN predicts the stiffness curve in a fraction of a second on a single-core CPU. After training the model, it was utilised to inverse design the metamaterial structure based on a desired stiffness response. Evolutionary optimisation is employed to iteratively feed various structural parameters into the model to find the optimised parameters of a metamaterial structure that can achieve the desired strain-stress response. The proposed metamaterial structure was experimentally validated through three-dimensional (3D) printing using flexible thermoplastic polyurethane (TPU) filament, demonstrating the efficiency and effectiveness of the proposed methodology.
{"title":"Inverse design of adaptive flexible structures using physical-enhanced neural network.","authors":"Moslem Mohammadi, Abbas Z Kouzani, Mahdi Bodaghi, Ali Zolfagharian","doi":"10.1080/17452759.2025.2530732","DOIUrl":"10.1080/17452759.2025.2530732","url":null,"abstract":"<p><p>Traditional design and analysis of mechanical metamaterials are complex and time-consuming, owing to their nonlinear characteristics. This paper proposes a computationally efficient inverse design framework to predict the nonlinear strain-stress response considering the buckling behaviour under a tensile load. Design and simulation processes of the structures are based on the reduced order model (ROM) of flexible structures, all within a single software environment, MATLAB/Simscape, using the flexible beam blocks. The physical-enhanced neural network (PENN) design is implemented in MATLAB, utilising the results of the ROM model for training and testing. The ROM model takes 4.5 min on average on a 12-core CPU, whereas the trained PENN predicts the stiffness curve in a fraction of a second on a single-core CPU. After training the model, it was utilised to inverse design the metamaterial structure based on a desired stiffness response. Evolutionary optimisation is employed to iteratively feed various structural parameters into the model to find the optimised parameters of a metamaterial structure that can achieve the desired strain-stress response. The proposed metamaterial structure was experimentally validated through three-dimensional (3D) printing using flexible thermoplastic polyurethane (TPU) filament, demonstrating the efficiency and effectiveness of the proposed methodology.</p>","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"20 1","pages":"e2530732"},"PeriodicalIF":8.8,"publicationDate":"2025-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12502832/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145252914","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Binder-based additive manufacturing is considerably advantageous for the production of hard-to-weld materials with complex shapes. Nonetheless, the incorporation of a binder poses challenges in achieving a homogeneous microstructure for composition-sensitive Ni–Mn–Sn–Co alloys. To address the trade-off between powder oxidation and binder removal in a closed system in the case of material extrusion additively manufactured Ni–Mn–Sn–Co alloys, this study proposes a one-step post-treatment sintering strategy with a small separation between the green parts and co-sintered materials. A homogeneous isotropic microstructure with premartensite at room temperature was obtained after only 2 h of directly sealed sintering. When the sintering time was increased, samples showed a slight loss of Mn, without any significant change in the martensitic transformation behaviour. Strong magneto-structural coupling with ΔM = 93 A m2 kg−1 and a large ΔSm of 23.1 J kg−1 K−1 along with a δTFWHM of 17.9 K and an RC value of 346.5 J kg−1 were achieved at 5.0 T in the sample sintered for 2 h. Additionally, a ΔTad of −1.99 K was directly measured at 1.38 T. This research shows the possibility of rapidly fabricating hard-to-weld and composition-sensitive Ni–Mn–X alloys with complex shapes.
基于粘结剂的增材制造对于复杂形状的难焊接材料的生产具有相当大的优势。然而，结合剂的加入对实现成分敏感的Ni-Mn-Sn-Co合金的均匀微观结构提出了挑战。为了解决在封闭系统中粉末氧化和粘结剂去除之间的权衡，在材料挤压增材制造的Ni-Mn-Sn-Co合金的情况下，本研究提出了一步后处理烧结策略，绿色部分和共烧结材料之间的距离很小。直接密封烧结2h后，在室温下获得了均匀的各向同性预马氏体组织。随着烧结时间的延长，试样中Mn有轻微的损失，但马氏体相变行为没有明显变化。在5.0 T烧结2 h的样品中，获得了ΔM = 93 A m2 kg - 1和ΔSm = 23.1 J kg - 1 K - 1的强磁结构耦合，δTFWHM为17.9 K， RC值为346.5 J kg - 1。此外，在1.38 T时，直接测量到ΔTad为- 1.99 K。
{"title":"Rapid preparation of Ni–Mn–Sn–Co lattice through material extrusion additive manufacturing and sintering","authors":"Shijiang Zhong, Mingfang Qian, Mengjiao Wang, Shuhe Gong, Xinxin Shen, Rui Wang, Zhenggang Jia, Ping Shen, Xuexi Zhang, Lin Geng","doi":"10.1080/17452759.2025.2499932","DOIUrl":"https://doi.org/10.1080/17452759.2025.2499932","url":null,"abstract":"Binder-based additive manufacturing is considerably advantageous for the production of hard-to-weld materials with complex shapes. Nonetheless, the incorporation of a binder poses challenges in achieving a homogeneous microstructure for composition-sensitive Ni–Mn–Sn–Co alloys. To address the trade-off between powder oxidation and binder removal in a closed system in the case of material extrusion additively manufactured Ni–Mn–Sn–Co alloys, this study proposes a one-step post-treatment sintering strategy with a small separation between the green parts and co-sintered materials. A homogeneous isotropic microstructure with premartensite at room temperature was obtained after only 2 h of directly sealed sintering. When the sintering time was increased, samples showed a slight loss of Mn, without any significant change in the martensitic transformation behaviour. Strong magneto-structural coupling with ΔM = 93 A m2 kg−1 and a large ΔSm of 23.1 J kg−1 K−1 along with a δTFWHM of 17.9 K and an RC value of 346.5 J kg−1 were achieved at 5.0 T in the sample sintered for 2 h. Additionally, a ΔTad of −1.99 K was directly measured at 1.38 T. This research shows the possibility of rapidly fabricating hard-to-weld and composition-sensitive Ni–Mn–X alloys with complex shapes.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"20 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147333234","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Vat photopolymerization (VPP) 3D printing technology is suited for intricate ceramic core forming due to its design freedom. However, solving the lateral over-cure width while formation is crucial. Graphene was used in VPP-3D printing of silica-based ceramic cores to examine its effects on forming and sintering, and a desirable curing coefficient was presented to evaluate the forming accuracy of single layer. A straightforward model using a modified Beer–Lambert law based on exposure time rather than exposure power predicts the effect of graphene on the VPP process at consistent curing depth and exposure time and clarifies how the curing process affects flexural strength and surface quality. The optimal graphene content was determined by double bond conversion rate, structural anisotropy, and mechanical properties. Increasing graphene concentration reduces curing sensitivity and exposure time threshold, allowing more liquid phase to cure and improving double bond conversion and interlayer bonding. However, excess graphene increases the conversion rate and stress concentration of green body. According to microstructural studies, extra graphene enhanced the likelihood of crack reformation after sintering. The ceramic cores had optimal forming and sintering capabilities with 0.6 wt.‰ graphene content. The approach offers significant insights for enhancing VPP ceramic 3D printing.
{"title":"Optimisation of curing models and ultra-high-precision forming strategy in vat photopolymerization of silica-based ceramic modified by graphene","authors":"Yongkang Yang, Xiqing Xu, Boran Wang, Shiyuan Li, Ziqi Jia, Xusen Guo, Shuhuai Wang, Shuxin Niu, Xin Li","doi":"10.1080/17452759.2025.2499450","DOIUrl":"https://doi.org/10.1080/17452759.2025.2499450","url":null,"abstract":"Vat photopolymerization (VPP) 3D printing technology is suited for intricate ceramic core forming due to its design freedom. However, solving the lateral over-cure width while formation is crucial. Graphene was used in VPP-3D printing of silica-based ceramic cores to examine its effects on forming and sintering, and a desirable curing coefficient was presented to evaluate the forming accuracy of single layer. A straightforward model using a modified Beer–Lambert law based on exposure time rather than exposure power predicts the effect of graphene on the VPP process at consistent curing depth and exposure time and clarifies how the curing process affects flexural strength and surface quality. The optimal graphene content was determined by double bond conversion rate, structural anisotropy, and mechanical properties. Increasing graphene concentration reduces curing sensitivity and exposure time threshold, allowing more liquid phase to cure and improving double bond conversion and interlayer bonding. However, excess graphene increases the conversion rate and stress concentration of green body. According to microstructural studies, extra graphene enhanced the likelihood of crack reformation after sintering. The ceramic cores had optimal forming and sintering capabilities with 0.6 wt.‰ graphene content. The approach offers significant insights for enhancing VPP ceramic 3D printing.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"20 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147333394","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-15DOI: 10.1080/17452759.2025.2450101
Yue Hu, Mingyue Jiang, Ping Shen
Traditional fabrication methods for metal–ceramic composites often struggle to achieve the level of control needed for material on-demand design and property optimisation, despite the potential for enhanced performance. This study presents a novel approach that overcomes these limitations by combining material extrusion-based additive manufacturing and pressure infiltration techniques, which enables the fabrication of compositionally graded Al2O3–B4C/Al layered composites with tailored properties. Precise control over the B4C/Al2O3 ratio allows for the fine-tuning of key mechanical properties, including bending strength, fracture toughness, and fracture work. The composites exhibit anisotropic behaviour, with performance influenced by the ceramic composition, loading direction, and layer spacing. A notable observation is the enhancement of damage tolerance through multi-crack propagation as the Al2O3 content in the ceramic layers increases. Additionally, wear tests demonstrate exceptional abrasion resistance, highlighting the synergistic effects of B4C hardness and Al2O3 toughness. This research establishes novel strategies for the design and fabrication of metal–ceramic composites with tailored properties, paving the way for their implementation in demanding applications where a combination of strength, toughness, and wear resistance is critical.
{"title":"Compositionally gradient Al <sub>2</sub> O <sub>3</sub> –B <sub>4</sub> C/Al composites with interpenetrating structure and tailored properties via material extrusion-based additive manufacturing and pressure infiltration","authors":"Yue Hu, Mingyue Jiang, Ping Shen","doi":"10.1080/17452759.2025.2450101","DOIUrl":"https://doi.org/10.1080/17452759.2025.2450101","url":null,"abstract":"Traditional fabrication methods for metal–ceramic composites often struggle to achieve the level of control needed for material on-demand design and property optimisation, despite the potential for enhanced performance. This study presents a novel approach that overcomes these limitations by combining material extrusion-based additive manufacturing and pressure infiltration techniques, which enables the fabrication of compositionally graded Al2O3–B4C/Al layered composites with tailored properties. Precise control over the B4C/Al2O3 ratio allows for the fine-tuning of key mechanical properties, including bending strength, fracture toughness, and fracture work. The composites exhibit anisotropic behaviour, with performance influenced by the ceramic composition, loading direction, and layer spacing. A notable observation is the enhancement of damage tolerance through multi-crack propagation as the Al2O3 content in the ceramic layers increases. Additionally, wear tests demonstrate exceptional abrasion resistance, highlighting the synergistic effects of B4C hardness and Al2O3 toughness. This research establishes novel strategies for the design and fabrication of metal–ceramic composites with tailored properties, paving the way for their implementation in demanding applications where a combination of strength, toughness, and wear resistance is critical.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"20 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147332993","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A novel underwater in-situ wire-based laser additive manufacturing (ULAM) technology is proposed for the in-service repair of underwater components in nuclear power plant. Duplex stainless steel (DSS) obtained in air and underwater environments were analysed using material characterisation and testing methods. The effects of underwater additive environments on the microstructure evolution, mechanical properties and corrosion resistance of the specimens were investigated. The results show that the laser heat input is consumed to balance the heat loss of the water-cooled base material during the underwater laser additive manufacturing process, leading to a reduction in the heat input to the molten pool. Underwater specimen exhibit a two-phase balance, with small ferrite grain boundary angles, resulting in better tensile strength and corrosion resistance. Laser reheat treatment leads to a phase change in microstructure, which can enhance the microhardness and the tensile strength. The ULAM system can meet the requirements of actual engineering for cladding layer.
{"title":"Microstructure and properties of underwater in-situ wire-based laser additive manufactured duplex stainless steel","authors":"Congwei Li, Jialei Zhu, Caimei Wang, Caiyan Deng, Lei Cui, Xiaochun Zhang, Chenglu Zhao, Xiangdong Jiao","doi":"10.1080/17452759.2024.2401925","DOIUrl":"https://doi.org/10.1080/17452759.2024.2401925","url":null,"abstract":"A novel underwater in-situ wire-based laser additive manufacturing (ULAM) technology is proposed for the in-service repair of underwater components in nuclear power plant. Duplex stainless steel (DSS) obtained in air and underwater environments were analysed using material characterisation and testing methods. The effects of underwater additive environments on the microstructure evolution, mechanical properties and corrosion resistance of the specimens were investigated. The results show that the laser heat input is consumed to balance the heat loss of the water-cooled base material during the underwater laser additive manufacturing process, leading to a reduction in the heat input to the molten pool. Underwater specimen exhibit a two-phase balance, with small ferrite grain boundary angles, resulting in better tensile strength and corrosion resistance. Laser reheat treatment leads to a phase change in microstructure, which can enhance the microhardness and the tensile strength. The ULAM system can meet the requirements of actual engineering for cladding layer.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"14 1","pages":""},"PeriodicalIF":10.6,"publicationDate":"2024-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142250701","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-12-31DOI: 10.1080/17452759.2024.2399789
Ze Chen, Zhongji Sun, Yang Qi, Wei Fan, Verner Soh Qun Liang, Sastry Yagnanna Kandukuri, Paulo Jorge Da Silva Bartolo, Kun Zhou
Laser-based directed energy deposition (L-DED) offers significant advantages for repairing metal structures, particularly in the marine and offshore industry where corrosion-resistant materials like Monel K-500 (a Ni-Cu alloy) lack strength and wear resistance. This study addresses this issue by producing Monel K-500 with high-strength Stellite 6 (a Co-Cr alloy). Two types of multi-material samples were created using L-DED: interlayered and mixed powder samples. The interlayered samples experienced cracking at the material interface, while the mixed powder samples were crack-free and exhibited improved mechanical properties, with yield strength increasing from 208.3 MPa to 490.2 MPa and ultimate tensile strength from 429.7 MPa to 887.0 MPa compared to single Monel K-500 samples. This research demonstrated the potential of in-situ alloying during the L-DED process to enhance alloy properties and highlighted the challenges of abrupt compositional changes leading to cracking, suggesting mitigation strategies for successful production.
{"title":"Laser-based directed energy deposition of Monel K-500 and Stellite 6 multi-materials","authors":"Ze Chen, Zhongji Sun, Yang Qi, Wei Fan, Verner Soh Qun Liang, Sastry Yagnanna Kandukuri, Paulo Jorge Da Silva Bartolo, Kun Zhou","doi":"10.1080/17452759.2024.2399789","DOIUrl":"https://doi.org/10.1080/17452759.2024.2399789","url":null,"abstract":"Laser-based directed energy deposition (L-DED) offers significant advantages for repairing metal structures, particularly in the marine and offshore industry where corrosion-resistant materials like Monel K-500 (a Ni-Cu alloy) lack strength and wear resistance. This study addresses this issue by producing Monel K-500 with high-strength Stellite 6 (a Co-Cr alloy). Two types of multi-material samples were created using L-DED: interlayered and mixed powder samples. The interlayered samples experienced cracking at the material interface, while the mixed powder samples were crack-free and exhibited improved mechanical properties, with yield strength increasing from 208.3 MPa to 490.2 MPa and ultimate tensile strength from 429.7 MPa to 887.0 MPa compared to single Monel K-500 samples. This research demonstrated the potential of in-situ alloying during the L-DED process to enhance alloy properties and highlighted the challenges of abrupt compositional changes leading to cracking, suggesting mitigation strategies for successful production.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"65 1","pages":""},"PeriodicalIF":10.6,"publicationDate":"2024-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142250700","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-12-31DOI: 10.1080/17452759.2023.2296128
Donghong Ding, Rong Huang, Tao Liu, Lei Yuan, Chuan Liu
Deposition path patterns play an important role in controlling residual stresses and deformation in direct energy deposition-arc (DED-arc) process. In this paper, the effects of various path patterns on the evolution of the temperature history, residual stress distribution, and substrate deformations are investigated through experiments and finite element analysis. The predicted results of temperature fields and substrate deformations are verified experimentally by the infrared thermal imager and the laser profile scanner, respectively. It is found that the path patterns have significant effects on the stress distribution in the first few layers, and the minimum substrate deformation is obtained by the zigzag path along the short edge of the block. The proposed finite element method and measuring method are confirmed to be effective and feasible, providing valuable insight into the residual stresses and deformations control in the DED-arc process.
{"title":"Effects of path patterns on residual stresses and deformations of directed energy deposition-arc built blocks","authors":"Donghong Ding, Rong Huang, Tao Liu, Lei Yuan, Chuan Liu","doi":"10.1080/17452759.2023.2296128","DOIUrl":"https://doi.org/10.1080/17452759.2023.2296128","url":null,"abstract":"Deposition path patterns play an important role in controlling residual stresses and deformation in direct energy deposition-arc (DED-arc) process. In this paper, the effects of various path patterns on the evolution of the temperature history, residual stress distribution, and substrate deformations are investigated through experiments and finite element analysis. The predicted results of temperature fields and substrate deformations are verified experimentally by the infrared thermal imager and the laser profile scanner, respectively. It is found that the path patterns have significant effects on the stress distribution in the first few layers, and the minimum substrate deformation is obtained by the zigzag path along the short edge of the block. The proposed finite element method and measuring method are confirmed to be effective and feasible, providing valuable insight into the residual stresses and deformations control in the DED-arc process.","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"18 1","pages":""},"PeriodicalIF":10.6,"publicationDate":"2024-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142250702","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-09-11DOI: 10.1080/17452759.2024.2396064
Konrad Gruber, Wojciech Stopyra, Karol Kobiela, Philipp Kohlwes, Jan Čapek, Efthymios Polatidis, Ingomar Kelbassa
Few attempts have been made so far to develop modifiers for in situ use in Inconel 718 PBF-LB/M fabrication. Reports show an increase in tensile strength compared to unmodified counterparts. Howeve...
{"title":"Achieving high strength and ductility in Inconel 718: tailoring grain structure through micron-sized carbide additives in PBF-LB/M additive manufacturing","authors":"Konrad Gruber, Wojciech Stopyra, Karol Kobiela, Philipp Kohlwes, Jan Čapek, Efthymios Polatidis, Ingomar Kelbassa","doi":"10.1080/17452759.2024.2396064","DOIUrl":"https://doi.org/10.1080/17452759.2024.2396064","url":null,"abstract":"Few attempts have been made so far to develop modifiers for in situ use in Inconel 718 PBF-LB/M fabrication. Reports show an increase in tensile strength compared to unmodified counterparts. Howeve...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":"7 1","pages":""},"PeriodicalIF":10.6,"publicationDate":"2024-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178961","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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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