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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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}
Pub Date : 2024-09-11DOI: 10.1080/17452759.2024.2396069
Ondřej Červinek, Michael Robert Tucker, Daniel Koutný, Markus Bambach
Communication antennas and optical systems of space-borne satellites require highly accurate relative positioning of components despite large variations in ambient temperature. As a potential solut...
{"title":"Computational and experimental investigation of thermally auxetic multi-metal lattice structures produced by laser powder bed fusion","authors":"Ondřej Červinek, Michael Robert Tucker, Daniel Koutný, Markus Bambach","doi":"10.1080/17452759.2024.2396069","DOIUrl":"https://doi.org/10.1080/17452759.2024.2396069","url":null,"abstract":"Communication antennas and optical systems of space-borne satellites require highly accurate relative positioning of components despite large variations in ambient temperature. As a potential solut...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":null,"pages":null},"PeriodicalIF":10.6,"publicationDate":"2024-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178962","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 : 2024-09-09DOI: 10.1080/17452759.2024.2399787
Xiangyu Wang, Liangfen Du, Zhenbang Liu, Mingyang Li, Yiwei Weng, Zhixin Liu, Yi Wei Daniel Tay, Zheng Fan, Teck Neng Wong, Ming Jen Tan
Cementitious materials incorporating recycled crumb rubber have become a common sustainable resolution in diverse building environments to achieve various functions in terms of lightweight, ductili...
{"title":"3D Cementitious composites printing with pretreated recycled crumb rubber: mechanical and acoustic insulation properties","authors":"Xiangyu Wang, Liangfen Du, Zhenbang Liu, Mingyang Li, Yiwei Weng, Zhixin Liu, Yi Wei Daniel Tay, Zheng Fan, Teck Neng Wong, Ming Jen Tan","doi":"10.1080/17452759.2024.2399787","DOIUrl":"https://doi.org/10.1080/17452759.2024.2399787","url":null,"abstract":"Cementitious materials incorporating recycled crumb rubber have become a common sustainable resolution in diverse building environments to achieve various functions in terms of lightweight, ductili...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":null,"pages":null},"PeriodicalIF":10.6,"publicationDate":"2024-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178963","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 : 2024-09-05DOI: 10.1080/17452759.2024.2399183
Chao Chen, Wenlong Li, Shupeng Wang
The existing methods for preparing titanium matrix composites (TMCs) are less efficient and more expensive. An interlayer laser cladding SiC during arc-directed energy deposition Ti-6Al-4V was deve...
{"title":"Interlayer laser cladding SiC regulates microstructure and mechanical properties of Ti-6Al-4V arc-directed energy deposited components","authors":"Chao Chen, Wenlong Li, Shupeng Wang","doi":"10.1080/17452759.2024.2399183","DOIUrl":"https://doi.org/10.1080/17452759.2024.2399183","url":null,"abstract":"The existing methods for preparing titanium matrix composites (TMCs) are less efficient and more expensive. An interlayer laser cladding SiC during arc-directed energy deposition Ti-6Al-4V was deve...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":null,"pages":null},"PeriodicalIF":10.6,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178964","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 : 2024-09-05DOI: 10.1080/17452759.2024.2397008
Jian Qin, Pradeeptta Taraphdar, Yongle Sun, James Wainwright, Wai Jun Lai, Shuo Feng, Jialuo Ding, Stewart Williams
Directed energy deposition additive manufacturing (DED-AM) has gained significant interest in producing large-scale metallic structural components. In this paper, a knowledge-based machine learning...
{"title":"Knowledge-based bidirectional thermal variable modelling for directed energy deposition additive manufacturing","authors":"Jian Qin, Pradeeptta Taraphdar, Yongle Sun, James Wainwright, Wai Jun Lai, Shuo Feng, Jialuo Ding, Stewart Williams","doi":"10.1080/17452759.2024.2397008","DOIUrl":"https://doi.org/10.1080/17452759.2024.2397008","url":null,"abstract":"Directed energy deposition additive manufacturing (DED-AM) has gained significant interest in producing large-scale metallic structural components. In this paper, a knowledge-based machine learning...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":null,"pages":null},"PeriodicalIF":10.6,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178970","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 : 2024-09-02DOI: 10.1080/17452759.2024.2391476
Hongping Zhang, Shuni Duan, Zhichao Hu, Litao Liu, Qi Han
Given the current situation that the evaluation system of the deformation and instability failure of 3DPC is immature, this study was devoted to shaping the performance of 3DPC to provide new ideas...
{"title":"Evaluation of plasticity and determination of deformation index of 3D-printed composite cement-based materials","authors":"Hongping Zhang, Shuni Duan, Zhichao Hu, Litao Liu, Qi Han","doi":"10.1080/17452759.2024.2391476","DOIUrl":"https://doi.org/10.1080/17452759.2024.2391476","url":null,"abstract":"Given the current situation that the evaluation system of the deformation and instability failure of 3DPC is immature, this study was devoted to shaping the performance of 3DPC to provide new ideas...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":null,"pages":null},"PeriodicalIF":10.6,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178965","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 : 2024-09-02DOI: 10.1080/17452759.2024.2397816
Max Galloway, Sung Hin Lam, Hoda Amel, Robert Richardson, Robert Kay, Masoud Jabbari
Most computational fluid dynamics (CFD) modelling of material extrusion additive manufacturing (MEX-AM) mainly relies on a moving boundary condition applied to the print bed and not the direct mode...
{"title":"Implementation of nozzle motion for material extrusion additive manufacturing in Ansys Fluent","authors":"Max Galloway, Sung Hin Lam, Hoda Amel, Robert Richardson, Robert Kay, Masoud Jabbari","doi":"10.1080/17452759.2024.2397816","DOIUrl":"https://doi.org/10.1080/17452759.2024.2397816","url":null,"abstract":"Most computational fluid dynamics (CFD) modelling of material extrusion additive manufacturing (MEX-AM) mainly relies on a moving boundary condition applied to the print bed and not the direct mode...","PeriodicalId":23756,"journal":{"name":"Virtual and Physical Prototyping","volume":null,"pages":null},"PeriodicalIF":10.6,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142178969","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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