Pub Date : 2023-10-31DOI: 10.1007/s40964-023-00527-3
T. Fiedler, M. Jähnig Domingues, C. Winter, J. Rösler
Abstract For applications where high thermal and/or electrical conductivity combined with reasonably high strength is required, copper alloys may be used. Although many different alloys were already developed in the past, additive manufacturing like laser powder bed fusion (PBF-LB/M) opens up new possibilities for alloy development, mainly driven by the very high cooling rates. This allows for the usage of precipitation-hardened alloys with compositions exceeding the maximum solubility. The present work focuses on the investigation of a well-known CuCr1Zr alloy as well as CuZr alloys with 1 and 2 wt.% Zr. For a fast, resource-efficient screening and demonstration of feasibility, the investigated alloys were not printed from powder. Instead, solid sheets were partially re-melted in a PBF-LB/M machine to obtain a microstructure similar to the printed state. This rapid-solidification microstructure is investigated, and precipitates with a size 50 nm or even smaller are found. After subsequent aging heat treatments, the hardness of the alloys exceeds the maximum hardness achievable with conventional manufacturing methods (excluding work hardening). The investigations in this work revealed the great hardening potential of these alloys for usage in the PBF-LB/M process.
{"title":"High conductive copper alloys for additive manufacturing","authors":"T. Fiedler, M. Jähnig Domingues, C. Winter, J. Rösler","doi":"10.1007/s40964-023-00527-3","DOIUrl":"https://doi.org/10.1007/s40964-023-00527-3","url":null,"abstract":"Abstract For applications where high thermal and/or electrical conductivity combined with reasonably high strength is required, copper alloys may be used. Although many different alloys were already developed in the past, additive manufacturing like laser powder bed fusion (PBF-LB/M) opens up new possibilities for alloy development, mainly driven by the very high cooling rates. This allows for the usage of precipitation-hardened alloys with compositions exceeding the maximum solubility. The present work focuses on the investigation of a well-known CuCr1Zr alloy as well as CuZr alloys with 1 and 2 wt.% Zr. For a fast, resource-efficient screening and demonstration of feasibility, the investigated alloys were not printed from powder. Instead, solid sheets were partially re-melted in a PBF-LB/M machine to obtain a microstructure similar to the printed state. This rapid-solidification microstructure is investigated, and precipitates with a size 50 nm or even smaller are found. After subsequent aging heat treatments, the hardness of the alloys exceeds the maximum hardness achievable with conventional manufacturing methods (excluding work hardening). The investigations in this work revealed the great hardening potential of these alloys for usage in the PBF-LB/M process.","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"449 ","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135870679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-30DOI: 10.1007/s40964-023-00512-w
Ali Zolfagharian, Eujin Pei, Giulia Scalet, Mahdi Bodaghi
{"title":"Special issue “New Trends in 4D Printing: from Design to Materials and Applications”","authors":"Ali Zolfagharian, Eujin Pei, Giulia Scalet, Mahdi Bodaghi","doi":"10.1007/s40964-023-00512-w","DOIUrl":"https://doi.org/10.1007/s40964-023-00512-w","url":null,"abstract":"","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"24 10","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136023367","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-29DOI: 10.1007/s40964-023-00528-2
René Wick-Joliat, Dirk Penner
Abstract Aluminum die casting is a well-established industrial process for mass producing aluminum parts with complex shapes, but design restrictions exclude some features like undercuts and hollow structures from being produced with this method. Water-soluble casting molds offer a promising solution to overcome those restrains, for example by hot pressing of salt cores or 3D printing of NaCl molds. Presently, 3D printing techniques available for NaCl are limited to direct ink writing (DIW) and photopolymerization. This study presents an approach to prepare NaCl parts by thermoplastic material extrusion (MEX) 3D printing. Firstly, a 3D printable feedstock is developed consisting of an organic binder, which is usually used for ceramic injection molding, and sodium chloride (NaCl) salt crystals. Various molds are then printed on a granulate-fed MEX printer. After thermal debinding and sintering at 690 °C, the 3D printed parts consist of pure NaCl. Furthermore, the same NaCl feedstock is used for injection molding. The bending strength of 3D printed samples with and without post-treatment are measured and compared to injection molded test specimens. Finally, metal casting in 3D printed NaCl molds is shown with tin or aluminum and the metal demonstrator parts with complex geometries such as gyroid structures and turbine wheels are released by dissolving the NaCl molds in water.
{"title":"Metal casting into NaCl molds fabricated by material extrusion 3D printing","authors":"René Wick-Joliat, Dirk Penner","doi":"10.1007/s40964-023-00528-2","DOIUrl":"https://doi.org/10.1007/s40964-023-00528-2","url":null,"abstract":"Abstract Aluminum die casting is a well-established industrial process for mass producing aluminum parts with complex shapes, but design restrictions exclude some features like undercuts and hollow structures from being produced with this method. Water-soluble casting molds offer a promising solution to overcome those restrains, for example by hot pressing of salt cores or 3D printing of NaCl molds. Presently, 3D printing techniques available for NaCl are limited to direct ink writing (DIW) and photopolymerization. This study presents an approach to prepare NaCl parts by thermoplastic material extrusion (MEX) 3D printing. Firstly, a 3D printable feedstock is developed consisting of an organic binder, which is usually used for ceramic injection molding, and sodium chloride (NaCl) salt crystals. Various molds are then printed on a granulate-fed MEX printer. After thermal debinding and sintering at 690 °C, the 3D printed parts consist of pure NaCl. Furthermore, the same NaCl feedstock is used for injection molding. The bending strength of 3D printed samples with and without post-treatment are measured and compared to injection molded test specimens. Finally, metal casting in 3D printed NaCl molds is shown with tin or aluminum and the metal demonstrator parts with complex geometries such as gyroid structures and turbine wheels are released by dissolving the NaCl molds in water.","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"17 2","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136134592","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-28DOI: 10.1007/s40964-023-00525-5
Nandagopal Vidhu, Ayush Gupta, Roozbeh Salajeghe, Jon Spangenberg, Deepak Marla
{"title":"A computational model for stereolithography apparatus (SLA) 3D printing","authors":"Nandagopal Vidhu, Ayush Gupta, Roozbeh Salajeghe, Jon Spangenberg, Deepak Marla","doi":"10.1007/s40964-023-00525-5","DOIUrl":"https://doi.org/10.1007/s40964-023-00525-5","url":null,"abstract":"","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"217 2","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136159369","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-28DOI: 10.1007/s40964-023-00526-4
Eric Gärtner, Inga Meyenborg, A. Toenjes
{"title":"Adapting Fe–Mn–Si–Cr shape memory alloy for laser powder bed fusion by adjusting the Mn content","authors":"Eric Gärtner, Inga Meyenborg, A. Toenjes","doi":"10.1007/s40964-023-00526-4","DOIUrl":"https://doi.org/10.1007/s40964-023-00526-4","url":null,"abstract":"","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"277 1 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139312104","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-27DOI: 10.1007/s40964-023-00522-8
Elroei Damri, Itzhak Orion, Yaron I. Ganor, Dor Braun, Eitan Tiferet
{"title":"Electron beam melting additive manufacturing process efficiency study of stainless steel","authors":"Elroei Damri, Itzhak Orion, Yaron I. Ganor, Dor Braun, Eitan Tiferet","doi":"10.1007/s40964-023-00522-8","DOIUrl":"https://doi.org/10.1007/s40964-023-00522-8","url":null,"abstract":"","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136261629","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract In this work, we present phase-field (PF) simulations directly coupled to thermodynamic and kinetic databases in three dimensions. The direct coupling allows consideration of the full alloy complexity of the CMSX-4 superalloy over a large range of temperatures. The simulation conditions are chosen for additive manufacturing utilizing Electron Beam Melting (EBM). Transformation of interdendritic liquid into eutectic $$gamma '$$ γ′ is considered. The simulation results confirm the unique segregation behavior of all the alloying elements. It is demonstrated that the treatment of the full complexity of alloy composition is superior to all approximations with quasi-binary or -ternary approximation and justifies the significantly increased computational effort. Our results demonstrate that multi-component simulations must become a standard for phase-field applications to real material systems.
{"title":"Solidification of the Ni-based superalloy CMSX-4 simulated with full complexity in 3-dimensions","authors":"Murali Uddagiri, Oleg Shchyglo, Ingo Steinbach, Marvin Tegeler","doi":"10.1007/s40964-023-00513-9","DOIUrl":"https://doi.org/10.1007/s40964-023-00513-9","url":null,"abstract":"Abstract In this work, we present phase-field (PF) simulations directly coupled to thermodynamic and kinetic databases in three dimensions. The direct coupling allows consideration of the full alloy complexity of the CMSX-4 superalloy over a large range of temperatures. The simulation conditions are chosen for additive manufacturing utilizing Electron Beam Melting (EBM). Transformation of interdendritic liquid into eutectic $$gamma '$$ <mml:math xmlns:mml=\"http://www.w3.org/1998/Math/MathML\"> <mml:msup> <mml:mi>γ</mml:mi> <mml:mo>′</mml:mo> </mml:msup> </mml:math> is considered. The simulation results confirm the unique segregation behavior of all the alloying elements. It is demonstrated that the treatment of the full complexity of alloy composition is superior to all approximations with quasi-binary or -ternary approximation and justifies the significantly increased computational effort. Our results demonstrate that multi-component simulations must become a standard for phase-field applications to real material systems.","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"14 2","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135316276","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-20DOI: 10.1007/s40964-023-00509-5
Lalit Kumar, Biranchi Panda, N. Muthu
{"title":"A simple potential energy formulation for 3D concrete printed structures considering the shear effects in the build direction","authors":"Lalit Kumar, Biranchi Panda, N. Muthu","doi":"10.1007/s40964-023-00509-5","DOIUrl":"https://doi.org/10.1007/s40964-023-00509-5","url":null,"abstract":"","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"16 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135617862","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-10-17DOI: 10.1007/s40964-023-00523-7
Andreas Wimmer, Hannes Panzer, Christopher Zoeller, Stefan Adami, Nikolaus A. Adams, Michael F. Zaeh
Abstract The variety of processable materials for the powder bed fusion of metals using a laser beam (PBF-LB/M) is still limited. In particular, high-strength aluminum alloys are difficult to process with PBF-LB/M without the occurrence of hot cracks. In situ alloying is a promising method to modify the physical properties of an alloy to reduce its hot cracking susceptibility. In this work, the aluminum alloy 7075 and blends with 2 wt.%, 4 wt.%, and 6 wt.% of Si were processed via PBF-LB/M. The Rappaz–Drezet–Gremaud (RDG) model and the Kou model were investigated regarding their capability of predicting the hot cracking behavior for the aluminum alloy 7075 and the three powder blends. The smoothed-particle hydrodynamics (SPH) method was used to gain the thermal input data for the RDG model. A clear tendency of a reduced hot cracking susceptibility with an increasing amount of Si was observed in the experiments and in the simulations. A detailed analysis of the type of the hot cracking mechanism in the aluminum alloy 7075 provided several indications of the presence of liquation cracking. The Kou model and the RDG model may be applicable for both solidification and liquation cracking. The presented methodology can be used to investigate any material combination and its susceptibility to hot cracking.
{"title":"Experimental and numerical investigations of the hot cracking susceptibility during the powder bed fusion of AA 7075 using a laser beam","authors":"Andreas Wimmer, Hannes Panzer, Christopher Zoeller, Stefan Adami, Nikolaus A. Adams, Michael F. Zaeh","doi":"10.1007/s40964-023-00523-7","DOIUrl":"https://doi.org/10.1007/s40964-023-00523-7","url":null,"abstract":"Abstract The variety of processable materials for the powder bed fusion of metals using a laser beam (PBF-LB/M) is still limited. In particular, high-strength aluminum alloys are difficult to process with PBF-LB/M without the occurrence of hot cracks. In situ alloying is a promising method to modify the physical properties of an alloy to reduce its hot cracking susceptibility. In this work, the aluminum alloy 7075 and blends with 2 wt.%, 4 wt.%, and 6 wt.% of Si were processed via PBF-LB/M. The Rappaz–Drezet–Gremaud (RDG) model and the Kou model were investigated regarding their capability of predicting the hot cracking behavior for the aluminum alloy 7075 and the three powder blends. The smoothed-particle hydrodynamics (SPH) method was used to gain the thermal input data for the RDG model. A clear tendency of a reduced hot cracking susceptibility with an increasing amount of Si was observed in the experiments and in the simulations. A detailed analysis of the type of the hot cracking mechanism in the aluminum alloy 7075 provided several indications of the presence of liquation cracking. The Kou model and the RDG model may be applicable for both solidification and liquation cracking. The presented methodology can be used to investigate any material combination and its susceptibility to hot cracking.","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"52 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136033468","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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