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}
Pub Date : 2023-10-17DOI: 10.1007/s40964-023-00519-3
Faizan Badar, Luigi-Jules Vandi, Danilo Carluccio, Michael Redmond, James I. Novak
Abstract Multicolour capability in additive manufacturing could play a key role in certain applications such as surgical training and consumer products. However, the ability to accurately 3D print colours is not well documented and could affect the realism of models produced through these technologies. As a recent system, the Stratasys J750 Digital Anatomy Printer has yet to be analyzed for its colour perception and accuracy, which is quantified through this study. This will allow users of this and similar material jetting systems with an improved understanding of the relationship between digitally applied colours and their result when 3D printed, as well as the influence of certain settings. Thirty-three rectangular prism models with different CMYK and RGB colours, as well as infill materials, were printed on a Stratasys J750 DAP printer. These were scanned on five faces using a Nix Mini 2 handheld colour sensor, documenting readings in CIELAB format. The data were analyzed using the CIEDE2000 colour difference formula, and its recent modifications for 3D printed objects. Results found statistically significant and perceptive differences in colour accuracy among different colours, core materials, and face orientations. It was also observed that the addition of VeroPureWhite as filler material instead of the default SUP706 support improved colour accuracy. The study recommends the following steps to improve colour accuracy: (i) avoid the addition of black (K) manually in CMYK colour space, (ii) use pure white as the base infill material instead of support material, (iii) add a little white (~ 10%–30%) to make samples opaque instead of translucent.
增材制造中的多色能力可以在某些应用中发挥关键作用，例如外科培训和消费产品。然而，准确3D打印颜色的能力没有很好的记录，可能会影响通过这些技术产生的模型的真实性。作为一个最新的系统，Stratasys J750数字解剖打印机还没有被分析其色彩感知和准确性，这是通过本研究量化。这将使这种和类似材料喷射系统的用户更好地理解数字应用颜色与3D打印结果之间的关系，以及某些设置的影响。在Stratasys J750 DAP打印机上打印了33个具有不同CMYK和RGB颜色以及填充材料的矩形棱镜模型。使用Nix Mini 2手持式颜色传感器在五张脸上扫描这些数据，以CIELAB格式记录读数。使用CIEDE2000色差公式及其最近对3D打印对象的修改对数据进行了分析。结果发现，不同颜色、核心材料和面部朝向在颜色准确性上存在统计学上的显著差异和感知差异。还观察到添加VeroPureWhite作为填充材料而不是默认的SUP706支持提高颜色精度。本研究建议采取以下步骤来提高色彩准确性:(i)避免在CMYK色彩空间中手动添加黑色(K)， (ii)使用纯白色作为基础填充材料而不是支撑材料，(iii)添加少量白色(~ 10%-30%)使样品不透明而不是半透明。
{"title":"Preliminary colour characterisation of a Stratasys J750 digital anatomy printer with different fillings and face orientations","authors":"Faizan Badar, Luigi-Jules Vandi, Danilo Carluccio, Michael Redmond, James I. Novak","doi":"10.1007/s40964-023-00519-3","DOIUrl":"https://doi.org/10.1007/s40964-023-00519-3","url":null,"abstract":"Abstract Multicolour capability in additive manufacturing could play a key role in certain applications such as surgical training and consumer products. However, the ability to accurately 3D print colours is not well documented and could affect the realism of models produced through these technologies. As a recent system, the Stratasys J750 Digital Anatomy Printer has yet to be analyzed for its colour perception and accuracy, which is quantified through this study. This will allow users of this and similar material jetting systems with an improved understanding of the relationship between digitally applied colours and their result when 3D printed, as well as the influence of certain settings. Thirty-three rectangular prism models with different CMYK and RGB colours, as well as infill materials, were printed on a Stratasys J750 DAP printer. These were scanned on five faces using a Nix Mini 2 handheld colour sensor, documenting readings in CIELAB format. The data were analyzed using the CIEDE2000 colour difference formula, and its recent modifications for 3D printed objects. Results found statistically significant and perceptive differences in colour accuracy among different colours, core materials, and face orientations. It was also observed that the addition of VeroPureWhite as filler material instead of the default SUP706 support improved colour accuracy. The study recommends the following steps to improve colour accuracy: (i) avoid the addition of black (K) manually in CMYK colour space, (ii) use pure white as the base infill material instead of support material, (iii) add a little white (~ 10%–30%) to make samples opaque instead of translucent.","PeriodicalId":36643,"journal":{"name":"Progress in Additive Manufacturing","volume":"36 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":"135994081","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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