Pub Date : 2025-09-01Epub Date: 2025-06-21DOI: 10.1016/j.mfglet.2025.06.201
Rahmat Riza , Muslim Mahardika , Budi Arifvianto
Multi-material additive manufacturing for joining two dissimilar polymers, such as the rigid polylactic-acid and the flexible thermoplastic polyurethane, has gained attention of researchers. However, the interaction between these two printed materials remains poorly understood. This study evaluated the shear strength at the interface between PLA and TPU materials, joined through fused filament fabrication, using peel-off testing following ASTM 3163-01 standard. The results revealed low shear strength at the interface of these two printed materials, indicating that their bonding mechanism was primarily driven by surface contact. Furthermore, the applied raster angles significantly influenced the measured shear strength of the printed materials.
{"title":"Shear strength at the interface between polylactic-acid and thermoplastic polyurethane layers processed with multi-material additive manufacturing","authors":"Rahmat Riza , Muslim Mahardika , Budi Arifvianto","doi":"10.1016/j.mfglet.2025.06.201","DOIUrl":"10.1016/j.mfglet.2025.06.201","url":null,"abstract":"<div><div>Multi-material additive manufacturing for joining two dissimilar polymers, such as the rigid polylactic-acid and the flexible thermoplastic polyurethane, has gained attention of researchers. However, the interaction between these two printed materials remains poorly understood. This study evaluated the shear strength at the interface between PLA and TPU materials, joined through fused filament fabrication, using peel-off testing following ASTM 3163-01 standard. The results revealed low shear strength at the interface of these two printed materials, indicating that their bonding mechanism was primarily driven by surface contact. Furthermore, the applied raster angles significantly influenced the measured shear strength of the printed materials.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 21-25"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502311","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 : 2025-09-01Epub Date: 2025-07-17DOI: 10.1016/j.mfglet.2025.06.210
Satyaki Sinha, Tuhin Mukherjee
Laser beam shaping is a process of adjusting the intensity profile of the beam to generate an optimal energy distribution at a specific location. In laser powder bed fusion (LPBF), the shape of the laser beam impacts peak temperature, melt pool geometry, and cooling rates, however, a detailed scientific understanding of these effects is lacking. In this research, a 3D transient heat transfer model is implemented to investigate the dependence of temperature fields, melt pool geometry, and cooling rates on six different laser beam shapes: Gaussian, elliptical-Gaussian, top hat, flat top, ring-shaped, and adjustable mode beam. The model results are validated using experimental data for different beam shapes during LPBF of an aluminum alloy, AlSi10Mg. We found that a Gaussian beam, with its concentrated power, results in high peak temperatures and a larger melt pool with slow cooling, whereas an elliptical Gaussian beam produces a wider pool. The top hat and flat top beams distribute power more uniformly, leading to lower peak temperatures and faster cooling, with the flat top beam creating a wider but shallower pool. The ring-shaped beam, spreading energy over a larger area, significantly reduces peak temperature and cooling rate, while the adjustable mode beam with 80 % power in the outer ring exhibits similar temperature fields and pool dimensions to the ring-shaped beam.
{"title":"Effects of beam shaping on temperature, pool geometry, and cooling rate in laser powder bed fusion","authors":"Satyaki Sinha, Tuhin Mukherjee","doi":"10.1016/j.mfglet.2025.06.210","DOIUrl":"10.1016/j.mfglet.2025.06.210","url":null,"abstract":"<div><div>Laser beam shaping is a process of adjusting the intensity profile of the beam to generate an optimal energy distribution at a specific location. In laser powder bed fusion (LPBF), the shape of the laser beam impacts peak temperature, melt pool geometry, and cooling rates, however, a detailed scientific understanding of these effects is lacking. In this research, a 3D transient heat transfer model is implemented to investigate the dependence of temperature fields, melt pool geometry, and cooling rates on six different laser beam shapes: Gaussian, elliptical-Gaussian, top hat, flat top, ring-shaped, and adjustable mode beam. The model results are validated using experimental data for different beam shapes during LPBF of an aluminum alloy, AlSi10Mg. We found that a Gaussian beam, with its concentrated power, results in high peak temperatures and a larger melt pool with slow cooling, whereas an elliptical Gaussian beam produces a wider pool. The top hat and flat top beams distribute power more uniformly, leading to lower peak temperatures and faster cooling, with the flat top beam creating a wider but shallower pool. The ring-shaped beam, spreading energy over a larger area, significantly reduces peak temperature and cooling rate, while the adjustable mode beam with 80 % power in the outer ring exhibits similar temperature fields and pool dimensions to the ring-shaped beam.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 53-59"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144695336","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 : 2025-09-01Epub Date: 2025-08-19DOI: 10.1016/j.mfglet.2025.08.003
Abhishek Kumar , Rajan Singh , Soumen Mandal , Gayatri Paul , Barnali Maji , Manab Mallik
The direct ink writing (DIW) technique prints alumina Pyramidoids. Ink formulation included the usage of pure alumina powder, phenolic resin, and deionized water. Alumina ink with a solid loading of 64 vol% provides suitable rheological properties for 3D printing. The synthesized ink was used for 3D printing of a pyramidoid and sintering at different temperatures (1500 °C–1600 °C). The sample sintered at 1600 °C exhibits a dense microstructure (98 %), good flexural strength (308.34 ± 10 MPa), moderate fracture toughness (4.01 ± 0.4 MPa.m1/2), and high hardness (1625 HV).
{"title":"Structure-property correlation of alumina pyramidoids fabricated by direct ink writing","authors":"Abhishek Kumar , Rajan Singh , Soumen Mandal , Gayatri Paul , Barnali Maji , Manab Mallik","doi":"10.1016/j.mfglet.2025.08.003","DOIUrl":"10.1016/j.mfglet.2025.08.003","url":null,"abstract":"<div><div>The direct ink writing (DIW) technique prints alumina Pyramidoids. Ink formulation included the usage of pure alumina powder, phenolic resin, and deionized water. Alumina ink with a solid loading of 64 vol% provides suitable rheological properties for 3D printing. The synthesized ink was used for 3D printing of a pyramidoid and sintering at different temperatures (1500 °C–1600 °C). The sample sintered at 1600 °C exhibits a dense microstructure (98 %), good flexural strength (308.34 ± 10 MPa), moderate fracture toughness (4.01 ± 0.4 MPa.m<sup>1/2</sup>), and high hardness (1625 HV).</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 107-111"},"PeriodicalIF":2.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902888","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 : 2025-09-01Epub Date: 2025-07-19DOI: 10.1016/j.mfglet.2025.06.208
M. El Mehtedi, M. Carta, P. Buonadonna
This study explores a novel recycling process for AA3105 aluminum chips, incorporating an AA1050 aluminum envelope to facilitate the use of lubricants and improve surface quality without compromising chip bonding. The process, conducted at 540 °C, enhances microstructural uniformity, mechanical properties, and surface finish, addressing key challenges associated with traditional recycling methods. Microstructural analysis using optical microscopy and SEM confirmed effective chip consolidation, with minimal defects and elongated grain structures aligned along the rolling direction. Tensile testing revealed enhanced mechanical properties with a yield strength of 99 MPa, ultimate tensile strength of 139 MPa, and elongation at break of 16.7 %.
{"title":"A novel direct hot rolling process for sustainable recycling of AA3105 aluminum chips using a protective envelopment","authors":"M. El Mehtedi, M. Carta, P. Buonadonna","doi":"10.1016/j.mfglet.2025.06.208","DOIUrl":"10.1016/j.mfglet.2025.06.208","url":null,"abstract":"<div><div>This study explores a novel recycling process for AA3105 aluminum chips, incorporating an AA1050 aluminum envelope to facilitate the use of lubricants and improve surface quality without compromising chip bonding. The process, conducted at 540 °C, enhances microstructural uniformity, mechanical properties, and surface finish, addressing key challenges associated with traditional recycling methods. Microstructural analysis using optical microscopy and SEM confirmed effective chip consolidation, with minimal defects and elongated grain structures aligned along the rolling direction. Tensile testing revealed enhanced mechanical properties with a yield strength of 99 MPa, ultimate tensile strength of 139 MPa, and elongation at break of 16.7 %.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 70-74"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711534","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 : 2025-09-01Epub Date: 2025-07-17DOI: 10.1016/j.mfglet.2025.06.206
Mateusz Kopec , Dominika Przygucka , Ryszard Sitek , Stanisław Jóźwiak
This study investigates the effect of build orientation on the fatigue performance of Haynes 282 alloy manufactured via Direct Metal Laser Sintering at 0°, 45°, and 90°. Fatigue tests revealed superior service life for 0° and 45° orientations, attributed to equiaxed grains and high-angle grain boundaries identified by EBSD. Vertical builds exhibited columnar grains and reduced fatigue resistance. This work provides the first systematic correlation between grain boundary character and low-cycle fatigue behavior in DMLS-manufactured Haynes 282, expanding current understanding beyond Inconel-based systems and offering insights for orientation-based design optimization in critical high-temperature applications.
{"title":"Orientation-dependent low-cycle fatigue and grain boundary evolution in DMLS-fabricated Haynes 282 superalloy","authors":"Mateusz Kopec , Dominika Przygucka , Ryszard Sitek , Stanisław Jóźwiak","doi":"10.1016/j.mfglet.2025.06.206","DOIUrl":"10.1016/j.mfglet.2025.06.206","url":null,"abstract":"<div><div>This study investigates the effect of build orientation on the fatigue performance of Haynes 282 alloy manufactured via Direct Metal Laser Sintering at 0°, 45°, and 90°. Fatigue tests revealed superior service life for 0° and 45° orientations, attributed to equiaxed grains and high-angle grain boundaries identified by EBSD. Vertical builds exhibited columnar grains and reduced fatigue resistance. This work provides the first systematic correlation between grain boundary character and low-cycle fatigue behavior in DMLS-manufactured Haynes 282, expanding current understanding beyond Inconel-based systems and offering insights for orientation-based design optimization in critical high-temperature applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 45-52"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144686442","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 : 2025-09-01Epub Date: 2025-07-17DOI: 10.1016/j.mfglet.2025.06.207
Zefeng Wang , Jie Tang , Jinwen Zhong , Hanqing Shi
Inducing compressive residual stress into surface layer is believed to enhance fatigue strength of materials. Water cavitation jet peening (WCJP) is recommended because of its high efficiency and uniform processing. This work proposes an enhanced WCJP technology by dissolving carbon dioxide (CO2). Mass loss, Vickers hardness, surface profile, residual stress, cavitation pit and grain size of the processed Aluminum were investigated. Results indicate that appropriate CO2 dissolution promotes cavitation peening with less surface distortion. The induced compressive residual stress is 28.6 % larger than pure waterjet peening. CO2 content of 200 mg/L is recommended to obtain a desired peening performance.
{"title":"Enhancing surface treatment performance of water cavitation jet peening by dissolving CO2","authors":"Zefeng Wang , Jie Tang , Jinwen Zhong , Hanqing Shi","doi":"10.1016/j.mfglet.2025.06.207","DOIUrl":"10.1016/j.mfglet.2025.06.207","url":null,"abstract":"<div><div>Inducing compressive residual stress into surface layer is believed to enhance fatigue strength of materials. Water cavitation jet peening (WCJP) is recommended because of its high efficiency and uniform processing. This work proposes an enhanced WCJP technology by dissolving carbon dioxide (CO<sub>2</sub>). Mass loss, Vickers hardness, surface profile, residual stress, cavitation pit and grain size of the processed Aluminum were investigated. Results indicate that appropriate CO<sub>2</sub> dissolution promotes cavitation peening with less surface distortion. The induced compressive residual stress is 28.6 % larger than pure waterjet peening. CO<sub>2</sub> content of 200 mg/L is recommended to obtain a desired peening performance.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 65-69"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144694922","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 : 2025-09-01Epub Date: 2025-07-02DOI: 10.1016/j.mfglet.2025.06.203
Nils Schmidt, Jan Peters, Tountzer Tsagkir Dereli, Monika Kipp, Dirk Biermann
The grinding wheel topography is an important factor contributing to the grinding process result and an essential component for many simulation methods. While vitrified bonded aluminum oxide grinding wheels are widely used in the industry, measuring their topography is difficult. The optical properties of grains and bond, exhibiting highly variable slopes, transparency and specular reflections, impede the direct measurement using optical measuring instruments. Hence, a method of combining multiple measurements with varied illumination settings is proposed. Combining 20 measurements, the percentage of non-measured points for the examined specimen could be reduced from 93.6 % to 30.3 % compared to a single measurement.
{"title":"Advances in digitizing the topography of vitrified bonded aluminum oxide grinding wheels","authors":"Nils Schmidt, Jan Peters, Tountzer Tsagkir Dereli, Monika Kipp, Dirk Biermann","doi":"10.1016/j.mfglet.2025.06.203","DOIUrl":"10.1016/j.mfglet.2025.06.203","url":null,"abstract":"<div><div>The grinding wheel topography is an important factor contributing to the grinding process result and an essential component for many simulation methods. While vitrified bonded aluminum oxide grinding wheels are widely used in the industry, measuring their topography is difficult. The optical properties of grains and bond, exhibiting highly variable slopes, transparency and specular reflections, impede the direct measurement using optical measuring instruments. Hence, a method of combining multiple measurements with varied illumination settings is proposed. Combining 20 measurements, the percentage of non-measured points for the examined specimen could be reduced from 93.6 % to 30.3 % compared to a single measurement.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 41-44"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604837","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 : 2025-09-01Epub Date: 2025-07-19DOI: 10.1016/j.mfglet.2025.06.209
B. Scott Taysom , Brian Milligan , Tim Roosendaal , Ben Schuessler , Mieka Clark , Teresa Lemmon , Scott Whalen
Aluminum is publicly perceived as recyclable, but mixed alloys and impurities in aluminum scrap require dilution via energy-intensive primary aluminum or downcycling to low-quality castings. In this study, cast billets of shredded aluminum scrap (Twitch) were blended with pre-consumer AA 6061, extruded into tubes via Shear Assisted Processing and Extrusion (ShAPE), and aged to T1 and T6 tempers. Microscopy reveals that ShAPE refined and distributed the deleterious AlFeSi phases. The Twitch extrusions had tensile properties comparable to AA 6061 yet without homogenizing or adding primary aluminum. Energy savings were 85% compared to conventional extrusion of primary aluminum alloys.
{"title":"Upcycling of aluminum Twitch scrap via Shear Assisted Processing and Extrusion (ShAPE)","authors":"B. Scott Taysom , Brian Milligan , Tim Roosendaal , Ben Schuessler , Mieka Clark , Teresa Lemmon , Scott Whalen","doi":"10.1016/j.mfglet.2025.06.209","DOIUrl":"10.1016/j.mfglet.2025.06.209","url":null,"abstract":"<div><div>Aluminum is publicly perceived as recyclable, but mixed alloys and impurities in aluminum scrap require dilution via energy-intensive primary aluminum or downcycling to low-quality castings. In this study, cast billets of shredded aluminum scrap (Twitch) were blended with pre-consumer AA 6061, extruded into tubes via Shear Assisted Processing and Extrusion (ShAPE), and aged to T1 and T6 tempers. Microscopy reveals that ShAPE refined and distributed the deleterious AlFeSi phases. The Twitch extrusions had tensile properties comparable to AA 6061 yet without homogenizing or adding primary aluminum. Energy savings were 85% compared to conventional extrusion of primary aluminum alloys.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 75-79"},"PeriodicalIF":2.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144722937","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 : 2025-09-01Epub Date: 2025-07-21DOI: 10.1016/j.mfglet.2025.07.003
Nagendra Yadav, Shuyang He, Zhengpeng Yao
The investigation of surface features and quality improvement of natural stones using optical microscopy is a prominent area of research. Pebbles, which are commonly found in nature and exhibit diverse shapes, possess significant characteristics such as surface texture, ripples, and roughness. These features are important for both scientific research and industrial applications. Recently, advancements in optical microscopic imaging techniques have made it possible to efficiently and accurately characterize these surface features of pebbles, establishing it as a key research focus. This paper highlights the unique advantages of Parameter Indirect Microscopy Imaging (PIMI) technology in analyzing the surface features of pebbles, comparing it with Finite-Difference Time-Domain (FDTD) software. The resolution of the stone images obtained has been calculated and found to closely align with the FDTD simulation results.
{"title":"Optical microscopy for surface investigations of pebbles stone","authors":"Nagendra Yadav, Shuyang He, Zhengpeng Yao","doi":"10.1016/j.mfglet.2025.07.003","DOIUrl":"10.1016/j.mfglet.2025.07.003","url":null,"abstract":"<div><div>The investigation of surface features and quality improvement of natural stones using optical microscopy is a prominent area of research. Pebbles, which are commonly found in nature and exhibit diverse shapes, possess significant characteristics such as surface texture, ripples, and roughness. These features are important for both scientific research and industrial applications. Recently, advancements in optical microscopic imaging techniques have made it possible to efficiently and accurately characterize these surface features of pebbles, establishing it as a key research focus. This paper highlights the unique advantages of Parameter Indirect Microscopy Imaging (PIMI) technology in analyzing the surface features of pebbles, comparing it with Finite-Difference Time-Domain (FDTD) software. The resolution of the stone images obtained has been calculated and found to closely align with the FDTD simulation results.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 60-64"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144694921","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 : 2025-09-01Epub Date: 2025-08-12DOI: 10.1016/j.mfglet.2025.07.007
Erik Denlinger, Zoe Michaleris , Tyler Nelson
This study evaluates the effect of accounting for powder in mechanical predictions for laser powder-bed-fusion by comparing: an inherent-strain based mechanical-only analysis, and thermomechanical simulations where the thermal analysis is conducted with and without powder elements. Results on Inconel 718 parts show that the thermal predictions with powder elements have less than 7 % error while the thermal predictions without powder elements could not capture the trend in measurements. In predicting the peak distortion, the thermomechanical model with powder elements has 21 % lower prediction error than the model without powder elements and 30 % lower prediction error than the mechanical-only analysis.
{"title":"Effect of accounting for powder in thermomechanical simulations for laser powder bed fusion","authors":"Erik Denlinger, Zoe Michaleris , Tyler Nelson","doi":"10.1016/j.mfglet.2025.07.007","DOIUrl":"10.1016/j.mfglet.2025.07.007","url":null,"abstract":"<div><div>This study evaluates the effect of accounting for powder in mechanical predictions for laser powder-bed-fusion by comparing: an inherent-strain based mechanical-only analysis, and thermomechanical simulations where the thermal analysis is conducted with and without powder elements. Results on Inconel 718 parts show that the thermal predictions with powder elements have less than 7 % error while the thermal predictions without powder elements could not capture the trend in measurements. In predicting the peak distortion, the thermomechanical model with powder elements has 21 % lower prediction error than the model without powder elements and 30 % lower prediction error than the mechanical-only analysis.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 93-100"},"PeriodicalIF":2.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144863842","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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