3D Printing and Additive Manufacturing最新文献

Traditional defect detection methods for metal additive manufacturing (AM) have the problems of low detection efficiency and accuracy, while the existing machine learning detection algorithms are of poor adaptability and complex structure. To address the above problems, this article proposed an improved You Only Look Once version 3 (YOLOv3) algorithm to detect the surface defects of metal AM based on multispectrum. The weighted k-means algorithm is used to cluster the target samples to improve the matching degree between the prior frame and the feature layer. The network structure of YOLOv3 is modified by using the lightweight MobileNetv3 to replace the Darknet-53 in the original YOLOv3 algorithm. Dilated convolution and Inceptionv3 are added to improve the detection capability for surface defects. A multispectrum measuring system was also developed to obtain the AM surface data with defects for experimental verification. The results show that the detection accuracy in the test set by YOLOv3-MobileNetv3 network is 11% higher than that by the original YOLOv3 network on average. The detection accuracy for cracking defects of the three types of defects is significantly increased by 23.8%, and the detection speed is also increased by 18.2%. The experimental results show that the improved YOLOv3 algorithm realizes the end-to-end surface defect detection for metal AM with high accuracy and fast speed, which can be further applied for online defect detection.

Postprocessing of additively manufactured (AM) metal parts to remove support structures or improve the surface condition can be a manually intensive process. One novel solution is a two-step, self-terminating etching process (STEP), which achieves both support removal and surface smoothing. While the STEP has been demonstrated for laser powder bed fusion (L-PBF) 316L stainless steel, this work evaluates the impact of pre-STEP heat treatments and resulting changes in dislocation density and microstructure on the resulting surface roughness and amount of material removed. Two pre-STEP heat treatments were evaluated: stress relief at 470°C for 5 h and recrystallization-solution annealing at 1060°C for 1 h. Additionally, one set of specimens was processed without the pre-STEP heat treatment (as-printed condition). Dislocation density and phase composition were quantified using X-ray diffraction along with standard, metallurgical stain-etching techniques. This work, for the first time, highlights the mechanisms of sensitization of AM L-PBF 316L stainless steel and provides fundamental insights into selective etching of these materials. Results showed that the sensitization depth decreased with increasing dislocation density. For samples etched at a STEP bias of 540 mV_SHE, material removal terminated at grain boundaries; therefore, the fine-grained stress-relieved specimen had the lowest post-STEP surface roughness. For surface roughness optimization, parts should be stress relived pre-STEP. However, to achieve more material removal, pre-STEP solution annealing should be performed.

In recent days, the additive manufacturing process plays a vital role in the production of tool electrodes, which are used in the electrical discharge machining (EDM) process. In this work, the copper (Cu) electrodes prepared using the direct metal laser sintering (DMLS) process are used for the EDM process. The performance of the DMLS Cu electrode is studied by machining the AA4032-TiC composite material using the EDM process. Then the performance of the DMLS Cu electrode is compared with the conventional Cu electrode. Three input parameters, such as peak current (A), pulse on time (s), and gap voltage (v), are selected for the EDM process. The performance measures, which are determined during the EDM process, are material removal rate (MRR), tool wear rate, surface roughness (SR), microstructural analysis of machined surface, and residual stress. At a higher pulse on time, more material was removed from the workpiece surface and thus MRR is enhanced. Likewise, at a higher peak current, the SR is amplified and thus wider craters are formed on the machined surface. The residual stress on the machined surface has influenced the formation of craters, microvoids, and globules. Lower SR and residual stress are attained by using DMLS Cu electrode, whereas MRR is higher when using conventional Cu electrode.

The austenitic 316L stainless steel (SS) is used extensively for marine applications as well as in construction, processing, and petrochemical industries due to its outstanding corrosion resistance properties. This study investigates the density, microhardness, and microstructural development of 316L SS samples fabricated by selective laser melting (SLM) under high laser energy densities. The selective laser melted (SLMed) specimens were fabricated under high laser energy densities (500, 400, and 333.33 J/mm³) and their metallurgical and mechanical properties were compared with the wrought specimen. SLMed 316L SS showed excellent printability, thereby enabling the fabrication of parts near full density. The porosity content present in the SLMed specimens was determined by both the image analysis method and Archimedes method. SLMed 316L specimens fabricated by the SLM process allowed observation of a microhardness of 253 HV_1.0 and achieved relative density up to 98.022%. Microstructural analysis using optical microscopy and phase composition analysis by X-ray diffraction (XRD) has been performed. Residual stresses were observed using the XRD method, and compressive stress (-68.9 MPa) was noticed in the as-printed specimen along the surface of the build direction. The microstructure of the as-built SLMed specimens consisted of a single-phase face-centered cubic solid solution with fine cellular and columnar grains along the build direction. The SLMed specimens seemed to yield better results than the wrought counterpart. IRB approval and Clinical Trial Registration Number are not applicable for this current work.

Wire and arc additive manufacturing (WAAM) is becoming a promising technique due to its high deposition rate and low cost. However, WAAM faces challenges of coarse grains. In this study, a novel in situ vibration method was proposed to suppress these imperfections of WAAM. Temperature and vibration distributions were explored first, and the optimized parameters were utilized for manufacturing low-carbon steel parts. The results revealed that after the vibration, the average grain size in fine grain zone was reduced from 9.8 to 7.1 μm, and that in coarse grain zone was declined from 10.6 to 7.4 μm, respectively. No large deformation occurred due to the low temperature. Grain refining was attributed to more dendrite fragments induced by excessive stress at the roots of dendrites. The refined grains enhanced mechanical strength of the parts in both X and Z directions and improved the average hardness. After the vibration, the ultimate tensile strength and yield strength were increased to 522.5 and 395 MPa, which represented an increase of 10% and 13.8%, respectively. The average hardness was improved to 163 HV, which was an increase of 10.1%.

Copper (Cu) nanoparticles are considered a promising alternative to silver (Ag) and gold (Au) for printed electronics applications. Because Cu has higher electrical conductivity, it is significantly cheaper than Ag and Au. To study the applicability of electronic printing, we prepared Ag@Cu conductive ink by using a stepwise feeding method to disperse nano Ag and nano Cu in ethanol and water. The ink has the advantages of nontoxic, low content, and low cost. A three-dimensional (3D) model was designed, and a conductive pattern was printed on the photo paper substrate using extrusion 3D printing technology. The influence of waterborne resin on the adhesion of conductive patterns is discussed. The printed conductive pattern can maintain the stability of conductivity after 100 bending cycles. The conductive pattern has good thermal stability. It can be tested 10 times under 2 conditions of 85°C and room temperature to maintain good conductivity. This shows that Ag@Cu conductive ink printed flexible electronic products are competitive.

Do extrusion temperature, printing speed, and layer time affect mechanical performance of interlayer bonds in material extrusion additive manufacturing (MEAM)? The question is one of the main challenges in 3D printing of polymers. This article aims to analyze the independent effect of printing parameters on interlayer bonding in MEAM. In previous research, printing parameters were unavoidably interrelated, such as printing speed and layer cooling time. Here, original specimen designs allow the effects to be studied independently for the first time to provide new understanding of the effects of a wide range of thermal factors on mechanical properties of 3D-printed polylactide. The experimental approach used direct GCode design to manufacture specially designed single-filament-thick specimens for tensile testing to measure mechanical and thermal properties normal to the interface between layers. In total, five different extrusion temperatures (a range of 60°C), five different printing speeds (a 16-fold change in the magnitude) and four different layer times (an 8-fold change) were independently studied. The results demonstrate interlayer bond strength to be equivalent to that of the bulk material within experimental scatter. This study provides strong evidence about the crucial role of microscale geometry for apparent interlayer bond strength relative to the role of thermal factors. By designing specimens specifically for the MEAM process, this study clearly demonstrates that bulk-material strength can be achieved for interlayer bonds in MEAM even when printing parameters change severalfold. Widespread industrial and academic efforts to improve interlayer bonding should be refocused to study extrusion geometry-the primary cause of anisotropy in MEAM.

In the production of geometries that traditional methods cannot produce, it is seen that additive manufacturing (AM) technology, which has come to the fore, has been used extensively in conformal cooling channel (CCC) applications in recent years. This study, conducted within the scope of CCC's use of applied mold cores in automotive industry plastic part production, aimed to reduce the cycle time in the injection printing process. The v1 geometry, which gives the analysis results for ideal printing quality from the channel geometries developed with three different design approaches, is produced with direct metal laser sintering, which is an AM laser sintering technology, and the injection printing cycle time has been reduced by 38%. CCC applied the study's primary motivation to develop duct geometry to provide balanced cooling in the automotive industry's mold cores produced with AM. It is known that the Computer Numerical Control machining process in traditional mold methods does not allow the processing of the channels in the internal geometries, and the deep areas where the heat is concentrated cannot be cooled sufficiently. In the study, CCC geometries where AM design parameters are used effectively and the balanced cooling performance expected from the die core can be achieved. The effects of different geometries on production are discussed.

We present a generative approach for creating three-dimensional lattice structures optimized for mass and deflection composed of thousands of one-dimensional strut primitives. Our approach draws inspiration from topology optimization principles. The proposed method iteratively determines unnecessary lattice struts through stress analysis, erodes those struts, and then randomly generates new struts across the entire structure. The objects resulting from this distributed optimization technique demonstrate high strength-to-weight ratios that are at par with state-of-the-art topology optimization approaches, but are qualitatively very different. We use a dynamics simulator that allows optimization of structures subject to dynamic load cases, such as vibrating structures and robotic components. Because optimization is performed simultaneously with simulation, the process scales efficiently on massively parallel graphics processing units. The intricate nature of the output lattices contributes to a new class of objects intended specifically for additive manufacturing. Our work contributes a highly parallel simulation method and simultaneous algorithm for analyzing and optimizing lattices with thousands of struts. In this study, we validate multiple versions of our algorithm across sample load cases, to show its potential for creating high-resolution objects with implicit optimized microstructural patterns.

Powder-based (inkjet) three-dimensional printing (3DP) technology presents great promise in the construction industry. The capacity to build complex geometries is one of the most appealing features of the process without formwork. This article focuses on the vital aspect of using a modified powder (CP) instead of commercial powder (ZP 151). It also discusses the effects of the size of specimens and the curing process of 3DP specimens. This article presents not only the improved mechanical properties of the mortar that are revealed through a heat-curing procedure but also the properties of the reinforced mortar with chopped glass fibers. Experiments are conducted on cubic printed mortar specimens and cured in an oven at different temperature regimes. Tests show that 80°C is the optimum heat-curing temperature to attain the highest compressive and flexural strength of the specimens. The orientation angle has a significant effect on the mechanical behavior of printed specimens. Therefore, specimens are prepared by printing at different orientation angles to compare the mechanical properties of common construction materials. Powder-based 3DP has three planes (XY, XZ, and YZ) along which a load can be applied to the specimen. The mechanical strength in each direction across each plane is different, making it an anisotropic material. For CP specimens, the highest compressive strength was obtained using a 0° rotation in the printing orientation of the XY plane. For shear strength, a 45° orientation gave the optimum result, while for tensile and flexural strength, a 0° orientation provided the highest values. The optimum strength for ZP 151 specimens in compression, shear, tension, and bending was obtained by printing with orientation angles of 0°, 30°, 0°, and 0°, respectively. Finally, laser scanning of the printed specimens has been conducted so the surface roughness profiles for the 3DP specimens of ZP 151 and CP can be compared and presented.