{"title":"Fabrication of Piezoelectric Structures with High Porosity by Digital Light Processing","authors":"Dongcai Zhang, Yaodong Yang, Xuhan Lv, Wei-Feng Rao","doi":"10.1089/3dp.2023.0079","DOIUrl":"https://doi.org/10.1089/3dp.2023.0079","url":null,"abstract":"","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"63 4","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136102378","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This article presents a fabrication strategy on the structural design, optimization, additive manufacturing, and processing of metal mirror. Specifically, the study showcases the topology design of a metal mirror with diameter of 200 mm, the additive manufacturing of standard aluminum-based powder (AlSi10Mg), the high-precision single-point diamond turning process of the surface. By setting the feasible domain partition, a topology optimization model suitable for metal additive manufacturing and subsequent surface shaping was constructed, which takes into account the multi-load machining load conditions of single-point diamond turning technology and the material topology representation of standard support structures for additive manufacturing. The results demonstrate that the optimization model effectively suppresses the vibration phenomenon during single-point cutting. Furthermore, the results of the optical interferometer surface inspection confirm that the design and processing strategy for additively manufactured metal mirrors demonstrated in this study can be directly applied to infrared band reflective imaging optical systems.
{"title":"Fabrication Strategy of Additively Manufactured Metal Mirror Based on Multi-Load Topology Optimization and Single-Point Diamond Turning","authors":"Qianglong Wang, Chong Wang, Yisheng Chen, Luchao Cheng, Chen Liu, Wenda Niu, Jitong Zhao, Zhiyu Zhang, Zhenyu Liu","doi":"10.1089/3dp.2023.0106","DOIUrl":"https://doi.org/10.1089/3dp.2023.0106","url":null,"abstract":"This article presents a fabrication strategy on the structural design, optimization, additive manufacturing, and processing of metal mirror. Specifically, the study showcases the topology design of a metal mirror with diameter of 200 mm, the additive manufacturing of standard aluminum-based powder (AlSi10Mg), the high-precision single-point diamond turning process of the surface. By setting the feasible domain partition, a topology optimization model suitable for metal additive manufacturing and subsequent surface shaping was constructed, which takes into account the multi-load machining load conditions of single-point diamond turning technology and the material topology representation of standard support structures for additive manufacturing. The results demonstrate that the optimization model effectively suppresses the vibration phenomenon during single-point cutting. Furthermore, the results of the optical interferometer surface inspection confirm that the design and processing strategy for additively manufactured metal mirrors demonstrated in this study can be directly applied to infrared band reflective imaging optical systems.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"51 4","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136263481","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mingju Lei, Yanen Wang, Qinghua Wei, Mingyang Li, Juan Zhang, Yanmei Wang
The varied material and the inherent complex microstructure make predicting the effective stiffness of fused deposition modeling (FDM) printed polylactic acid (PLA)/carbon fiber (CF) composite a troublesome problem. This article proposes a microstructure scanning electron microscope (SEM) mapping modeling and numerical mean procedure to calculate the effective stiffness of FDM printing PLA/CF laminates. The printed PLA/CF parts were modeled as a continuum of 3D uniform linear elasticity with orthotropic anisotropy, and their elastic behavior was characterized by orthotropic constitutive relations. Micromechanical models of two typical deposition configurations, 0° unidirectional aligned configuration and 0°/90° angle-ply configuration of the printed parts were established based on the periodic representative volume element (RVE) technique. The elastic constants of the RVE models were estimated by volume average method in the finite element stress analysis, and the effects of deposition configurations, CF length, and content on the effective stiffness were also investigated. The results show that the effective stiffness of FDM printing PLA/CF composite is closely related to CF length, content, and the deposition configuration. With the increase of CF length and content, the Young's modulus and shear modulus of printed PLA/CF parts increase, whereas Poisson's ratio decreases. The printed PLA/CF parts with 0° unidirectional aligned configuration exhibits orthotropic characteristics, and the maximum Young's modulus appears along the first axis. The 0°/90° angle-ply FDM PLA/CF composite exhibits transverse isotropic characteristics and the lowest Young's modulus is found along the thickness direction.
{"title":"Numerical Homogenization Calculation of Effective Stiffness of Fused Deposition Modeling Printing Carbon Fiber Reinforced Polylactic Acid Composites","authors":"Mingju Lei, Yanen Wang, Qinghua Wei, Mingyang Li, Juan Zhang, Yanmei Wang","doi":"10.1089/3dp.2023.0131","DOIUrl":"https://doi.org/10.1089/3dp.2023.0131","url":null,"abstract":"The varied material and the inherent complex microstructure make predicting the effective stiffness of fused deposition modeling (FDM) printed polylactic acid (PLA)/carbon fiber (CF) composite a troublesome problem. This article proposes a microstructure scanning electron microscope (SEM) mapping modeling and numerical mean procedure to calculate the effective stiffness of FDM printing PLA/CF laminates. The printed PLA/CF parts were modeled as a continuum of 3D uniform linear elasticity with orthotropic anisotropy, and their elastic behavior was characterized by orthotropic constitutive relations. Micromechanical models of two typical deposition configurations, 0° unidirectional aligned configuration and 0°/90° angle-ply configuration of the printed parts were established based on the periodic representative volume element (RVE) technique. The elastic constants of the RVE models were estimated by volume average method in the finite element stress analysis, and the effects of deposition configurations, CF length, and content on the effective stiffness were also investigated. The results show that the effective stiffness of FDM printing PLA/CF composite is closely related to CF length, content, and the deposition configuration. With the increase of CF length and content, the Young's modulus and shear modulus of printed PLA/CF parts increase, whereas Poisson's ratio decreases. The printed PLA/CF parts with 0° unidirectional aligned configuration exhibits orthotropic characteristics, and the maximum Young's modulus appears along the first axis. The 0°/90° angle-ply FDM PLA/CF composite exhibits transverse isotropic characteristics and the lowest Young's modulus is found along the thickness direction.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135729984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Robocasting calcium phosphate compounds as a novel approach to creating customized structures with interconnected pores not only overcomes the limitations of traditional fabrication methods of calcium phosphate substitutes but also boosts the potential for bone tissue regeneration. The ink development is a key step in 3D printing. In this study, different inks consisting of magnesium- and sodium-doped carbonated hydroxyapatite, β-tricalcium phosphate, and Pluronic F-127 were prepared to design biomimetic bone scaffolds. To achieve suitable printability and subsequently, structures with high shape fidelity and appropriate mechanical properties, the selected compositions were evaluated by rheological analysis and mechanical tests. The results demonstrated that the prepared inks exhibited shear thinning behavior, and by increasing the concentration of Pluronic and biphasic calcium phosphate (BCP), more consistent gels were obtained that were able to maintain their shape after printing. The compressive strength of the scaffolds varied in the range of ∼8–60 MPa. The morphology of the sintered scaffolds in the scanning electron microscopy images also showed a dual macro- and micropore-size architecture, which can promote the adhesion of proteins and cell behavior. Our findings indicated that bioinspired BCP scaffolds can be fabricated with relatively high precision for use as cancellous bone substitutes.
{"title":"Development of Bioinspired Biphasic Calcium Phosphate Inks for Manufacturing Bone Scaffolds by Robocasting","authors":"Samira Tajvar, Afra Hadjizadeh, Saeed Saber Samandari","doi":"10.1089/3dp.2023.0082","DOIUrl":"https://doi.org/10.1089/3dp.2023.0082","url":null,"abstract":"Robocasting calcium phosphate compounds as a novel approach to creating customized structures with interconnected pores not only overcomes the limitations of traditional fabrication methods of calcium phosphate substitutes but also boosts the potential for bone tissue regeneration. The ink development is a key step in 3D printing. In this study, different inks consisting of magnesium- and sodium-doped carbonated hydroxyapatite, β-tricalcium phosphate, and Pluronic F-127 were prepared to design biomimetic bone scaffolds. To achieve suitable printability and subsequently, structures with high shape fidelity and appropriate mechanical properties, the selected compositions were evaluated by rheological analysis and mechanical tests. The results demonstrated that the prepared inks exhibited shear thinning behavior, and by increasing the concentration of Pluronic and biphasic calcium phosphate (BCP), more consistent gels were obtained that were able to maintain their shape after printing. The compressive strength of the scaffolds varied in the range of ∼8–60 MPa. The morphology of the sintered scaffolds in the scanning electron microscopy images also showed a dual macro- and micropore-size architecture, which can promote the adhesion of proteins and cell behavior. Our findings indicated that bioinspired BCP scaffolds can be fabricated with relatively high precision for use as cancellous bone substitutes.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"69 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135779149","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Additive manufacturing (AM) techniques have the potential to produce complex parts, and many of these techniques require the use of support structures to prevent deformations and to minimize thermal effects during the printing process, particularly when building overhangs and internal cavities. However, removing the support structures through postprocessing incurs additional costs and time penalties. Unlike other AM techniques, support structures are not used in directed energy deposition (DED) technique due to its working principle. Therefore, special multiaxis complex path-planning strategies for DED are adopted to print relatively simple overhang geometries. Nevertheless, printing internal channels using this technique can still be challenging or nearly impossible. In this work, a novel DED process using graphite as a support material is proposed for additively manufacturing simple and complex internal channels. The support material is easily removed without requiring extensive machining processes. The results demonstrated that the support material did not negatively impact part quality, and in fact, the presence of different carbides at the interaction zone increased hardness and Young's modulus. Moreover, there were no cracks and or porosity at the support material-part interface. This study is the first of its kind to demonstrate the potential for using graphite as a support material for DED processes in additively manufacturing parts with complex internal channels and overhangs and highlights the need for further research in this area.
{"title":"Directed Energy Deposition of Parts with Internal Channels Using Removable Graphite Supports","authors":"Dilara Celik, Ali Karaca, Bahattin Koc","doi":"10.1089/3dp.2023.0057","DOIUrl":"https://doi.org/10.1089/3dp.2023.0057","url":null,"abstract":"Additive manufacturing (AM) techniques have the potential to produce complex parts, and many of these techniques require the use of support structures to prevent deformations and to minimize thermal effects during the printing process, particularly when building overhangs and internal cavities. However, removing the support structures through postprocessing incurs additional costs and time penalties. Unlike other AM techniques, support structures are not used in directed energy deposition (DED) technique due to its working principle. Therefore, special multiaxis complex path-planning strategies for DED are adopted to print relatively simple overhang geometries. Nevertheless, printing internal channels using this technique can still be challenging or nearly impossible. In this work, a novel DED process using graphite as a support material is proposed for additively manufacturing simple and complex internal channels. The support material is easily removed without requiring extensive machining processes. The results demonstrated that the support material did not negatively impact part quality, and in fact, the presence of different carbides at the interaction zone increased hardness and Young's modulus. Moreover, there were no cracks and or porosity at the support material-part interface. This study is the first of its kind to demonstrate the potential for using graphite as a support material for DED processes in additively manufacturing parts with complex internal channels and overhangs and highlights the need for further research in this area.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"50 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135855549","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Xiaomei Zheng, Yongqing Wang, Guohong Du, Shaoshuai Yin
3D printing is an indispensable technology in modern life and is widely used in aerospace, exoskeleton, and architecture. The increasing accuracy requirements of 3D printed objects in these fields require high-precision measurement methods to obtain accurate data. Based on the precision measurement requirements, in this study, a fast multifrequency phase unwrapping method based on 3D printing object appearance acquisition is proposed. By performing standard image acquisition of 3D printed objects that are not limited to materials and sampling locations, the surface shape and texture details of the objects can be accurately reconstructed using this method, independent of ambient light, with high robustness. Compared with the conventional multifrequency method, the required projection pattern is reduced from 12 to 9 and the overall measurement efficiency is improved by 25%, while maintaining the advantages of the independent pixel calculation method of the multifrequency method. In addition, the effectiveness of the method is experimentally verified by complex surface reconstruction experiments and plaster model experiments, which provide accurate measurement accuracy with high efficiency and precision. Therefore, the method can provide accurate measurements for 3D printed objects.
{"title":"Fast Multifrequency Phase Unwrapping Method Based on 3D Printing Object Appearance Acquisition","authors":"Xiaomei Zheng, Yongqing Wang, Guohong Du, Shaoshuai Yin","doi":"10.1089/3dp.2023.0166","DOIUrl":"https://doi.org/10.1089/3dp.2023.0166","url":null,"abstract":"3D printing is an indispensable technology in modern life and is widely used in aerospace, exoskeleton, and architecture. The increasing accuracy requirements of 3D printed objects in these fields require high-precision measurement methods to obtain accurate data. Based on the precision measurement requirements, in this study, a fast multifrequency phase unwrapping method based on 3D printing object appearance acquisition is proposed. By performing standard image acquisition of 3D printed objects that are not limited to materials and sampling locations, the surface shape and texture details of the objects can be accurately reconstructed using this method, independent of ambient light, with high robustness. Compared with the conventional multifrequency method, the required projection pattern is reduced from 12 to 9 and the overall measurement efficiency is improved by 25%, while maintaining the advantages of the independent pixel calculation method of the multifrequency method. In addition, the effectiveness of the method is experimentally verified by complex surface reconstruction experiments and plaster model experiments, which provide accurate measurement accuracy with high efficiency and precision. Therefore, the method can provide accurate measurements for 3D printed objects.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136097322","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Suian Wang, Chuang Deng, Olanrewaju Ojo, Bamidele Akinrinlola, Jared Kozub, Nan Wu
Auxetic honeycomb structures have been applied in lightweight sandwich structure and impact energy absorption applications due to their unique deformation performance. Based on the traditional two-dimensional reentrant honeycomb structure, a modified three-dimensional (3D) reentrant lattice structure with negative Poisson's ratio (NPR) is proposed. The studies on fabrication and design parameters are conducted, leading to a new understanding of the effects of these parameters on the printing quality and mechanical properties of such lattice structure with reentrant diagonal struts. Additive manufacturing (AM), specifically laser powder bed fusion, is used to fabricate five groups of 18Ni350 Maraging Steel samples with different geometric and printing parameters. The compression test is conducted to obtain the effects of NPR on the quasi-static stress-strain relationship of the proposed structure. The results show that smaller hatch distance and scan speed for 3D printing process can lead to less porosity level and more complete printing, resulting in larger stiffness and yield strength of the structure. The preferred AM process variables to improve structural quality with thin angled struts (diameter ≤0.5 mm) are presented. Moreover, with the help of the tuned finite element model based on experimental results, parametric analysis is conducted to confirm the effect of design parameters, including reentrant angle, strut cross-section shape, and size, on the compressive properties of the structure.
{"title":"Additive Manufacturability and Parametric Studies on an Extended Three-Dimensional Re-Entrant Auxetic Structure with Angled Struts","authors":"Suian Wang, Chuang Deng, Olanrewaju Ojo, Bamidele Akinrinlola, Jared Kozub, Nan Wu","doi":"10.1089/3dp.2023.0086","DOIUrl":"https://doi.org/10.1089/3dp.2023.0086","url":null,"abstract":"Auxetic honeycomb structures have been applied in lightweight sandwich structure and impact energy absorption applications due to their unique deformation performance. Based on the traditional two-dimensional reentrant honeycomb structure, a modified three-dimensional (3D) reentrant lattice structure with negative Poisson's ratio (NPR) is proposed. The studies on fabrication and design parameters are conducted, leading to a new understanding of the effects of these parameters on the printing quality and mechanical properties of such lattice structure with reentrant diagonal struts. Additive manufacturing (AM), specifically laser powder bed fusion, is used to fabricate five groups of 18Ni350 Maraging Steel samples with different geometric and printing parameters. The compression test is conducted to obtain the effects of NPR on the quasi-static stress-strain relationship of the proposed structure. The results show that smaller hatch distance and scan speed for 3D printing process can lead to less porosity level and more complete printing, resulting in larger stiffness and yield strength of the structure. The preferred AM process variables to improve structural quality with thin angled struts (diameter ≤0.5 mm) are presented. Moreover, with the help of the tuned finite element model based on experimental results, parametric analysis is conducted to confirm the effect of design parameters, including reentrant angle, strut cross-section shape, and size, on the compressive properties of the structure.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"19 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136355094","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abigail Batley, Richard Glithro, Bryce Dyer, Philip Sewell
As additive manufacturing (AM) with composite materials becomes more widely used in industry to create high-strength components, it is vital to have quantified material properties that provide designers and engineers accurate data to decide which materials are suitable for their applications. This study replicates the build processes and tensile tests undertaken by AM material manufacturers to compare tensile strengths achieved with those stated on the manufacturers' data sheets. These are important data to research and analyze as either it will corroborate properties given by the manufacturers and provide confidence in the values provided or it will show that the manufacturer's values cannot always be achieved and that designers and engineers must be more critical about the values manufacturers are providing when using the materials in their own applications. Tensile tests were performed on additively manufactured specimens that had been built using the same parameters that were used during the manufacturers' testing procedures. Digital image correlation was used to accurately measure strain in the test samples, enabling material properties to be determined. Microscopy analysis enabled the visual inspection of the print quality, the identification of defects, and the determination of volume fraction with the samples. The results show inconsistencies between the tensile strength results achieved during this study and the tensile strengths stated by the manufacturers. The results show that two materials exceeded the expected values and one material did not reach the expected value. Analysis of the 3D printed specimens shows that poor fiber–matrix wetting, large voids, and weak interfacial bonding were accountable for the lower-than-expected tensile strength results. While good print quality, low void percentage, proper fiber–matrix wetting, and good control measures were accountable for results that exceeded expectation. These results show that designers and engineers cannot solely rely on material data sheets to establish the mechanical properties of their 3D printed components.
{"title":"Evaluation of Tensile Strength and Repeatability of 3D Printed Carbon Fiber Materials and Processes","authors":"Abigail Batley, Richard Glithro, Bryce Dyer, Philip Sewell","doi":"10.1089/3dp.2022.0262","DOIUrl":"https://doi.org/10.1089/3dp.2022.0262","url":null,"abstract":"As additive manufacturing (AM) with composite materials becomes more widely used in industry to create high-strength components, it is vital to have quantified material properties that provide designers and engineers accurate data to decide which materials are suitable for their applications. This study replicates the build processes and tensile tests undertaken by AM material manufacturers to compare tensile strengths achieved with those stated on the manufacturers' data sheets. These are important data to research and analyze as either it will corroborate properties given by the manufacturers and provide confidence in the values provided or it will show that the manufacturer's values cannot always be achieved and that designers and engineers must be more critical about the values manufacturers are providing when using the materials in their own applications. Tensile tests were performed on additively manufactured specimens that had been built using the same parameters that were used during the manufacturers' testing procedures. Digital image correlation was used to accurately measure strain in the test samples, enabling material properties to be determined. Microscopy analysis enabled the visual inspection of the print quality, the identification of defects, and the determination of volume fraction with the samples. The results show inconsistencies between the tensile strength results achieved during this study and the tensile strengths stated by the manufacturers. The results show that two materials exceeded the expected values and one material did not reach the expected value. Analysis of the 3D printed specimens shows that poor fiber–matrix wetting, large voids, and weak interfacial bonding were accountable for the lower-than-expected tensile strength results. While good print quality, low void percentage, proper fiber–matrix wetting, and good control measures were accountable for results that exceeded expectation. These results show that designers and engineers cannot solely rely on material data sheets to establish the mechanical properties of their 3D printed components.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"44 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136293039","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Matthew Drummond, Abdelkrem Eltaggaz, Ibrahim Nouzil, Ibrahim Deiab
The fused deposition modeling (FDM) form of additive manufacturing provides a low-cost opportunity to quickly create unique parts with complex geometries using a high degree of precision. This is accomplished through a layer-by-layer extrusion of a metallic infused thermoplastic from a heated nozzle onto a build plate, until the 3D part is achieved. The ability to produce cheaply manufactured FDM printed cast iron parts would allow industries to bypass casting lead times and create custom cast iron parts without a machined mold. However, there has been minimal research into FDM printing of cast iron and the corresponding effects of printing parameters. The current study aims to determine the acceptable printing parameter ranges for FDM printed cast iron. The effects of three printing parameters (flow rate, infill density, and layer height) were studied with regard to the porosity, shrinkage, mass, and volume of the FDM printed cast iron. A flow rate range of 145–185% was determined to provide good-quality print while an infill density in the range of 100–125% for most flow rates provided acceptable print quality. Furthermore, the layer height was determined to have no significant effect on the printed part. Regarding the effect of printing parameters on the shrinkage, mass, and volume of the FDM printed part, the study showed that increasing the flow rate and infill density resulted in reduced shrinkage and a higher relative sintered mass and volume. Additionally, increasing the layer height showed an insignificant change in the sintered mass, volume, and shrinkage. Sintered samples obtained densities ranging between 5.02 and 5.44 g/cc and porosity measurements from 7.14% to 18.85%. This is one of the first studies on the FDM printing of cast iron. The results would enable researchers and hobbyists to successfully print their first cast iron part.
{"title":"Establishment of Select Printing Parameters for Low-Cost Fused Deposition Modeling Printed Cast Iron Through Experimental Optimization","authors":"Matthew Drummond, Abdelkrem Eltaggaz, Ibrahim Nouzil, Ibrahim Deiab","doi":"10.1089/3dp.2023.0114","DOIUrl":"https://doi.org/10.1089/3dp.2023.0114","url":null,"abstract":"The fused deposition modeling (FDM) form of additive manufacturing provides a low-cost opportunity to quickly create unique parts with complex geometries using a high degree of precision. This is accomplished through a layer-by-layer extrusion of a metallic infused thermoplastic from a heated nozzle onto a build plate, until the 3D part is achieved. The ability to produce cheaply manufactured FDM printed cast iron parts would allow industries to bypass casting lead times and create custom cast iron parts without a machined mold. However, there has been minimal research into FDM printing of cast iron and the corresponding effects of printing parameters. The current study aims to determine the acceptable printing parameter ranges for FDM printed cast iron. The effects of three printing parameters (flow rate, infill density, and layer height) were studied with regard to the porosity, shrinkage, mass, and volume of the FDM printed cast iron. A flow rate range of 145–185% was determined to provide good-quality print while an infill density in the range of 100–125% for most flow rates provided acceptable print quality. Furthermore, the layer height was determined to have no significant effect on the printed part. Regarding the effect of printing parameters on the shrinkage, mass, and volume of the FDM printed part, the study showed that increasing the flow rate and infill density resulted in reduced shrinkage and a higher relative sintered mass and volume. Additionally, increasing the layer height showed an insignificant change in the sintered mass, volume, and shrinkage. Sintered samples obtained densities ranging between 5.02 and 5.44 g/cc and porosity measurements from 7.14% to 18.85%. This is one of the first studies on the FDM printing of cast iron. The results would enable researchers and hobbyists to successfully print their first cast iron part.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"42 3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136293235","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The high-temperature mechanical properties and fracture mechanism of selective laser melting (SLM) manufactured nickel-based alloy are highly important for its application. In this article, small punch test (SPT) method is used to study the mechanical properties of SLM-manufactured GH4169 over a wide temperature range from 25°C to 600°C. With the increase of temperature, the decreasing ratio of maximum load is only 18.75% from 25°C to 600°C, and the yield load fluctuates with temperature, proving that it maintains the excellent load-bearing ability at high temperature. From the variation law of the normalized SPT fracture energy versus temperature, the ductile-to-brittle transition temperature of SLM-manufactured GH4169 is 413.63°C indicating the change of fracture mechanism. Moreover, the “fish scale” printed layer near the fracture surface changes from the difficult deformed microstructure to significant deformed one, leading to the variation of the fracture mechanism from brittle cleavage fracture traversing the printed layers to ductile fracture along the printed layers. This article reveals the variations of strength parameters, fracture energy, and fracture mechanism with temperature for SLM-manufactured GH4169 over a wide temperature range, which provides basic data for its application at different temperatures.
{"title":"Mechanical Properties and Fracture Mechanism of Selective Laser Melting Manufactured Nickel-Based Alloy by Small Punch Test Over a Wide Temperature Range","authors":"Jian Peng, Xiangxuan Geng, Jian Bao, Zhiquan Zuo, Mingxuan Gao, Jiacheng Gu","doi":"10.1089/3dp.2023.0130","DOIUrl":"https://doi.org/10.1089/3dp.2023.0130","url":null,"abstract":"The high-temperature mechanical properties and fracture mechanism of selective laser melting (SLM) manufactured nickel-based alloy are highly important for its application. In this article, small punch test (SPT) method is used to study the mechanical properties of SLM-manufactured GH4169 over a wide temperature range from 25°C to 600°C. With the increase of temperature, the decreasing ratio of maximum load is only 18.75% from 25°C to 600°C, and the yield load fluctuates with temperature, proving that it maintains the excellent load-bearing ability at high temperature. From the variation law of the normalized SPT fracture energy versus temperature, the ductile-to-brittle transition temperature of SLM-manufactured GH4169 is 413.63°C indicating the change of fracture mechanism. Moreover, the “fish scale” printed layer near the fracture surface changes from the difficult deformed microstructure to significant deformed one, leading to the variation of the fracture mechanism from brittle cleavage fracture traversing the printed layers to ductile fracture along the printed layers. This article reveals the variations of strength parameters, fracture energy, and fracture mechanism with temperature for SLM-manufactured GH4169 over a wide temperature range, which provides basic data for its application at different temperatures.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"37 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136293568","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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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