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High-speed 3D printing of alloy architectures enabled by continuous liquid interface production 高速3D打印合金结构实现连续液界面生产
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-27 DOI: 10.1016/j.addma.2026.105092
Dylan Joralmon, Vaibhav Mistari, August Bant, Soham Khairnar, Amir Danial Azimiand, Xiangjia Li
Metal additive manufacturing (MAM) has received a lot of research attention since high-quality alloy components with optimized designs can be produced for a wide range of applications in aerospace and biomedical industries. However, the printing resolution, high operational cost, and overall printing time hinder the full potential of MAM as a solution for realizing next generation functionally graded multi-metals. Herein, a low viscosity copper nickel (CuNi) alloy precursor resin was incorporated into the continuous liquid interface production (CLIP) 3D printing process resulting in microscale CuNi alloy objects with low surface roughness (Ra = 0.795 µm) and superior printing speed (exceeding 130 µm/s). Because alloy precursor additives are used to synthesize CuNi alloy parts, physical properties, such as relative density and microstructure porosity, can be controlled by adjusting the CuNi composition, sintering temperature, and metal precursor concentration resulting in microporosity values ranging from extremely dense to highly porous (0.2 %-5.71 %). Moreover, continuously 3D printed CuNi alloys are monolithic and exhibit a uniform microstructure after post-heat treatment, showing an overall volumetric shrinkage of 60–75 %, resulting in isotropic physical properties displayed in the final printed part. Due to the high level of control over the process, novel alloy metamaterials such as bio-inspired lattice structures with microscale porosity and good mechanical or thermal properties can be easily reproduced. This research demonstrates that alloy and multi-metal 3D objects fabricated through the layer-less AM approach provides a cost-effective and innovative strategy to overcome the current limitations of layer-based multi-metal AM technologies.
金属增材制造(MAM)受到了广泛的研究关注,因为经过优化设计的高质量合金部件可以在航空航天和生物医学工业中广泛应用。然而,打印分辨率、高操作成本和整体打印时间阻碍了MAM作为实现下一代功能梯度多金属的解决方案的全部潜力。本文将低粘度铜镍(CuNi)合金前驱体树脂加入到连续液界面生产(CLIP) 3D打印工艺中,得到了表面粗糙度低(Ra = 0.795 µm)、打印速度快(超过130 µm/s)的微尺度CuNi合金物体。由于使用合金前驱体添加剂来合成CuNi合金零件,因此可以通过调节CuNi成分、烧结温度和金属前驱体浓度来控制相对密度和微观组织孔隙率等物理性能,从而使微孔隙率从极致密到高多孔(0.2 %-5.71 %)。此外,连续3D打印的CuNi合金是整体的,经过热处理后具有均匀的微观结构,整体体积收缩率为60 - 75% %,从而在最终打印部件中显示出各向同性的物理性能。由于对工艺的高度控制,新型合金超材料,如具有微孔隙度和良好机械或热性能的仿生晶格结构,可以很容易地复制。该研究表明,通过无层增材制造方法制造合金和多金属3D物体,为克服当前基于层的多金属增材制造技术的局限性提供了一种具有成本效益和创新性的策略。
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引用次数: 0
Corrigendum to “Formation of compositionally graded grains and molten-salt corrosion behavior in wire-arc additive manufactured NiMoCr alloy-cladded steel” [Addit. Manuf. 116 (2026), 105079] “在电弧添加剂制造的NiMoCr合金包覆钢中组成梯度晶粒的形成和熔盐腐蚀行为”的勘误[add .]说明书116 (2026),105079]
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-25 DOI: 10.1016/j.addma.2026.105084
Hanliang Zhu , Zhijun Qiu , Zhiyang Wang , Ondrej Muránsky , Inna Karatchevtseva , Huijun Li
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引用次数: 0
Acoustic emission directionality of the melt pool in laser powder bed fusion additive manufacturing 激光粉末床熔融增材制造中熔池声发射的方向性
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-25 DOI: 10.1016/j.addma.2026.105096
Shivam Shukla , Rik Vaerenberg , Milad Hamidi Nasab , Konstantinos Gryllias , Bey Vrancken
Vibro-acoustic monitoring has emerged as a promising approach for process monitoring and control in laser powder bed fusion (LPBF). Its high temporal resolution and capability to capture events occurring on the microsecond scale can assist in developing a comprehensive understanding of complex melt pool dynamics and laser-material interaction. However, the physical linkage between the acoustic signal and the process remains a challenge. This work attempts to uncover the complex mechanism of the LPBF process by understanding acoustic signals and linking them with the actual physical conditions. A microphone is used to capture the acoustic emissions (AE) generated from the processing zone. Additionally, an on-axis high-speed camera is used for melt pool monitoring and spatter tracking. Analyzing AE signals shows that signal energy fluctuations within the frequency band of 100–250 kHz are influenced by changes in inherent processing conditions, such as scan direction and the orientation of the vector sequence direction. These fluctuations are correlated with backward vapor plume, melt pool asymmetry, and spatter ejection during layer processing. The study further reveals that during processing, the spatter ejects toward the built side of the layer. As most of the previous work on the use of acoustic emission monitoring of laser powder bed fusion relied heavily on machine learning (ML) for regime classification and anomaly detection, correlating acoustic signals with the actual physical events will add to data labeling by providing complementary contextual information, thereby enhancing the performance of these models. Additionally, this contextual information is a prerequisite to be able to advance acoustic monitoring from the layer level to the more local defect level.
振动声监测已成为激光粉末床熔合(LPBF)过程监测和控制的一种有前途的方法。它的高时间分辨率和捕捉微秒级事件的能力有助于全面了解复杂的熔池动力学和激光材料相互作用。然而,声信号和过程之间的物理联系仍然是一个挑战。本研究试图通过理解声信号并将其与实际物理条件联系起来,揭示LPBF过程的复杂机制。麦克风用于捕获从加工区产生的声发射(AE)。此外,一个轴向高速摄像机用于熔池监测和飞溅跟踪。对声发射信号的分析表明,100-250 kHz频段内的信号能量波动受固有处理条件(如扫描方向和矢量序列方向方向)变化的影响。这些波动与层加工过程中的向后蒸汽羽流、熔池不对称和溅射有关。研究进一步表明,在加工过程中,飞溅物向层的内置侧喷射。由于之前使用声发射监测激光粉末床融合的大部分工作都严重依赖于机器学习(ML)进行状态分类和异常检测,因此将声信号与实际物理事件相关联将通过提供补充的上下文信息来增加数据标记,从而提高这些模型的性能。此外,上下文信息是能够将声学监测从层级推进到更局部的缺陷级的先决条件。
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引用次数: 0
Preparation and precision control of alumina-based ceramic core using the SLA-Micromilling hybrid process 采用sla -微铣复合工艺制备氧化铝基陶瓷芯及其精度控制
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-24 DOI: 10.1016/j.addma.2026.105095
Hongyu Xing , Wenxuan Jiang , Xinfeng Wang , Laixiao Lu , Zhenzhong Zhang , Guangchao Hao , Yanhua Zhao , Bin Zou , Chuanzhen Huang
SLA-3D printing technology offers significant advantages in the fabrication of complex ceramic cores. However, several issues must be addressed immediately, which include dimensional deviations caused by light scattering in ceramic-resin slurries, deformation resulting from anisotropic shrinkage during sintering, and surface quality limitations caused by interlayer step effects. To address these issues, a SLA-Micromilling hybrid manufacturing process for preparing alumina-based ceramic cores is proposed, which consists of three stages: SLA-3D printing of the green body, micro-milling refinement of the green body, and debinding sintering. Firstly, a KH570-H/Al2O3 ceramic slurry suitable for SLA-3D printing was designed and prepared, capable of being transformed into SiO2/Al2O3 ceramic. During high-temperature sintering, this slurry forms rod-like mullite phases, which improve mechanical properties through a whisker-toughening mechanism. At a sintering temperature of 1400 ℃, the material exhibits a porosity of 33.7 % and a flexural strength of 28.7 MPa. The shrinkage rates in the x, y, and z directions were 10.4 %, 9.8 %, and 13.7 %, respectively. Secondly, to address dimensional deviations caused by the size sensitivity of SLA-3D printed green bodies and sintering anisotropy, a segmented compensation model was established, reducing the deviation rate in both the printing and sintering stages to approximately 5 %. Micro-milling technology was introduced to enhance machining precision even further. A systematic investigation of the material removal mechanisms during micro-milling of green bodies was conducted, including the effects of resin softening and adhesion, as well as ceramic particle attachment on tool wear. Optimizing cutting parameters (ap=0.3 mm, n = 1100 r/min, f=75 mm/min) resulted in the blank’s surface roughness Ra of 0.3018 μm. Finally, alumina-based complex core samples fabricated using a composite process of SLA printing, micro-milling, and sintering resulted in a significant reduction of surface roughness from 3.571 μm to 0.3113 μm, with a dimensional standard deviation of 0.0588 mm. And the thermal shock resistance, high-temperature creep resistance, and high-temperature chemical stability of ceramic core samples were evaluated.
SLA-3D打印技术在复杂陶瓷芯的制造方面具有显著的优势。然而,有几个问题必须立即解决,其中包括陶瓷树脂浆料中的光散射引起的尺寸偏差,烧结过程中各向异性收缩引起的变形,以及层间台阶效应引起的表面质量限制。为了解决这些问题,提出了一种用于制备氧化铝基陶瓷芯的sla -微铣削混合制造工艺,该工艺包括三个阶段:坯体的SLA-3D打印、坯体的微铣削细化和脱粘烧结。首先,设计并制备了适合SLA-3D打印的KH570-H/Al2O3陶瓷浆料,并将其转化为SiO2/Al2O3陶瓷;在高温烧结过程中,浆料形成棒状莫来石相,通过晶须增韧机制提高机械性能。在1400℃的烧结温度下,材料的孔隙率为33.7% %,抗弯强度为28.7 MPa。x、y、z方向收缩率分别为10.4 %、9.8 %、13.7 %。其次,针对SLA-3D打印绿体尺寸敏感性和烧结各向异性导致的尺寸偏差,建立了分段补偿模型,将打印和烧结阶段的偏差率降低到约5 %。微铣削技术的引入进一步提高了加工精度。系统研究了绿体微铣削过程中材料的去除机理,包括树脂软化和粘附作用以及陶瓷颗粒附着对刀具磨损的影响。优化切削参数(ap=0.3 mm, n = 1100 r/min, f=75 mm/min)后,毛坯表面粗糙度Ra为0.3018 μm。最后,采用SLA打印、微铣削和烧结复合工艺制备的氧化铝基复合芯样品,表面粗糙度从3.571 μm显著降低到0.3113 μm,尺寸标准偏差为0.0588 mm。并对陶瓷岩心样品的抗热震性、高温蠕变性和高温化学稳定性进行了评价。
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引用次数: 0
STEAM: A scalable data-driven surrogate modeling framework for part-scale scanwise thermal process simulation of laser powder bed fusion 蒸汽:一个可扩展的数据驱动的替代建模框架,用于激光粉末床熔合的局部扫描热过程模拟
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-22 DOI: 10.1016/j.addma.2026.105090
Berkay Bostan, Praveen Vulimiri, Shawn Hinnebusch, Dhruba Aryal, Albert C. To
Simulating scanwise thermal behavior at part scale in laser powder bed fusion (LPBF) is essential for understanding defects and optimizing process parameters, but it remains prohibitively expensive for real engineering parts. While finite element method (FEM) based process simulations provide valuable insights, the steep computational cost limits their routine application. This work introduces a scalable data-driven surrogate modeling framework for scanwise LPBF thermal simulation through deep learning called STEAM (Scanwise Thermal Emulator for Additive Manufacturing) to predict the transient thermal history of complex parts. The key features behind the proposed framework include 1) a compact dataset constructed from geometrically distinct modular blocks capturing representative thermal patterns, and 2) a combination of temporal and spatial features employed as model inputs to capture key physical phenomena influencing thermal behavior. Temporal features describe how each node interacts with the moving heat source over time, while spatial features capture the effect of the surrounding geometry on local heat conduction and boundary conditions. The model is validated on 2.5D test geometries as much as ∼10 times larger than the training cases with different geometric complexity. On large-scale test blocks, STEAM achieves an of 0.97, and 29.61 °C mean absolute error, with a 1237–3648 × speedup compared with FEM using four GPUs (i.e., 309–912 × per GPU). Importantly, performance improves with increasing model complexity, which is promising for further scaling STEAM to larger and more complex LPBF domains. These results demonstrate that the STEAM framework provides a promising path toward fast and accurate thermal prediction in real-world LPBF parts.
模拟激光粉末床熔合(LPBF)中零件尺度的扫描热行为对于了解缺陷和优化工艺参数至关重要,但对于实际工程零件来说仍然过于昂贵。虽然基于有限元方法(FEM)的过程模拟提供了有价值的见解,但高昂的计算成本限制了它们的常规应用。这项工作通过深度学习为scanwise LPBF热模拟引入了一个可扩展的数据驱动代理建模框架,称为STEAM (scanwise热模拟器用于增材制造),以预测复杂零件的瞬态热历史。提出的框架背后的关键特征包括:1)由几何上不同的模块块构建的紧凑数据集,捕获具有代表性的热模式;2)将时空特征组合作为模型输入,捕获影响热行为的关键物理现象。时间特征描述了每个节点如何随着时间的推移与移动的热源相互作用,而空间特征捕捉了周围几何形状对局部热传导和边界条件的影响。该模型在2.5D测试几何上进行了验证,测试几何比具有不同几何复杂度的训练案例大10倍。在大规模测试块上,STEAM的R²为0.97,平均绝对误差为29.61°C,与使用四个GPU(即每个GPU 309-912 ×)的FEM相比,加速提高了1237-3648 × 。重要的是,性能随着模型复杂性的增加而提高,这有望进一步将STEAM扩展到更大、更复杂的LPBF领域。这些结果表明,STEAM框架为实现实际LPBF零件的快速准确热预测提供了一条有希望的途径。
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引用次数: 0
Process-aware topology optimization leveraging deep learning surrogate model-based functions for laser powder bed fusion 基于深度学习代理模型的激光粉末床融合过程感知拓扑优化
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-22 DOI: 10.1016/j.addma.2026.105094
Praveen S. Vulimiri, Shane Garner, Albert C. To
Additive manufacturing (AM) methods have greatly matured over the years to produce complex metal parts not previously possible. One of the major methods is laser powder bed fusion (LPBF) AM, which melts and sinters powder in a layer-by-layer manner to build a part. However, during the process, the laser melting of the metal powders introduces thermal stresses that distort the part, possibly causing recoater blade interference and build failure. Topology optimization (TO) approaches have been developed to control the residual stress and distortion with geometric constraints and simplified process simulations using the finite element analysis (FEA) method. Due to computational complexity, these works ignore inelastic deformations and material nonlinearities. Indeed, early attempts incorporating these effects limit themselves to support regions or small domains for the same reason. This work enables the first computationally tractable, support-free part TO of residual inelastic deformations due to LPBF manufacturing and end-use application simultaneously. The framework leverages a data-driven surrogate model trained on elastoplastic FEA layerwise modified inherent strain simulations for stainless steel 316L. The residual deformations and sensitivities can be calculated in seconds, easily coupling with the FEA-based end-use application and analytic maximum volume constraint. A multi-objective, discrete, gradient-based TO analysis minimizes the top surface vertical distortion at each layer alongside the end-use application, scaling to hundreds of thousands of design variables. In fact, the largest test example with over 400 iterations converged in less time than the single verification FEA simulation, 2.5 days versus 4 days. Two test examples with various overhang angle constraints are computationally verified and experimentally validated. Notably, the process-aware designs replace convex openings with columnar or thin wall supports and concave openings with teardrop-like openings. In both simulation and experiment, the process-aware designs distorted less, protruded less above the powder layer, and caused zero build failures.
多年来,增材制造(AM)方法已经非常成熟,可以生产以前不可能生产的复杂金属零件。其中一种主要的方法是激光粉末床熔融增材制造(LPBF),它以一层一层的方式熔化和烧结粉末来制造零件。然而,在此过程中,激光熔化金属粉末会引入热应力,使零件变形,可能导致重涂机叶片干扰和构建失败。利用几何约束和简化的有限元模拟方法,开发了拓扑优化方法来控制残余应力和变形。由于计算的复杂性,这些工作忽略了非弹性变形和材料非线性。事实上,由于同样的原因,早期尝试将这些影响限制在支持区域或小领域。这项工作使第一个可计算处理的,无支撑的零件TO的残余非弹性变形,由于LPBF制造和最终应用同时进行。该框架利用了一个数据驱动的代理模型,该模型是在不锈钢316L的弹塑性有限元分层修正固有应变模拟中训练出来的。残余变形和灵敏度可以在几秒钟内计算出来,很容易与基于有限元的最终用途应用和分析的最大体积约束相结合。多目标、离散、基于梯度的TO分析可以最大限度地减少最终应用中每一层的顶部表面垂直变形,扩展到数十万个设计变量。事实上,超过400次迭代的最大测试示例比单个验证FEA模拟在更短的时间内收敛,2.5天对4天。对两个具有不同悬挑角约束的测试实例进行了计算验证和实验验证。值得注意的是,过程感知设计用柱状或薄壁支撑代替凸开口,用泪滴状开口代替凹开口。在模拟和实验中,工艺感知设计的变形较小,粉末层上方突出较少,并且造成零构建失败。
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引用次数: 0
Integrating 3D-printed metal and polymer geometries with CMOS microdevices toward MEMS high-resolution lateral force sensing 将3d打印金属和聚合物几何形状与CMOS微器件集成到MEMS高分辨率横向力传感
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-21 DOI: 10.1016/j.addma.2026.105085
Isha Lodhi , Devin K. Brown , Durga Gajula , B.D. Haile , David R. Myers , Wilbur A. Lam , Azadeh Ansari
Advances in metal 3D-microprinting technologies, such as electrodeposition, have meant that Micro-Electro-Mechanical Systems (MEMS) are no longer limited to soft, non-conductive polymers only. However, challenges such as process compatibility, limited optical resolution (and hence alignment), is why metal micro-additive processes have not been integrated with active CMOS circuitry or microdevices. This work demonstrates methods for integrating high-aspect-ratio (HAR) 3D-printed metal pillars with piezoresistive microdevices to produce compact, high-sensitivity MEMS lateral force sensors. Building on our prior demonstration of the first MEMS device made using traditionally (CMOS) fabricated, functional microdevices with 3D-printed metal, we describe the chip and device level modifications necessary for post-CMOS metal 3D-printing using the aqueous and acidic copper electrodeposition workflow. By using surface height mapping of 2.5D alignment marks patterned adjacent to the sub-micron width piezoresistors, we achieve repeatable print-to-microdevice alignment accuracy better than < ±0.5 μm across chips. The resulting sensors pair N-type, silicon-doped piezoresistors with electrodeposited copper pillars (aspect ratio >70). Electrical measurements confirm device integrity after electrodeposition, while electro-mechanical characterization of the force sensors yield sensitivities up to ΔR/R0 = 0.26% μN−1, and a noise-limited resolution of ±35 nN. The electrodeposited HAR copper pillar sensors exhibit excellent linearity, repeatability, and high resistance to delamination due to the metal-to-metal bonding between the copper pillars and underlying conductive traces. In a second study separate to metal 3D-printing, we boost the MEMS force sensor sensitivity with introduction of stress-concentrating, “open” trenches around the silicon piezoresistors. This approach was tested with two-photon polymerized pillars. The polymer pillar sensors, with open trenches, demonstrate sensitivities up to 0.44% μN−1, and a corresponding higher force resolution of ±20 nN. These sensors also show excellent repeatability and low hysteresis but delaminate off of the silicon devices near Fx ≈ 6 μN. Given that both sensor types use pillar-based, out-of-plane mechanics, the active on-chip footprint is confined to a few μm2, making them well suited for high spatial resolution force mapping and forming dense arrays for biological cell/tissue mechanics.
金属3d微打印技术的进步,如电沉积,意味着微机电系统(MEMS)不再局限于软的、不导电的聚合物。然而,诸如工艺兼容性、有限的光学分辨率(以及校准)等挑战是金属微增材工艺尚未与有源CMOS电路或微器件集成的原因。这项工作展示了将高纵横比(HAR) 3d打印金属柱与压阻式微器件集成在一起的方法,以生产紧凑、高灵敏度的MEMS横向力传感器。在我们之前演示的第一个使用传统(CMOS)制造的MEMS器件的基础上,我们描述了使用水和酸性铜电沉积工作流程进行后CMOS金属3d打印所需的芯片和器件级修改。通过使用与亚微米宽度压敏电阻相邻的2.5D对齐标记的表面高度映射,我们实现了可重复的打印到微器件的对齐精度,其精度优于芯片之间的±0.5 μm。由此产生的传感器将n型掺杂硅的压阻与电沉积铜柱配对(长宽比>;70)。电测量证实了电沉积后器件的完整性,而力传感器的机电特性产生灵敏度高达ΔR/R0 = 0.26% μN−1,噪声限制分辨率为±35 nN。电沉积HAR铜柱传感器由于铜柱和底层导电迹线之间的金属对金属结合,具有良好的线性、可重复性和高抗分层性。在与金属3d打印分离的第二项研究中,我们通过在硅压敏电阻周围引入应力集中的“开放式”沟槽来提高MEMS力传感器的灵敏度。用双光子聚合柱对该方法进行了测试。该聚合物柱传感器的灵敏度可达0.44% μN−1,相应的力分辨率可达±20 nN。这些传感器也具有优异的重复性和低迟滞,但在Fx≈6 μN附近会从硅器件上脱落。考虑到这两种传感器类型都使用基于柱的平面外力学,芯片上的主动足迹被限制在几μm2,这使得它们非常适合用于高空间分辨率的力映射和形成生物细胞/组织力学的密集阵列。
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引用次数: 0
Rapid layerwise process model calibration through a surrogate model for interpass temperature history in laser powder bed fusion 通过替代模型对激光粉末床熔合过程中道间温度历史进行快速分层过程模型标定
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-19 DOI: 10.1016/j.addma.2026.105091
Shawn Hinnebusch , Praveen S. Vulimiri , Christapher G. Lang , Alaa Olleak , Florian X. Dugast , Albert C. To
Layerwise thermal process simulation is widely used for predicting heat buildup and residual stress in parts built by the laser powder bed fusion (LPBF) process. However, calibration of layerwise process simulation model parameters (such as absorptivity and convection coefficients) using in-process thermal measurements typically requires hundreds of process simulations to reach convergence due to the large model parameter space. To significantly reduce the number of process simulations needed for calibration, this work proposes a surrogate model (SGM) to accurately model the relationship between simulated interpass temperature time history and model parameters needing calibration using simple functions. Specifically, the SGM is constructed by fitting multi-variate polynomials to the temperature histories mapped to a low-dimensional model space through the principal component analysis (PCA), as a function of the process model parameters. Since the SGM is 4–5 orders of magnitude faster than finite element method based process simulations, it can be used to calibrate the model parameters in several minutes. The SGM specifically developed for calibrating three process model parameters requires only ten process simulations to fit its coefficients and is tested to be accurate using 18 simulated temperature histories to fit ten model coefficients, yielding a mean absolute percentage error (MAPE) between 0.12 % and 2.04 % across four test geometries. Applying the fitted surrogate models to calibrate absorptivity, top surface convection coefficient, and part-side surface convection coefficient to match the temperature histories measured by an infrared camera, a MAPE between 2.84 % and 3.46 % is achieved across the four test geometries using the same set of model parameters. Two unseen geometries are tested with the fully calibrated FEM model with errors under 3.7 % MAPE. The proposed SGM approach is demonstrated to be a valuable tool for accurate part-scale thermal prediction by significantly reducing calibration time and computational resources.
分层热过程模拟被广泛用于预测激光粉末床熔合(LPBF)工艺制造的零件的积热和残余应力。然而,由于模型参数空间大,使用过程中热测量的分层过程模拟模型参数(如吸收率和对流系数)的校准通常需要数百个过程模拟才能达到收敛。为了显著减少校准所需的过程模拟次数,本工作提出了一个替代模型(SGM),该模型可以使用简单的函数准确地模拟模拟的通间温度时间历史与需要校准的模型参数之间的关系。具体而言,SGM是通过主成分分析(PCA)将多变量多项式拟合到映射到低维模型空间的温度历史,作为过程模型参数的函数来构建的。由于SGM比基于有限元方法的过程模拟快4-5个数量级,因此可以在几分钟内用于校准模型参数。专门为校准三个过程模型参数而开发的SGM只需要10个过程模拟来拟合其系数,并且使用18个模拟温度历史来拟合10个模型系数进行了准确测试,在四个测试几何形状中产生的平均绝对百分比误差(MAPE)在0.12 %和2.04 %之间。利用拟合的替代模型来校准吸收率、顶面对流系数和部分面对流系数,以匹配红外相机测量的温度历史,使用相同的模型参数,在四种测试几何形状中获得了2.84 %和3.46 %之间的MAPE。用完全校准的有限元模型测试了两个看不见的几何形状,误差在3.7 % MAPE以下。该方法通过显著减少校准时间和计算资源,被证明是一种有价值的精确局部尺度热预测工具。
{"title":"Rapid layerwise process model calibration through a surrogate model for interpass temperature history in laser powder bed fusion","authors":"Shawn Hinnebusch ,&nbsp;Praveen S. Vulimiri ,&nbsp;Christapher G. Lang ,&nbsp;Alaa Olleak ,&nbsp;Florian X. Dugast ,&nbsp;Albert C. To","doi":"10.1016/j.addma.2026.105091","DOIUrl":"10.1016/j.addma.2026.105091","url":null,"abstract":"<div><div>Layerwise thermal process simulation is widely used for predicting heat buildup and residual stress in parts built by the laser powder bed fusion (LPBF) process. However, calibration of layerwise process simulation model parameters (such as absorptivity and convection coefficients) using in-process thermal measurements typically requires hundreds of process simulations to reach convergence due to the large model parameter space. To significantly reduce the number of process simulations needed for calibration, this work proposes a surrogate model (SGM) to accurately model the relationship between simulated interpass temperature time history and model parameters needing calibration using simple functions. Specifically, the SGM is constructed by fitting multi-variate polynomials to the temperature histories mapped to a low-dimensional model space through the principal component analysis (PCA), as a function of the process model parameters. Since the SGM is 4–5 orders of magnitude faster than finite element method based process simulations, it can be used to calibrate the model parameters in several minutes. The SGM specifically developed for calibrating three process model parameters requires only ten process simulations to fit its coefficients and is tested to be accurate using 18 simulated temperature histories to fit ten model coefficients, yielding a mean absolute percentage error (MAPE) between 0.12 % and 2.04 % across four test geometries. Applying the fitted surrogate models to calibrate absorptivity, top surface convection coefficient, and part-side surface convection coefficient to match the temperature histories measured by an infrared camera, a MAPE between 2.84 % and 3.46 % is achieved across the four test geometries using the same set of model parameters. Two unseen geometries are tested with the fully calibrated FEM model with errors under 3.7 % MAPE. The proposed SGM approach is demonstrated to be a valuable tool for accurate part-scale thermal prediction by significantly reducing calibration time and computational resources.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"118 ","pages":"Article 105091"},"PeriodicalIF":11.1,"publicationDate":"2026-01-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Direct Ink Writing of metakaolin-based geopolymers: Rheology and printability control using PEG and inorganic fillers 偏高岭土聚合物的直接油墨书写:使用聚乙二醇和无机填料的流变性和印刷性控制
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-17 DOI: 10.1016/j.addma.2026.105086
Xavier Lacambra-Andreu , Mario Scheel , Arnaud Poulesquen
This study aims to optimize the rheological properties of metakaolin (MK) based geopolymers for Direct Ink Writing (DIW) applications. The research explores the effects of Polyethylene Glycol (PEG) and calcite (HP) as rheological modifiers, focusing on their impact on yield stress, shear modulus, the time-dependent evolution of viscosity and structural stability. Through rheological analysis, we identify the formulation with the optimal balance between buildability and extrudability. Results demonstrate that PEG significantly decreases geopolymerization kinetics, increasing the printability window, while HP enhances the mechanical stiffness and yield stress of geopolymer paste. A comprehensive rheological evaluation, including stress growth, oscillatory tests, and creep experiments, highlights the importance of following long-term behavior. A case study on column printing demonstrates the importance of rheological controlling by predicting and confirming critical failure heights (sagging and buckling). X-ray tomography confirms the internal porosity and structural integrity of the printed filters. This work establishes the potential for geopolymer formulations in innovative applications like 3D-printed filtration systems by offering an approach to create formulations that combine printability, shape stability, and mechanical integrity.
本研究旨在优化用于直接墨水书写(DIW)的偏高岭土(MK)基地聚合物的流变性能。该研究探讨了聚乙二醇(PEG)和方解石(HP)作为流变改性剂的影响,重点研究了它们对屈服应力、剪切模量、粘度随时间演变和结构稳定性的影响。通过流变学分析,我们确定了在可构建性和可挤压性之间达到最佳平衡的配方。结果表明,聚乙二醇显著降低了地聚合物动力学,增加了可打印性窗口,而HP提高了地聚合物浆料的机械刚度和屈服应力。综合流变学评估,包括应力增长、振荡试验和蠕变实验,强调了遵循长期行为的重要性。以圆柱印刷为例,说明了通过预测和确定临界失效高度(下垂和屈曲)进行流变控制的重要性。x射线断层扫描证实了印刷滤光片的内部孔隙度和结构完整性。这项工作通过提供一种方法来创建结合可打印性、形状稳定性和机械完整性的配方,从而确立了地聚合物配方在3d打印过滤系统等创新应用中的潜力。
{"title":"Direct Ink Writing of metakaolin-based geopolymers: Rheology and printability control using PEG and inorganic fillers","authors":"Xavier Lacambra-Andreu ,&nbsp;Mario Scheel ,&nbsp;Arnaud Poulesquen","doi":"10.1016/j.addma.2026.105086","DOIUrl":"10.1016/j.addma.2026.105086","url":null,"abstract":"<div><div>This study aims to optimize the rheological properties of metakaolin (MK) based geopolymers for Direct Ink Writing (DIW) applications. The research explores the effects of Polyethylene Glycol (PEG) and calcite (HP) as rheological modifiers, focusing on their impact on yield stress, shear modulus, the time-dependent evolution of viscosity and structural stability. Through rheological analysis, we identify the formulation with the optimal balance between buildability and extrudability. Results demonstrate that PEG significantly decreases geopolymerization kinetics, increasing the printability window, while HP enhances the mechanical stiffness and yield stress of geopolymer paste. A comprehensive rheological evaluation, including stress growth, oscillatory tests, and creep experiments, highlights the importance of following long-term behavior. A case study on column printing demonstrates the importance of rheological controlling by predicting and confirming critical failure heights (sagging and buckling). X-ray tomography confirms the internal porosity and structural integrity of the printed filters. This work establishes the potential for geopolymer formulations in innovative applications like 3D-printed filtration systems by offering an approach to create formulations that combine printability, shape stability, and mechanical integrity.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"117 ","pages":"Article 105086"},"PeriodicalIF":11.1,"publicationDate":"2026-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146025210","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Accelerating laser ray tracing in high fidelity physics simulations of laser melting using squeeze U-net 利用挤压U-net加速激光熔化高保真物理模拟中的激光追踪
IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2026-01-14 DOI: 10.1016/j.addma.2026.105087
Robert C. Blake, Saad A. Khairallah
Laser melting is a core component of the ongoing industrial revolution, dubbed Industry 4.0, as lasers facilitate fast and precise melting and fusion in advanced manufacturing. There is a strong need to optimize the laser process using simulations. However, this has proven challenging as high fidelity simulations are needed for predictive modeling and this is currently prohibitively expensive even when run on hundreds of processors on high performance computers. The challenge is capturing complex physics of laser material interaction, fluid dynamics, thermal physics and material phase transformations at various length and time scales. To close this technological gap, we modified a squeeze U-net to accelerate the laser ray tracing component of such high fidelity models by 4x–40x while preserving the core physics principle of conservation of energy with 97% accuracy. This approach enables the accurate modeling of global laser energy absorption as a function of local surface temperatures and complex surface topologies, which govern the reflection directions and energy losses of laser rays upon interacting with the material surface.
激光熔化是正在进行的工业革命的核心组成部分,被称为工业4.0,因为激光在先进制造中促进了快速精确的熔化和融合。有一个强烈的需要,以优化激光过程中使用模拟。然而,这已经被证明是具有挑战性的,因为预测建模需要高保真度的模拟,而且即使在高性能计算机上运行数百个处理器,目前这也非常昂贵。挑战在于捕捉各种长度和时间尺度下激光材料相互作用、流体动力学、热物理和材料相变的复杂物理。为了缩小这一技术差距,我们改进了挤压U-net,将这种高保真模型的激光跟踪组件加速了4 - 40倍,同时以97%的精度保留了能量守恒的核心物理原理。这种方法能够精确地模拟全局激光能量吸收作为局部表面温度和复杂表面拓扑的函数,这决定了激光与材料表面相互作用时的反射方向和能量损失。
{"title":"Accelerating laser ray tracing in high fidelity physics simulations of laser melting using squeeze U-net","authors":"Robert C. Blake,&nbsp;Saad A. Khairallah","doi":"10.1016/j.addma.2026.105087","DOIUrl":"10.1016/j.addma.2026.105087","url":null,"abstract":"<div><div>Laser melting is a core component of the ongoing industrial revolution, dubbed Industry 4.0, as lasers facilitate fast and precise melting and fusion in advanced manufacturing. There is a strong need to optimize the laser process using simulations. However, this has proven challenging as high fidelity simulations are needed for predictive modeling and this is currently prohibitively expensive even when run on hundreds of processors on high performance computers. The challenge is capturing complex physics of laser material interaction, fluid dynamics, thermal physics and material phase transformations at various length and time scales. To close this technological gap, we modified a squeeze U-net to accelerate the laser ray tracing component of such high fidelity models by <span><math><mo>∼</mo></math></span>4x–40x while preserving the core physics principle of conservation of energy with 97% accuracy. This approach enables the accurate modeling of global laser energy absorption as a function of local surface temperatures and complex surface topologies, which govern the reflection directions and energy losses of laser rays upon interacting with the material surface.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"118 ","pages":"Article 105087"},"PeriodicalIF":11.1,"publicationDate":"2026-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146006637","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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Additive manufacturing
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