Additive manufacturing最新文献_第2页

Concurrent optimization of laser scanning path and structural topology for thermal distortion control in additive manufacturing 面向增材制造热变形控制的激光扫描路径与结构拓扑并行优化

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105046

Xiaoyu Huang , Yi Xiong , Mingdong Zhou

A systemic topology optimization approach is presented in this work to concurrent design parts, their supports, and laser scanning paths for powder bed metal additive manufacturing (AM), aiming to achieve controllable thermal distortion, optimized mechanical properties, and minimum material consumption. A novel density-based parametrization model is proposed to concurrently represent both structural topology and laser path with island scanning pattern. To avoid the recoater collision during the AM process, a thermal deformation constraint is developed based on inherent strain method, in which the structural type and laser scanning pattern related strains are calibrated and validated by AM experiments. Additionally, an overhang constraint and a two-field-based length scale control formulation are employed to further guarantee manufacturability. The proposed approach exhibits a desirable gain in design freedoms as well as reduction of supports consumption with improved mechanical performance of the optimized prototype, compared conventional to topology-only optimization. Besides, the concurrent optimization of structure topology and laser scanning path exhibits superior performance in thermal distortion control compared to sequential optimization.

本文提出了一种系统的拓扑优化方法，用于粉末床金属增材制造（AM）的零件、支架和激光扫描路径的并行设计，旨在实现可控的热变形、优化的机械性能和最小的材料消耗。提出了一种新的基于密度的参数化模型，可以同时表示结构拓扑和具有岛状扫描模式的激光路径。为了避免增材制造过程中的重拍器碰撞，提出了一种基于固有应变法的热变形约束方法，并通过增材制造实验对结构类型和激光扫描模式相关应变进行了标定和验证。此外，还采用了悬垂约束和基于两场的长度尺度控制公式来进一步保证可制造性。与传统的拓扑优化相比，所提出的方法在设计自由度上获得了理想的增益，并且通过改进优化原型的机械性能来减少支架消耗。此外，结构拓扑和激光扫描路径并行优化在热变形控制方面表现出优于顺序优化的性能。

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引用次数: 0

Crack-free nickel-copper (Monel K500/GRCop-42) interfaces formed under alternating build sequences via multi-material laser powder bed fusion 多材料激光粉末床熔接在交替构建顺序下形成无裂纹镍铜（Monel K500/GRCop-42）界面

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105037

Chonghao Wang , Yijun Wang , Haiyang Fan , Youqing Sun , Shoufeng Yang

Bimetallic nickel-copper systems are promising for aerospace components requiring combined strength and thermal conductivity, yet interfacial cracking during laser powder bed fusion remains a critical challenge. Based on recent studies indicating that nickel alloy compositional modification can alleviate interfacial issues, Monel K500 has shown particular potential given its high copper content and correspondingly low mixing enthalpy with copper alloys. However, the interfacial formation mechanism in Monel/copper systems warrants a thorough investigation. Therefore, this study specifically investigated the Monel K500/GRCop-42 interfacial characteristics fabricated via laser powder bed fusion. The high copper content and absence of low-miscibility elements of Monel K500 substantially reduces mixing enthalpy with CuCrNb, suppressing liquid-phase separation in molten pools while eliminating brittle intermetallic phase formation. These synergistic effects collectively enable crack-free interfaces, with alternating build sequences (NiCu→CuCrNb versus CuCrNb→NiCu) producing distinct interfacial morphologies. The NiCu/CuCrNb configuration forms planar boundaries with gradual composition gradients, whereas the reverse sequence develops zig-zag interfaces characterized by heterogeneous elemental mixing. Compositional heterogeneity disrupts epitaxial columnar growth across the interface, promoting near-equiaxed grain formation that enhances thermal stress accommodation capability within the interfacial region. Tensile tests reveal robust bonding as vertical specimens fracture exclusively in the CuCrNb region, while horizontal bimetals achieve approximately 30 % enhancements in both tensile strength and ductility compared to single-material CuCrNb.

双金属镍铜系统对于航空航天部件来说是很有前途的，需要综合强度和导热性，但在激光粉末床熔化过程中，界面开裂仍然是一个关键的挑战。最近的研究表明，镍合金的成分改性可以缓解界面问题，Monel K500由于其高铜含量和相应的低混合焓而显示出特别的潜力。然而，蒙乃尔/铜体系的界面形成机制值得深入研究。因此，本研究专门研究了激光粉末床熔合制备的Monel K500/GRCop-42的界面特性。Monel K500的高铜含量和不含低混相元素大大降低了与CuCrNb的混合焓，抑制了熔池中的液相分离，同时消除了脆性金属间相的形成。这些协同效应共同使界面无裂纹，交替构建序列（NiCu→CuCrNb vs CuCrNb→NiCu）产生不同的界面形态。NiCu/CuCrNb结构形成了具有渐变组成梯度的平面边界，而相反的结构则形成了具有非均质元素混合特征的锯齿形界面。成分的非均质性破坏了界面上外延柱的生长，促进了近等轴晶粒的形成，增强了界面区域内的热应力调节能力。拉伸测试表明，垂直试样只在CuCrNb区域断裂，而水平双金属与单一材料CuCrNb相比，拉伸强度和延展性都提高了约30 %。

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引用次数: 0

Tailoring strength and ductility in Ti-5553/Ti-42Nb layered heterostructures produced by laser powder bed fusion 激光粉末床熔合制备Ti-5553/Ti-42Nb层状异质结构的裁剪强度和延展性

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105033

João Felipe Queiroz Rodrigues , Márcio Sangali , Gilberto Vicente Prandi , Matheus Valentim , Leticia Falcão Starck , Kaio Niitsu Campo , Juliano Soyama , Rubens Caram

The fabrication of heterogeneous structures represents a versatile approach to tailoring the strength vs. ductility relationship. In this work, a layered heterostructure based on different Ti alloys was produced by laser powder bed fusion, consisting of alternating layers of a strong heat-treatable alloy (Ti-5553) and a more ductile, tougher material (Ti-42Nb). The results indicate that the layers were dense and retained their nominal composition with good dimensional precision. The material alternation disrupted continuous epitaxial growth across macro-layers, reducing crystallographic texture intensity and overall anisotropy. The solution treatment followed by aging could significantly alter the strength of the layered heterostructure without causing delamination. Stiffness could be tuned, from approximately 65 GPa after solution treatment to approximately 94 GPa after aging at 500 °C. In its as-built state, the heterostructure exhibited an excellent combination of properties, with an ultimate tensile strength of around 800 MPa and an elongation of over 10 %. Fracture analysis revealed that microvoid coalescence was the primary failure mechanism in both alloy layers. Thermodynamic calculations and diffusion simulations clarified α-phase precipitation and interlayer oxygen diffusion effects, which influence the mechanical properties and microstructural evolution. These results provide valuable insight and practical guidelines for designing multi-material metallic additive manufacturing components with tunable mechanical properties.

异质结构的制造代表了一种剪裁强度与延性关系的通用方法。在这项工作中，通过激光粉末床熔合产生了基于不同Ti合金的层状异质结构，由强热处理合金（Ti-5553）和更韧性，更坚韧的材料（Ti- 42nb）交替层组成。结果表明，所制备的膜层致密且保持了其标称成分，具有良好的尺寸精度。材料的交替破坏了宏观层间的连续外延生长，降低了晶体织构强度和整体各向异性。固溶后时效处理可以显著改变层状异质组织的强度，但不会引起分层。硬度可以调整，从固溶处理后的约65 GPa到500°C时效后的约94 GPa。在其构建状态下，异质结构表现出优异的综合性能，其极限拉伸强度约为800 MPa，伸长率超过10 %。断口分析表明，微孔洞聚结是两层合金的主要破坏机制。热力学计算和扩散模拟表明α相析出和层间氧扩散效应影响了合金的力学性能和微观组织演变。这些结果为设计具有可调力学性能的多材料金属增材制造部件提供了有价值的见解和实用指南。

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引用次数: 0

Dual-wavelength digital-light projection for precise spatial-temporal photochemical reaction-kinetics control 双波长数字光投影精确的时空光化学反应动力学控制

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105021

Taeseung Hwang, Kaiwen Hsiao

Controlling multi-wavelengths photochemical reactions with spatial-temporal precision at the micrometer length-scale is at the heart of engineering functionally graded materials. Dual-wavelength (445 nm and 349 nm) imaging projection system based DLP platform with < 200 nm projection resolution is developed. To understand dual-wavelength reaction-diffusion kinetics tunability, a wavelength-dependent photo-RAFT chemistry is employed. Orthogonally controlled, structural illumination of UV and blue patterns are developed with varying dual-wavelength projection distance, projection area ratio, and power ratio to control the competition between photopolymerization and photoinhibition at micrometer length scales (1–4

μ

m). A simulation model that combines laser optics and photo-RAFT based reaction-kinetics is developed to elucidate transient radical concentration and degree of conversion. A close agreement between simulation and experiment is obtained and prediction of printing resolution is achieved. Finally, a large-area (millimeter length scale) dual-wavelengths controlled printed micro-structured array is established that indicates the scalability of the dual-wavelength imaging projection system-based, nano-resolution DLP platform.

在微米长度尺度上以时空精度控制多波长光化学反应是工程功能梯度材料的核心。研制了基于<； 200 nm投影分辨率的DLP平台双波长（445 nm和349 nm）成像投影系统。为了理解双波长反应扩散动力学的可调性，采用了波长相关的光筏化学。在正交控制下，通过改变双波长投影距离、投影面积比和功率比来控制微米尺度（1-4 μm）光聚合和光抑制之间的竞争，形成UV和蓝色图案的结构照明。建立了一种结合激光光学和基于光筏反应动力学的模拟模型来解释瞬态自由基浓度和转化程度。仿真结果与实验结果吻合较好，实现了打印分辨率的预测。最后，建立了一个大面积（毫米长度尺度）双波长控制的印刷微结构阵列，表明了基于双波长成像投影系统的纳米分辨率DLP平台的可扩展性。

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引用次数: 0

Silane-based particle-matrix coupling in intumescent flame retardant systems for PBF-LB/P 膨胀型阻燃体系中基于硅烷的颗粒-基质耦合

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105039

Paul Roumeliotis , Samuel Schlicht , Rainer Detsch , Qaisar Nawaz , Aldo R. Boccaccini , Dietmar Drummer

Flame retardancy for samples manufactured in laser-based powder bed fusion (PBF-LB/P) is one of the major concerns to overcome for the application of the materials in environments with high safety standards. However, the trade-off between flame retardant and mechanical properties remains challenging. In this study, we demonstrate the enhancement of mechanical properties of an intumescent flame retardant (FR) system based on ammonium polyphosphate (APP), Pentaerythritol (PER) and manganese(II)-oxide (MnO) through chemically enhanced filler-matrix adhesion. We introduce the silane-based modifications of organic and inorganic flame retardant additives based on the aminosilane compounds APTES and TMSPED alongside the stable processing of surface-functionalized PA12-FR systems in PBF-LB/P.

Mechanical testing of the samples show an increase of tensile strength by 24 % and elongation at break by 58 %, showing a dependence on the applied energy density and the used aminosilane compound. Corresponding micrographs of fracture surfaces unveil the enhanced adhesion between additives and polymer matrix. Further investigation demonstrate no negative influence of the surface modification on crystallization behaviour, tested via X-ray Diffraction (XRD), or fire properties of the samples. Whilst limiting oxygen index (LOI) results remain unaffected by the aminosilane treatment, corresponding cone calorimeter results show a decline in total heat release (THR) by 10 %, which demonstrates enhanced full-fire burning characteristics.

激光粉末床熔合（PBF-LB/P）样品的阻燃性是该材料在高安全标准环境中应用时需要克服的主要问题之一。然而，阻燃性和机械性能之间的权衡仍然具有挑战性。在这项研究中，我们证明了一种基于聚磷酸铵（APP）、季戊四醇（PER）和氧化锰（MnO）的膨胀型阻燃剂（FR）体系的机械性能通过化学增强填料-基质的粘附性而增强。我们介绍了基于氨基硅烷化合物APTES和TMSPED的有机和无机阻燃添加剂的硅烷改性，以及PBF-LB/P中表面功能化PA12-FR体系的稳定加工。力学测试表明，试样的抗拉强度提高了24% %，断裂伸长率提高了58% %，这与所施加的能量密度和所使用的氨基硅烷化合物有关。相应的断裂面显微照片揭示了添加剂与聚合物基体之间增强的附着力。进一步的研究表明，通过x射线衍射（XRD）测试，表面改性对结晶行为或样品的燃烧性能没有负面影响。虽然极限氧指数（LOI）结果不受氨基硅烷处理的影响，但相应的锥量热计结果显示总放热（THR）下降了10 %，这表明全火燃烧特性得到了增强。

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引用次数: 0

High-performance electromagnetic micropumps fabricated via multi-material jetting additive manufacturing 采用多材料喷射增材制造技术制造高性能电磁微泵

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105038

Chen Lin , Xu Chen , Zeyu Wang , Xiaotong Guo , Michail E. Kiziroglou , Eric M. Yeatman

Micropumps serve as key sources of liquid propulsion in various microfluidic applications. High-performance with low fabrication complexity and cost is vital for disposable applications and mass production but remain challenging for electromagnetic reciprocating micropumps. Multi-material jetting (MMJ) 3D printing offers an opportunity owing to multi-material integration and high production efficiency while maintaining satisfactory resolution and surface quality for pump performance. However, there has been no previous demonstration of efficient fabrication of cost-effective liquid passive-valve electromagnetic micropumps based on MMJ 3D printing or other additive manufacturing techniques due to challenges in 3D model design and tailored fabrication workflow. This work proposes a new 3D model design to allow high-quality integration of soft and rigid elements and facilitate efficient assembly with good sealing based on a tailored fabrication workflow. Experimental optimization of micropumps is performed by comparing the performance of prototypes with varying chamber volume and membrane thickness. The devices are magnetically actuated wirelessly and exhibit a maximum flow rate and backpressure of 8.7 mL/min and 5.9 kPa at 1 W actuation power for a pump diaphragm diameter of 8 mm. Low material cost, estimated to be 1.1 £ per micropump, has been achieved. The membrane's viscoelastic behavior during operation is characterized. Flow rate stability tests show the coefficient of variation down to 6–11 % for an instant flow rate ranging from 4 to 7 mL/min, indicating feasibility in practical applications. These results suggest the great promise of MMJ 3D printing for low-cost, high-performance, miniature micropumps suitable for low-voltage disposable applications and mass production.

在各种微流体应用中，微泵是液体推进的关键来源。高性能、低制造复杂性和低成本对于一次性应用和大规模生产至关重要，但对于电磁往复微泵来说仍然是一个挑战。多材料喷射（MMJ） 3D打印提供了一个机会，因为多材料集成和高生产效率，同时保持令人满意的分辨率和表面质量的泵性能。然而，由于3D模型设计和定制制造工作流程的挑战，目前还没有基于MMJ 3D打印或其他增材制造技术高效制造具有成本效益的液体被动阀电磁微泵的演示。这项工作提出了一种新的3D模型设计，允许高质量的软硬元件集成，并促进基于定制制造工作流程的高效装配和良好的密封性。通过对比不同腔室体积和膜厚的原型泵的性能，对微泵进行了实验优化。该装置采用磁力无线驱动，在1 W驱动功率下，泵隔膜直径为8 mm时，最大流量和背压分别为8.7 mL/min和5.9 kPa。低材料成本，估计为1.1 £ 每微泵，已经实现。表征了膜在运行过程中的粘弹性行为。流量稳定性试验表明，瞬时流量为4 ~ 7 mL/min时，变异系数可达6-11 %，表明在实际应用中是可行的。这些结果表明，MMJ 3D打印在低成本、高性能、适用于低压一次性应用和大规模生产的微型微泵方面有着巨大的前景。

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引用次数: 0

Nanoprinting of compound eye-inspired NiO/ZnO heterostructure for enhanced UV-sensing performances 复合眼激发NiO/ZnO异质结构的纳米打印增强紫外传感性能

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105043

Kai Li , Xuchen Yang , Fan Du , Jinbang Li , Dazhi Wang , Yang Lu

Bioinspired optical sensor design through biomimetic replication of dragonfly compound eye architectures demonstrates significant potential for developing advanced photodetection systems with enhanced angular resolution, adaptive motion tracking, and superior photon management capabilities. This work introduced a novel laser-integrated electrohydrodynamic jet (E-Jet) printing pore formation methodology that enables precision fabrication of biomimetic NiO/ZnO heterojunction photodetectors featuring structurally graded porous architectures. This synergistic manufacturing approach achieves remarkable printing resolution spanning ∼80 nm to ∼80 μm, while dynamic laser processing creates hierarchical porosity that mimics natural optical systems. First-principles calculations combined with optoelectronic characterization reveal that the bioengineered heterostructure demonstrates exceptional performance metrics, including a high photocurrent density of 7.524 × 10⁻¹² A with a photocurrent-to-dark current ratio exceeding 50:1 under 600 μW·cm⁻² UV illumination. The device exhibits rapid response dynamics and outstanding cyclic stability. The printing processes and the performance of photoelectric sensors were predictive analyzed using machine learning. This manufacturing breakthrough enables precise spatial modulation of semiconductor band structures and three-dimensional (3D) carrier transport pathways unattainable through conventional fabrication techniques. The demonstrated strategy not only advances biomimetic optoelectronics but also establishes a new paradigm for designing multiscale functional architectures in energy harvesting and adaptive sensing technologies.

仿生复制蜻蜓复眼结构的仿生光学传感器设计，展示了开发具有增强角分辨率、自适应运动跟踪和优越光子管理能力的先进光探测系统的巨大潜力。这项工作介绍了一种新型的激光集成电流体动力射流（E-Jet）打印孔隙形成方法，该方法能够精确制造具有结构梯度多孔结构的仿生NiO/ZnO异质结光电探测器。这种协同制造方法实现了跨越~ 80 nm到~ 80 μm的卓越打印分辨率，而动态激光加工产生了模仿自然光学系统的分层孔隙。第一性原理计算结合光电特性表明，生物工程异质结构表现出优异的性能指标，包括在600 μW·cm−2紫外线照射下，光电流密度高达7.524 × 10−12 a，光电流与暗电流比超过50:1。该装置具有快速的响应动力学和出色的循环稳定性。利用机器学习对光电传感器的打印过程和性能进行了预测分析。这一制造突破使半导体带结构和三维（3D）载流子传输路径的精确空间调制成为可能，这是传统制造技术无法实现的。所展示的策略不仅推进了仿生光电子学，而且为设计能量收集和自适应传感技术中的多尺度功能架构建立了新的范例。

{"title":"Nanoprinting of compound eye-inspired NiO/ZnO heterostructure for enhanced UV-sensing performances","authors":"Kai Li , Xuchen Yang , Fan Du , Jinbang Li , Dazhi Wang , Yang Lu","doi":"10.1016/j.addma.2025.105043","DOIUrl":"10.1016/j.addma.2025.105043","url":null,"abstract":"<div><div>Bioinspired optical sensor design through biomimetic replication of dragonfly compound eye architectures demonstrates significant potential for developing advanced photodetection systems with enhanced angular resolution, adaptive motion tracking, and superior photon management capabilities. This work introduced a novel laser-integrated electrohydrodynamic jet (E-Jet) printing pore formation methodology that enables precision fabrication of biomimetic NiO/ZnO heterojunction photodetectors featuring structurally graded porous architectures. This synergistic manufacturing approach achieves remarkable printing resolution spanning ∼80 nm to ∼80 μm, while dynamic laser processing creates hierarchical porosity that mimics natural optical systems. First-principles calculations combined with optoelectronic characterization reveal that the bioengineered heterostructure demonstrates exceptional performance metrics, including a high photocurrent density of 7.524 × 10<sup>−12</sup> A with a photocurrent-to-dark current ratio exceeding 50:1 under 600 μW·cm<sup>−2</sup> UV illumination. The device exhibits rapid response dynamics and outstanding cyclic stability. The printing processes and the performance of photoelectric sensors were predictive analyzed using machine learning. This manufacturing breakthrough enables precise spatial modulation of semiconductor band structures and three-dimensional (3D) carrier transport pathways unattainable through conventional fabrication techniques. The demonstrated strategy not only advances biomimetic optoelectronics but also establishes a new paradigm for designing multiscale functional architectures in energy harvesting and adaptive sensing technologies.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"114 ","pages":"Article 105043"},"PeriodicalIF":11.1,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681655","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

Detection of aluminum evaporation for TiAl using electron optical imaging in an electron beam powder bed fusion system — A feasibility study 电子束粉末床熔合系统中电子光学成像检测TiAl铝蒸发的可行性研究

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105034

Timo Berger, Jakob Renner, Benjamin Wahlmann, Carolin Körner

Electron optical (ELO) imaging has emerged as a powerful in-situ monitoring technique for electron beam powder bed fusion (PBF-EB). Until now, ELO imaging has been primarily used to analyze surface topography to detect defects such as porosity, cracks and bulging. However, the intensity of the ELO signal also depends on the composition of the material. In this work, element contrast is demonstrated by eliminating the influence of surface topography using a four-detector ELO system. The effectiveness of element contrast is demonstrated by monitoring alloy composition changes resulting from aluminum evaporation during the melting of squares on a titanium aluminide plate at room temperature. It is shown that the element contrast makes it feasible to extract the material-dependent ELO signal, even for highly bulged surfaces. Based on that, the method enables to detect changes in aluminum content due to evaporation, emphasizing the possible potential of a four-detector ELO system and the element contrast for in-situ aluminum evaporation detection for titanium aluminide alloys in PBF-EB.

电子光学成像（ELO）已成为电子束粉末床熔合（PBF-EB）的一种强有力的原位监测技术。到目前为止，ELO成像主要用于分析表面形貌，以检测气孔、裂缝和胀形等缺陷。然而，ELO信号的强度也取决于材料的组成。在这项工作中，通过使用四探测器ELO系统消除表面形貌的影响来证明元素对比。通过监测在室温下钛铝化板上方形熔化过程中铝蒸发引起的合金成分变化，证明了元素对比的有效性。结果表明，即使对于高度凸起的表面，元素对比也可以提取与材料相关的ELO信号。在此基础上，该方法能够检测由于蒸发引起的铝含量的变化，强调了四探测器ELO系统和元素对比在PBF-EB中铝化物钛合金铝蒸发原位检测中的可能潜力。

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引用次数: 0

Part-scale keyhole pore detection in laser powder bed fusion using coaxial photodiodes 同轴光电二极管在激光粉末床熔合中的部分尺度锁孔孔检测

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105031

Chuxiao Meng , Conor Porter , Sina Malakpour Estalaki , Seongyeon Yang , Garrett Mathesen , Jian Cao

Pore formation in Laser Powder Bed Fusion (L-PBF) significantly impacts mechanical properties, often caused by unstable keyhole collapse due to excessive laser energy density. Traditional ex-situ CT scanning for pore detection is time-consuming, costly, and often limited in size. We present a rapid pore detection method, predicting pore counts in L-PBF-fabricated samples efficiently and non-destructively. Our approach employs a peak detection algorithm for coaxial photodiode melt pool monitoring (MPM) signals to identify keyhole collapse patterns, precursors to keyhole pore formation. By smoothing MPM signals with cubic polynomials and applying interval-based thresholding, we identify peaks precisely. Validated against CT scans, the method shows strong correlation (R² = 0.95) between MPM peaks and pore counts across eight samples, with an average prediction time of 36 s for a 2400 mm³ sample. The method works best in the high energy density, unstable keyhole regime, and overpredicts pores in the near-optimal regime. This highly scalable, cost-effective solution outperforms prior pores detection techniques in speed and simplicity, with high potential for industrial applicability, particularly if more attempts from diverse research groups or industrial applications are shared to advance the overall coverage of material types, machine types and part geometry.

激光粉末床熔合（L-PBF）过程中孔隙的形成对材料的力学性能有显著影响，通常是由于激光能量密度过大导致锁孔坍塌不稳定造成的。传统的非原位CT扫描用于孔隙检测既耗时又昂贵，而且通常尺寸有限。我们提出了一种快速的孔隙检测方法，可以有效和非破坏性地预测l - pbf制备样品中的孔隙计数。我们的方法采用同轴光电二极管熔池监测（MPM）信号的峰值检测算法来识别锁孔塌陷模式，即锁孔孔隙形成的前兆。通过使用三次多项式平滑MPM信号并应用基于区间的阈值处理，我们精确地识别出峰值。通过CT扫描验证，该方法在8个样本中显示出MPM峰值与孔隙数之间的强相关性（R²= 0.95），对于2400 mm³ 样本，平均预测时间为36 s。该方法在高能量密度、不稳定的锁孔状态下效果最好，而在接近最佳状态下，该方法对孔隙的预测过高。这种高度可扩展，经济高效的解决方案在速度和简单性方面优于先前的孔隙检测技术，具有很高的工业适用性潜力，特别是如果来自不同研究小组或工业应用的更多尝试被共享，以推进材料类型，机器类型和零件几何形状的整体覆盖。

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引用次数: 0

An improved dynamic inherent strain method for efficient prediction of residual stresses and deformations in metal additive manufacturing 一种改进的动态固有应变法，用于金属增材制造中残余应力和变形的有效预测

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-25 DOI: 10.1016/j.addma.2025.105025

Junfang Qi , Xue Liu , Peng Dong , Quan Li , Yabin Yang

This study proposes a novel inherent strain approach, termed the Improved Dynamic Inherent Strain (IDIS) method, for efficient and accurate prediction of residual stresses and deformations in metal additive manufacturing (MAM). Building upon the previously developed Dynamic Inherent Strain (DIS) method, the IDIS method incorporates a more comprehensive treatment of three-dimensional stress/strain interactions based on the theory of total plasticity. The accuracy of the IDIS model is evaluated through two benchmark experiments reported in the literature: a wire and arc additive manufacturing (WAAM) process with single-track deposition per layer, and a standard laser powder bed fusion (LPBF) test. Results show that both the DIS and IDIS models achieve good accuracy in deformation prediction, with a maximum error of approximately 5 %. Compared to the DIS model, the IDIS model significantly improves stress prediction accuracy, particularly in capturing stress distribution trends more precisely. The study also examines the influence of different layer activation thickness (LAT) on prediction accuracy in LPBF simulations. It is found that a larger LAT yields higher stress prediction accuracy at the bottom of the part, while a smaller LAT provides better accuracy at the top. A mixed-LAT technique is proposed, which achieves high accuracy at both the bottom and top of the part while improving computational efficiency by 99.5 % without compromising accuracy. This work offers an effective and practical framework for rapid residual stress and deformation prediction in large-scale MAM components.

本研究提出了一种新的固有应变方法，称为改进的动态固有应变（IDIS）方法，用于有效和准确地预测金属增材制造（MAM）中的残余应力和变形。在先前开发的动态固有应变（DIS）方法的基础上，IDIS方法结合了基于总塑性理论的更全面的三维应力/应变相互作用处理。通过文献中报道的两个基准实验来评估IDIS模型的准确性：每层单轨道沉积的导线和电弧增材制造（WAAM）工艺，以及标准的激光粉末床熔化（LPBF）测试。结果表明，DIS和IDIS模型均具有较好的变形预测精度，最大误差约为5 %。与DIS模型相比，IDIS模型显著提高了应力预测精度，特别是在更精确地捕捉应力分布趋势方面。研究了不同激活层厚度（LAT）对LPBF模拟预测精度的影响。研究发现，较大的LAT在零件底部产生较高的应力预测精度，而较小的LAT在零件顶部提供较好的精度。提出了一种混合lat技术，在不影响精度的情况下，在零件的底部和顶部都实现了高精度，计算效率提高了99.5% %。该工作为大型MAM构件的残余应力和变形的快速预测提供了一个有效和实用的框架。

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引用次数: 0