Additive manufacturing最新文献_第2页

Competition between pore coalescence-controlled and pore growth-controlled fracture in 316L stainless steel by laser powder bed fusion: Effect of pore size and spacing 316L不锈钢激光粉末床熔接气孔聚结控制断裂与气孔生长控制断裂的竞争：孔径和间距的影响

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-09 DOI: 10.1016/j.addma.2026.105116

Michaela A. Luebbers , Allison M. Beese

In this study, the effect of pore size and spacing of groups of internal pores on mechanical properties and dominant ductile fracture mechanisms in additively manufactured 316L stainless steel under uniaxial tension was investigated. Tensile samples, with one or four penny-shaped pores at the center axial plane, with varying pore size and spacing, were fabricated using laser powder bed fusion. Two regimes of ductile fracture behavior were studied: a coalescence-dominated regime in which large, closely spaced pores coalesced before or near ultimate tensile strength (UTS), reducing sample ductility compared to dense samples, and a growth-dominated regime in which small, widely spaced pores grew independently even well after UTS, not significantly impacting sample ductility compared to dense samples. The modified Mohr-Coloumb ductile fracture model was used to capture ligament fracture, acting as an indicator for the coalescence of adjacent pores: fracture predicted before or near experimental UTS correctly correlated to pore configurations in the coalescence-controlled regime, while fracture predicted well after UTS correctly correlated to configurations in the growth-controlled regime. The results presented here provide a framework to determine whether pore groupings, in additively manufactured or conventionally processed alloys, are likely to accelerate fracture, aiding the qualification of these parts for structural applications.

研究了增材制造316L不锈钢在单轴拉伸作用下，孔隙大小和内部孔隙群间距对其力学性能和主要韧性断裂机制的影响。采用激光粉末床熔融法制备了在中心轴向面具有1个或4个不同孔径和间距的便士状孔隙的拉伸试样。研究人员研究了两种韧性断裂行为：一种是以聚结为主导的模式，在此模式下，大而密集的孔隙在极限拉伸强度（UTS）之前或附近聚结，与致密样品相比，降低了样品的延展性；另一种是以生长为主导的模式，在此模式下，小而密集的孔隙即使在极限拉伸强度（UTS）之后也能独立生长，与致密样品相比，对样品的延展性没有显著影响。修正的mohr - colummb韧性断裂模型用于捕获韧带断裂，作为相邻孔隙聚并的指标：在聚并控制状态下，实验UTS之前或附近的裂缝预测与孔隙构型正确相关，而在生长控制状态下，UTS之后的裂缝预测与构型正确相关。本文给出的结果提供了一个框架，以确定在增材制造或常规加工合金中，孔隙组是否可能加速断裂，有助于这些部件的结构应用资格。

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引用次数: 0

Mechanistic insights into debinding-induced defects in VPP-printed ceramics vpp印刷陶瓷中脱胶缺陷的机理研究

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-20 DOI: 10.1016/j.addma.2026.105130

Yuseok Kim, Sadaf Sobhani

Debinding remains a critical bottleneck in vat photopolymerization (VPP) of ceramics, where internal gas evolution and constrained shrinkage drive delamination and cracking. Here, we present a fracture-mechanics-based framework that connects binder stiffness and thermally generated gas-pressure to the driving forces of delamination and shrinkage-induced cracking in VPP-printed ceramics. By integrating this framework with an internal gas-pressure model informed from TGA measurements, we show how binder modulus governs defect energetics and morphology during debinding, enabling relative comparisons across binder systems. We fabricate alumina specimens using four binders, spanning two groups with relatively different mechanical properties, and measure their debinding-induced defects, flexural strength, thermal conductivity, and porosity. Compliant binders (2HEA and PPGDA) are found to be less prone to both delamination and surface cracking, whereas stiff binders (HDDA and PEGDA) exacerbate both defect modes. Mixed-binder systems exploit ratio-dependent synergies between these competing behaviors, simultaneously minimizing delamination and surface cracking and achieving up to a sevenfold increase in flexural strength, a 3.5-fold increase in thermal conductivity, and a sevenfold reduction in open porosity relative to single-binder systems. These findings provide a mechanistic basis for interpreting debinding-induced defects and offer practical guidance for selecting and combining binders to reduce cracking and delamination in VPP-printed ceramics.

脱粘仍然是陶瓷还原光聚合（VPP）的关键瓶颈，其中内部气体演化和约束收缩驱动分层和开裂。在这里，我们提出了一个基于断裂力学的框架，将粘合剂刚度和热生成的气压与vpp印刷陶瓷的分层和收缩诱导开裂的驱动力联系起来。通过将该框架与来自TGA测量的内部气体压力模型相结合，我们展示了粘合剂模量如何在脱胶过程中控制缺陷的能量学和形态，从而实现了不同粘合剂系统之间的相对比较。我们使用四种粘合剂制作氧化铝样品，跨越两组相对不同的机械性能，并测量它们的脱粘缺陷，弯曲强度，导热性和孔隙率。柔性粘结剂（2HEA和PPGDA）不易发生分层和表面开裂，而刚性粘结剂（HDDA和PEGDA）会加剧这两种缺陷模式。与单一粘结剂体系相比，混合粘结剂体系利用了这些相互竞争行为之间的比例依赖协同作用，同时最大限度地减少了分层和表面开裂，并将抗折强度提高了7倍，导热系数提高了3.5倍，开放孔隙率降低了7倍。这些发现为解释脱粘缺陷提供了机制基础，并为选择和组合粘结剂以减少vpp印刷陶瓷的开裂和分层提供了实用指导。

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引用次数: 0

3D printing of mesoscopic porous anodes to enhance gas transport in solid oxide fuel cells 3D打印介观多孔阳极以增强固体氧化物燃料电池中的气体传输

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-13 DOI: 10.1016/j.addma.2026.105111

Jinsi Yuan , Mingfeng Wu , Shixiang Yu , Jing Shao , Youkun Tao , Haijiang Wang , Jiaming Bai

Solid oxide fuel cells (SOFCs) are highly efficient energy conversion devices with broad fuel flexibility. Concentration polarization has been identified as the dominant factor causing voltage loss under high-current conditions, and mesoscopic porous electrodes have shown promise in alleviating this issue. However, the techniques available for fabricating customized and intricate mesoscopic porous SOFC electrodes remain limited. Herein, we utilized vat photopolymerization 3D printing to fabricate SOFC anode supports with mesoscopic interconnected array of conical channels (IACC). This IACC structure effectively enhanced gas transport, leading to a significant reduction in concentration overpotential in the SOFC. A peak power density of 745 mW·cm⁻² was achieved at 800 ℃ in an SOFC configured with a (La_0.75Sr_0.25)_0.95MnO₃ cathode, outperforming most existing studies. The novel, efficient, and controllable approach for optimizing mass transport within the electrodes, opens new avenues for developing high-performance SOFCs.

固体氧化物燃料电池（sofc）是一种高效的能量转换装置，具有广泛的燃料灵活性。浓度极化已被确定为在大电流条件下导致电压损失的主要因素，介观多孔电极有望缓解这一问题。然而，可用于制造定制和复杂介观多孔SOFC电极的技术仍然有限。在此，我们利用还原光聚合3D打印技术制备了具有介观锥形通道互联阵列（IACC）的SOFC阳极支架。这种IACC结构有效地增强了气体输运，从而显著降低了SOFC中的浓度过电位。在800℃下，采用（La0.75Sr0.25）0.95MnO3阴极的SOFC，峰值功率密度达到745 mW·cm−2，优于大多数现有研究。这种新颖、高效、可控的优化电极内质量传输的方法，为开发高性能sofc开辟了新的途径。

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引用次数: 0

Additive manufacturing of ceramic-metal composites with 3D interpenetrating networks via material and process design 基于材料和工艺设计的三维互穿网络陶瓷-金属复合材料增材制造

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-18 DOI: 10.1016/j.addma.2026.105132

Xiaowen Pu , Dhandapani Kuzhandaivel , Lixin Wu , Zixiang Weng

The integration of high electrical and thermal conductivity within a robust, lightweight structural material represents a significant challenge for additively manufactured components in next-generation electronics. However, the digital light processing (DLP) of ceramic-metal composites is plagued by slurry instability, oxidative degradation, and profound co-sintering incompatibility, which disrupts the formation of continuous conductive pathways. Inspired by the bicontinuous vasculature of plant leaves, we report a holistic strategy for fabricating alumina-copper (Al₂O₃-Cu) composites with a three-dimentionally continuous, venation-like copper network via DLP. This is achieved by molecular interface engineering using a transient silane coating that ensures powder stability and strong bonding, coupled with a scientifically designed multi-stage thermal protocol that overcomes the thermomechanical mismatch. We demonstrate a critical architectural transition: the Cu phase evolves from isolated islands into a percolating three-dimensional (3D) network at 20 wt% Cu, acting as a synthetic vascular system. This architected composite exhibits exceptional multifunctionality: a thermal conductivity of 66.02 W/(m·K), electrical conductivity of 362.32 S/cm, and hardness of 8.82 GPa, at a density of just 4.13 g/cm³, a 54 % reduction from pure copper. Furthermore, we reveal a metallic phase-dominated densification mechanism that enables a high density with exceptionally low and uniform shrinkage, which is a critical breakthrough for precision additive manufacturing. This study establishes a generalizable blueprint for architecting continuous functional pathways in composites via DLP, paving the way for advanced integrated components in thermal management and electronics applications.

在坚固的轻质结构材料中集成高导电性和导热性是下一代电子产品中增材制造组件的重大挑战。然而，陶瓷-金属复合材料的数字光处理（DLP）受到浆料不稳定、氧化降解和严重共烧结不相容性的困扰，从而破坏了连续导电途径的形成。受植物叶片的双连续脉管系统的启发，我们报告了一种通过DLP制造具有三维连续，脉状铜网络的氧化铝-铜（Al2O3-Cu）复合材料的整体策略。这是通过分子界面工程实现的，使用瞬态硅烷涂层，确保粉末稳定性和强结合，再加上科学设计的多阶段热协议，克服了热-机械不匹配。我们展示了一个关键的建筑转变：铜相从孤立的岛屿演变成一个渗透的三维（3D）网络，在20 wt%的Cu中，作为一个合成的血管系统。这种结构的复合材料具有优异的多功能性：导热系数为66.02 W/(m·K)，电导率为362.32 S/cm，硬度为8.82 GPa，密度仅为4.13 g/cm3，比纯铜降低了54 %。此外，我们揭示了一种金属相主导的致密化机制，该机制可以实现高密度且收缩异常低且均匀，这是精密增材制造的关键突破。本研究为通过DLP构建复合材料的连续功能路径建立了一个通用蓝图，为热管理和电子应用中的先进集成组件铺平了道路。

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引用次数: 0

System-level multi-stage modeling and multi-criteria optimization of direct ink writing 直墨书写的系统级多阶段建模和多准则优化

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-16 DOI: 10.1016/j.addma.2026.105122

Wuyang Chen , Chenyu Xu , Licheng Liang , Chi Zhou , Hongyue Sun

Direct ink writing (DIW) has emerged as an additive manufacturing technique for fabricating multiple functional structures, but its deployment is often limited by stage-wise optimization that overlooks system-level trade-offs among printability, structural integrity, and energy efficiency. To address this gap, we develop an integrated experimental platform and a unified modeling and optimization framework that spans ink preparation, printing, drying, and product characterization in a DIW system. We conduct an experiment with 81 runs on silica inks by varying material composition and printing speeds, with measurements ranging from rheometry, 3D scanning, drying, to thermal conductivity. Building on these data, we propose the Multi-stage modeling and Multi-criteria Optimization Network (MMO-Net), a deep neural network with GRU-based cross-stage feature transition and multi-task heads that jointly predict rheological properties, printing time, geometric fidelity before and after drying, and cracking probability. Compared with linear regression and a deep multi-stage multi-task learning baseline, MMO-Net achieves the lowest total regression loss and 100% accuracy in cracking classification on the test set. Coupling MMO-Net with Bayesian optimization further enables multi-criteria search over controllable parameters, yielding a process setting that simultaneously reduces cracking probability, printing time, and thermal conductivity while maintaining target thickness, which is confirmed by validation experiments. The proposed framework demonstrates a scalable route toward system-level modeling and optimization of DIW.

直接墨水书写（DIW）已经成为一种用于制造多种功能结构的增材制造技术，但其部署往往受到阶段优化的限制，忽略了系统级可打印性、结构完整性和能源效率之间的权衡。为了解决这一差距，我们开发了一个集成的实验平台和统一的建模和优化框架，涵盖了油墨制备，印刷，干燥和产品表征的DIW系统。我们通过不同的材料成分和印刷速度，在硅胶油墨上进行了81次实验，测量范围从流变学、3D扫描、干燥到导热性。在这些数据的基础上，我们提出了多阶段建模和多准则优化网络（MMO-Net），这是一个基于gru的跨阶段特征转换和多任务头的深度神经网络，可以共同预测流变特性、打印时间、干燥前后的几何保真度和开裂概率。与线性回归和深度多阶段多任务学习基线相比，MMO-Net在测试集上实现了最小的总回归损失和100%的破解分类准确率。MMO-Net与贝叶斯优化的耦合进一步实现了对可控参数的多准则搜索，产生的工艺设置在保持目标厚度的同时降低了开裂概率、打印时间和热导率，这一点得到了验证实验的证实。提出的框架展示了一种可扩展的系统级建模和DIW优化路径。

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引用次数: 0

Geometry-adaptive reinforcement learning for optimization of bed separation forces in DLP 3D printing of fragile structures 基于几何自适应强化学习的脆弱结构DLP 3D打印床层分离力优化

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-14 DOI: 10.1016/j.addma.2026.105125

Min-Kyung Seo, Jeong-Hun Kang, Ju-Chan Yuk, Suk-Hee Park

This study presents a physics-informed reinforcement learning (RL) framework for optimizing the digital light processing (DLP) 3D printing of high-viscosity, porogen-containing photopolymer composites. In conventional DLP printing, the detachment of cured layers from the vat film generates large separation force, often leading to fracture in fragile structures such as thin posts or gradient lattices. To address this challenge, an RL-based control system was developed that adaptively adjusts the bed-lifting speed layer-by-layer based on cross-sectional geometry and finite element analysis (FEA) of stress distribution. The optimized control effectively reduced peak stresses and enabled successful fabrication of mechanically delicate, porous architectures. Experimental validation with salt-resin composites confirmed that the optimized process maintained structural stability while preserving mechanical compliance comparable to soft biological tissues. Furthermore, the framework was extended to gradient lattice structures, demonstrating fine control over stiffness and replication of cartilage-like nonlinear mechanical behavior. These results highlight the potential of RL-based process optimization as a generalizable strategy for improving the printability and functional performance of DLP-fabricated biomimetic materials.

本研究提出了一种基于物理的强化学习（RL）框架，用于优化高粘度、含气孔的光聚合物复合材料的数字光处理（DLP） 3D打印。在传统的DLP印刷中，固化层与还原膜的分离会产生很大的分离力，经常导致薄桩或梯度晶格等脆弱结构的断裂。为了解决这一问题，研究人员开发了一种基于rl的控制系统，该系统可以根据截面几何形状和应力分布的有限元分析（FEA）逐层自适应调整提床速度。优化后的控制有效地降低了峰值应力，并成功地制造了机械上精细的多孔结构。盐-树脂复合材料的实验验证证实，优化后的工艺保持了结构稳定性，同时保持了与柔软生物组织相当的机械顺应性。此外，框架扩展到梯度晶格结构，展示了对刚度的精细控制和软骨样非线性力学行为的复制。这些结果突出了基于rl的工艺优化作为提高dlp制造的仿生材料的可打印性和功能性能的通用策略的潜力。

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引用次数: 0

Substepped and advected subdomain methods for part-scale LPBF modeling 局部尺度LPBF建模的子域法和子域法

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-09 DOI: 10.1016/j.addma.2026.105098

Mehdi Slimani, Michele Chiumenti, Miguel Cervera

This work presents substepping schemes for part-scale Laser Powder Bed Fusion (LPBF) modeling where the computational domain is divided into a fast partition with a small time-step and a slow one using a large time-step. These schemes are of special interest due to the disparity of time scales present in LPBF applications, which renders simulation prohibitively expensive unless simplifications are made. A Robin–Robin substepper is proposed and compared to the scheme proposed by Hodge (2021).

Additionally, the introduction of an advected subdomain in the fast partition is proposed. This approach was first presented in Slimani et al. (2024) and allows for larger time-steps, as the problem in the Heat Affected Zone (HAZ) is posed in the moving reference frame of the laser, where the thermal field is significantly steadier than in the fixed frame.

These methods are used in combination to obtain a computationally efficient scheme for LPBF thermal simulations. The proposed methods are implemented in FEniCSx. Their strengths and weaknesses are evaluated through 2D benchmarks, comparison with experimental melt pool data, and 3D LPBF simulations.

本文提出了局部尺度激光粉末床融合（LPBF）建模的子步进方案，其中计算域分为小时间步长的快速分区和大时间步长的慢分区。由于LPBF应用中存在时间尺度的差异，这些方案特别有趣，除非进行简化，否则会使模拟成本过高。提出了一种Robin-Robin子步进算法，并与Hodge（2021）提出的方案进行了比较。此外，提出了在快速分割中引入平流子域的方法。该方法首次在Slimani等人（2024）中提出，并允许更大的时间步长，因为热影响区（HAZ）中的问题是在激光的移动参考系中提出的，其中热场明显比固定参考系更稳定。将这些方法结合使用，获得了一种计算效率高的LPBF热模拟方案。提出的方法在FEniCSx中实现。通过2D基准测试、与实验熔池数据的比较以及3D LPBF模拟来评估它们的优缺点。

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引用次数: 0

A differentiable material point method solver for the modeling, simulation and analysis of extrusion-flow process for 3D concrete printing 一种可微物质点法求解器，用于三维混凝土打印挤压流动过程的建模、仿真和分析

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-19 DOI: 10.1016/j.addma.2026.105126

Wenchang Zhang , Chuanqi Liu , Yiwei Weng , Tianju Xue , Jidong Zhao

Recent years have witnessed rapid development in 3D Concrete Printing (3DCP), which offers a highly automated construction process with significant reductions in material, labor, and time costs. However, deviations from the original design often occur as a result of the complex extrusion-flow behavior of fresh concrete and the associated layer deformations, which are primarily caused by insufficient understanding of key process parameters. In this study, a differentiable material point method (MPM) solver is developed for the modeling and analysis of 3DCP processes, enhanced with reverse-mode automatic differentiation techniques built upon the discrete adjoint method to enable end-to-end derivative computations. The extrusion-flow process of 3DCP is modeled as a weakly compressible Bingham fluid. For single-layer deposition under various printing conditions, the maximum deviations in predicted width and height remain within 20% of experimental measurements. Despite the increased deviations for multi-layer structures due to cumulative effects, the framework provides a robust foundation for simulating the 3DCP process. Beyond its predictive capabilities, the differentiable MPM framework exhibits high efficiency in sensitivity analysis. As demonstrated in a case study of sensitivity with respect to eight process parameters, the framework reduced the computational time to just 60% of that required by the central difference method. This efficient gradient computation provides quantitative insight into 3DCP mechanics and offers a pathway for optimizing process parameters to improve final product quality.

近年来，3D混凝土打印（3DCP）发展迅速，它提供了一个高度自动化的施工过程，显著降低了材料、人工和时间成本。然而，由于新混凝土复杂的挤压流动行为和相关的层变形，通常会出现与原始设计的偏差，而这些变形主要是由于对关键工艺参数的理解不足造成的。在本研究中，开发了一种可微物质点法（MPM）求解器，用于三维cp过程的建模和分析，并在离散伴随方法的基础上增强了逆模自动微分技术，以实现端到端导数计算。将三维cp的挤压流动过程建模为弱可压缩Bingham流体。对于各种印刷条件下的单层沉积，预测宽度和高度的最大偏差保持在实验测量值的20%以内。尽管由于累积效应导致多层结构的偏差增加，但该框架为模拟3DCP过程提供了坚实的基础。除了预测能力外，可微MPM框架在敏感性分析中也表现出高效率。正如对八个过程参数的敏感性的案例研究所证明的那样，该框架将计算时间减少到中心差分法所需时间的60%。这种高效的梯度计算为三维cp力学提供了定量的洞察，并为优化工艺参数以提高最终产品质量提供了途径。

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引用次数: 0

Orientation and strain-rate effects on high-temperature plasticity of 316 L stainless steel fabricated by laser powder bed fusion 取向和应变率对激光粉末床熔合316 L不锈钢高温塑性的影响

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-11 DOI: 10.1016/j.addma.2026.105115

Baibhav Karan , Santosh Kumar Shaw , Apu Sarkar , Kiomars Moheimani , Sabyasachi Chatterjee , Mingxing Zhang , Ayan Bhowmik

The extremely rapid cooling rates inherent to laser powder bed fusion (LPBF) processing produce unique microstructural features. In LPBF-fabricated 316 L stainless steel (SS316L), the formation of metastable sub-grain structures enriched with dislocations has been directly associated with superior tensile performance at ambient conditions. However, the absence or instability of these substructures at elevated temperatures can significantly alter mechanical behaviour. In this work, the high-temperature deformation response of LPBF-fabricated SS316L is systematically investigated, with particular emphasis on the effects of build orientation and strain rate. Uniaxial tensile tests were conducted along both the vertical (along the build direction) and horizontal (perpendicular to the build direction) orientations at a temperature of 850 °C under multiple strain rates. At room temperature, plasticity was primarily accommodated by dislocation slip and deformation twinning, whereas at elevated temperatures, a transition was observed, with dynamic recrystallisation becoming the dominant mechanism, especially in horizontally built specimens. However, the vertical samples retained elongated grains and exhibited comparatively limited recrystallisation. The tensile response demonstrated strong dependence on both strain rate and build orientation. The experimental findings, corroborated by crystal plasticity modelling, provide important insights into the orientation- and temperature-dependent plasticity mechanisms of LPBF SS316L. The applied model is capable of accurately predicting the high-temperature mechanical response by incorporating various temperature-dependent mechanisms.

激光粉末床熔合（LPBF）加工固有的极快冷却速度产生独特的微观结构特征。在lpbf制备的316 L不锈钢（SS316L）中，丰富位错的亚稳亚晶结构的形成与优越的环境拉伸性能直接相关。然而，这些亚结构在高温下的缺失或不稳定会显著改变机械行为。本文系统地研究了lpbf制备的SS316L的高温变形响应，重点研究了构建取向和应变速率的影响。在850℃的温度下，在多种应变速率下，沿垂直（沿构建方向）和水平（垂直于构建方向）方向进行单轴拉伸试验。在室温下，塑性主要由位错滑移和变形孪晶调节，而在高温下，观察到一个转变，动态再结晶成为主要机制，特别是在水平构建的样品中。然而，纵向样品保留了拉长的晶粒，表现出相对有限的再结晶。拉伸响应对应变速率和构建取向都有很强的依赖性。实验结果得到了晶体塑性模型的证实，为LPBF SS316L的取向和温度依赖塑性机制提供了重要的见解。该模型结合了多种温度相关机制，能够准确预测高温力学响应。

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引用次数: 0

Defect-free DLP additive manufacturing of complex Ti64 components by non-reactive diluent assisted debinding 用非反应性稀释剂辅助脱粘制备复杂Ti64组分的无缺陷DLP增材制造

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2026-03-05 Epub Date: 2026-02-12 DOI: 10.1016/j.addma.2026.105121

Huiling Wang, Juncheng Lu, Jinsi Yuan, Zhaohui Zhang, Xiangwei Wen, Jiaming Bai

Digital Light Processing (DLP) technology is expected to be widely applied in the additive manufacturing of metal materials with complex structural components due to its high resolution and efficiency. However, defects introduced during debinding limit the forming quality of the components. In this research, the non-reactive diluent polypropylene glycol (PPG) is added to Ti6Al4V (Ti64) alloy slurry, and their effects on the thermal decomposition behaviors of green parts are studied based on experimental investigations and numerical simulations. The results indicate that the PPG addition can promote the smooth decomposition of organic matter by constructing gas transmission passages in the early stages of debinding processes, which significantly reduces the temperature difference, residual content of organic matter, pore pressure, and maximum principal stress between the surface and center of the green part, thus reducing the crack defects in the final components. When the addition amount of PPG is 20 wt%, the defect-free Ti64 components with complex structures and excellent mechanical properties can be efficiently fabricated. This research can provide references for the design of Ti64 photopolymerization slurry, further expanding the applications of DLP technology in the field of metal additive manufacturing.

数字光处理（DLP）技术以其高分辨率和高效率的特点，有望在复杂结构部件金属材料的增材制造中得到广泛应用。然而，在脱脂过程中引入的缺陷限制了零件的成形质量。通过实验研究和数值模拟，研究了在Ti6Al4V （Ti64）合金料浆中加入非活性稀释剂聚丙烯乙二醇（PPG）对生坯热分解行为的影响。结果表明，PPG的加入可以通过在脱粘过程早期构建气体传输通道，促进有机质的顺利分解，显著降低了青坯表面与中心之间的温差、有机质残留量、孔隙压力和最大主应力，从而减少了最终构件的裂纹缺陷。当PPG的添加量为20 wt%时，可以有效地制备出结构复杂、力学性能优异的无缺陷Ti64构件。本研究可为Ti64光聚合浆料的设计提供参考，进一步拓展DLP技术在金属增材制造领域的应用。

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引用次数: 0