Additive manufacturing最新文献_第3页

Multimodal synchrotron characterization of the formation and spatial distribution of retained austenite in PBF-LB/M-manufactured ferritic–martensitic steel PBF-LB/ m制铁素体-马氏体钢中残余奥氏体形成和空间分布的多模态同步加速器表征

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-24 DOI: 10.1016/j.addma.2025.105055

Natan Garrivier , Steven Van Petegem , Manuel Pouchon , Markus Strobl , Enrico Tosoratti , Adam Cretton , Ken Vidar Falch , Dario Ferreira Sanchez , Malgorzata Grazyna Makowska

Metal additive manufacturing is a promising route for producing complex, highly customized embedded structures for nuclear fusion environments, such as breeding blankets and divertors. These applications require steels with high thermomechanical stability and resistance to irradiation, yet AM processing often leads to undesired microstructural heterogeneities, including the formation of metastable phases. In this work, we investigate the formation and spatial distribution of retained austenite in Laser Powder Bed Fusion (PBF-LB/M) — processed ferritic–martensitic stainless steel (AISI 415) using multimodal synchrotron-based characterization. Micron-resolution 2D and 3D synchrotron X-ray Diffraction and X-ray Fluorescence mapping, combined with operando XRD during PBF-LB/M, reveal the presence of retained

γ

-phase in periodic mesostructures at concentrations up to 0.5 wt%, depending on scanning strategy. We demonstrated that this result, gained from volumetric measurements based on

μ

XRD scanning imaging, cannot be gathered by any surface-sensitive technique (e.g. EBSD) due to depth limitations and phase transformation artifacts during sample preparation. No correlation between

γ

-phase formation and elemental segregation was observed. Operando XRD measurements show that cooling rates critically affect phase evolution: wall-like geometries exhibit rapid cooling (

\sim 1 0^{5}

to

1 0^{6}

K/s) and complete martensitic transformation, whereas bulk samples cool more slowly (

\sim 1 0^{4}

K/s), allowing up to 0.5 wt.% of

γ

-phase to be retained. These results demonstrate the strong influence of both scanning strategy and thermal history on phase stability in PBF-LB/M steels, supporting the qualification of AM-built components for nuclear applications.

金属增材制造是一种很有前途的方法，可以为核聚变环境生产复杂的、高度定制的嵌入式结构，如繁殖毯和分流器。这些应用需要具有高热机械稳定性和耐辐照性的钢，然而增材制造通常会导致不希望的微观结构不均匀性，包括亚稳相的形成。在这项工作中，我们研究了激光粉末床熔合（PBF-LB/M）加工铁素体-马氏体不锈钢（AISI 415）中残余奥氏体的形成和空间分布。在PBF-LB/M过程中，采用微米分辨率二维和三维同步加速器x射线衍射和x射线荧光作图，结合operando XRD，发现在浓度高达0.5 wt%的周期性介观结构中存在保留的γ-相，这取决于扫描策略。我们证明，由于样品制备过程中的深度限制和相变伪影，任何表面敏感技术（如EBSD）都无法收集到基于μXRD扫描成像的体积测量结果。γ相的形成与元素偏析没有相关性。Operando XRD测量结果表明，冷却速率对相演化有重要影响：壁状几何形状表现出快速冷却（~ 105 ~ 106 K/s）和完全马氏体转变，而大块样品冷却更慢（~ 104 K/s），允许高达0.5 wt.%的γ相保留。这些结果表明，扫描策略和热历史对PBF-LB/M钢的相稳定性有很强的影响，支持am制造的核应用部件的资格。

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引用次数: 0

Novel method for achieving high-performance Ti/Al dissimilar structure via hybrid solid-liquid phase additive manufacturing 采用混合固液相增材制造实现高性能Ti/Al异种结构的新方法

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-23 DOI: 10.1016/j.addma.2025.105064

Yu Sun , Rongmao Du , Yanlong Fan , Hongtao Zhang , Junlin Pan , Xiaoya Tang , Jingwu Xu , Guo Yu , Xiaoli Wang , Qingxian Hu , Peng He

The growing demand for heterogeneous metal structures in aerospace and new energy vehicle industries has made the reliability of welding or additive manufacturing for such structures a critical industry focus. This paper proposes a hybrid solid-liquid phase additive manufacturing technique. The specific implementation involves first consolidating a niobium interlayer onto a aluminum alloy substrate via ultrasonic solid-phase additive manufacturing, followed by sequentially depositing titanium alloy structures using laser wire-feed additive manufacturing to achieve high-quality, rapid fabrication of Ti/Al dissimilar structures. During this hybrid manufacturing process, the ultrasonic technique induces strong mechanical interlocking through plastic deformation and atomic diffusion, while the subsequent laser deposition optimizes metallurgical bonding and suppresses brittle intermetallic formation via precise thermal control. The resulting dissimilar metal interface exhibits a unique hybrid microstructure combining solid-phase bonding and solidified liquid-phase reaction zones, significantly enhancing tensile and shear strength of the heterogeneous metal structures while effectively reducing residual stresses. Compared to direct additive manufacturing, the maximum tensile strength of the single-track ten-layer additive sample had reached to 127 MPa, an increase of 72 %; then the maximum interfacial shear strength was increased of 244.7 % to be 81 MPa when multi-track and multi-layer additive manufacturing was carried out, strengthened by interlocking chains between adjacent tracks on the interface. This solid-liquid phase hybrid additive manufacturing technology also provides an innovative solution for other cost-effective and high-performance dissimilar metal components.

航空航天和新能源汽车行业对异质金属结构的需求日益增长，使得这种结构的焊接或增材制造的可靠性成为关键的行业焦点。本文提出了一种混合固液相增材制造技术。具体实施包括首先通过超声固相增材制造将铌中间层巩固到铝合金基板上，然后使用激光线进给增材制造依次沉积钛合金结构，以实现高质量，快速制造Ti/Al不同结构。在这种混合制造过程中，超声波技术通过塑性变形和原子扩散诱导出强的机械联锁，而随后的激光沉积通过精确的热控制优化了冶金结合并抑制了脆性金属间质的形成。由此产生的异种金属界面呈现出固相结合和液相凝固反应区相结合的独特杂化微观结构，显著提高了非均质金属结构的拉伸和剪切强度，同时有效降低了残余应力。与直接增材制造相比，单轨十层增材样品的最大抗拉强度达到127 MPa，提高了72 %；采用多径、多层增材制造时，界面最大抗剪强度提高了244.7 %，达到81 MPa，并通过界面上相邻径间的联锁链进行强化。这种固液相混合增材制造技术也为其他具有成本效益和高性能的异种金属部件提供了创新的解决方案。

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引用次数: 0

A perforated strip-based three-dimensional reinforcement strategy for 3D printed concrete: Flexural testing of beams as a proof of concept 基于穿孔条的3D打印混凝土三维加固策略：梁的弯曲测试作为概念验证

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-23 DOI: 10.1016/j.addma.2025.105065

North Beifang Deng , Sizhe Wang , Mingyang Li , Xiangyu Wang , Zhenbang Liu , Teck Neng Wong , Bak Koon Teoh , Ming Jen Tan

The reinforcement of 3D printed concrete structures remains a critical bottleneck hindering the widespread application of 3D printing technology in construction. To address this challenge, this study proposes a novel reinforcement strategy combining perforated strips and rebars to form three-dimensional frameworks for structural members. The reinforcement strategy is seamlessly integrated into the layer-by-layer concrete printing process and adaptable for complex geometries. To validate its feasibility and structural performance, large-scale 3D printed beams were fabricated and tested under flexural loading. The proposed strategy markedly enhanced the flexural performance of printed beams, with reinforced printed beams reaching over 100 % of the ultimate capacity and 90 % of the ductility of well-reinforced cast beams. Both experimental observations and finite element analysis confirmed that the failure mode corresponded to typical flexural failure of reinforced concrete beams. Moreover, existing design codes (such as Eurocode 2 and GB/T 50010–2010) were proved to be applicable in guiding the design of 3D printed members using this reinforcement strategy, facilitating practical engineering application of 3D printed concrete structures.

3D打印混凝土结构的加固仍然是阻碍3D打印技术在建筑领域广泛应用的关键瓶颈。为了应对这一挑战，本研究提出了一种新的加固策略，将穿孔带和钢筋结合起来，形成结构构件的三维框架。加固策略无缝地集成到逐层混凝土打印过程中，并适用于复杂的几何形状。为了验证其可行性和结构性能，制作了大型3D打印梁并进行了弯曲荷载试验。所提出的策略显著提高了印刷梁的抗弯性能，增强的印刷梁达到了100% %的极限承载力和90% %的良好增强的浇铸梁的延性。试验观察和有限元分析均证实其破坏模式符合典型钢筋混凝土梁的受弯破坏。并且，现有的设计规范（如Eurocode 2和GB/T 50010-2010）被证明适用于指导采用这种加固策略的3D打印构件的设计，促进了3D打印混凝土结构的实际工程应用。

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引用次数: 0

Graph neural operator: A DeepONet-based framework for learning thermo-mechanical distortion in metallic additive manufacturing 图神经算子：基于deeponet的金属增材制造热机械变形学习框架

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-23 DOI: 10.1016/j.addma.2025.105063

Zhonghao Chen , Haochen Mu , Zhao Zhang , Lei Yuan , Donghong Ding , Hongtao Zhu , Ninshu Ma , Zengxi Pan

Recent advances in machine learning (ML) have enabled efficient modelling of process-structure-property relationships in metallic additive manufacturing (AM), offering promising alternatives to conventional simulation-based methods. However, most ML models rely on input-output regression paradigms, which limit their ability to generalize to unseen geometrical scenarios. This paper proposes a graph neural operator that integrates deep operator network (DeepONet) with graph neural networks (GNNs) to simulate the thermo-mechanical constitutive behaviour in metallic AM. The proposed DeepONet-GNN framework decouples the thermal and structural fields, leveraging sparse temperature measurements to predict full-field z-direction distortion across unseen geometries. Layer-wise evaluations across multiple structures indicate that the model maintains stable predictive accuracy, and robustness to variations in sensor distribution, with an RMSE of 0.0881 mm. Compared to a coupled GNN, DeepONet-GNN reaches convergence with similar accuracy using 50 % fewer training epochs. The proposed DeepONet-GNN model demonstrates the ability to generalize to unseen geometries while leveraging only 5 % of the temperature sensor data, highlighting the potential of graph neural operators as accurate and scalable surrogates for real-time prediction in AM processes.

机器学习（ML）的最新进展使金属增材制造（AM）中工艺-结构-性能关系的有效建模成为可能，为传统的基于仿真的方法提供了有希望的替代方案。然而，大多数ML模型依赖于输入-输出回归范式，这限制了它们推广到未知几何场景的能力。本文提出了一种将深度算子网络（DeepONet）与图神经网络（gnn）相结合的图神经算子来模拟金属增材制造中的热-力学本构行为。提出的DeepONet-GNN框架解耦了热场和结构场，利用稀疏的温度测量来预测不可见几何形状的全场z方向畸变。跨多个结构的分层评估表明，模型保持稳定的预测精度，并且对传感器分布的变化具有鲁棒性，RMSE为0.0881 mm。与耦合的GNN相比，DeepONet-GNN使用的训练epoch减少了50% %，达到了相似精度的收敛。提出的DeepONet-GNN模型展示了推广到未见过的几何形状的能力，同时仅利用5 %的温度传感器数据，突出了图神经算子作为增材制造过程中实时预测的准确和可扩展替代品的潜力。

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引用次数: 0

Non-planar additive manufacturing: A comprehensive review of path planning, system integration, process control, and applications 非平面增材制造：路径规划、系统集成、过程控制和应用的全面回顾

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-20 DOI: 10.1016/j.addma.2025.105059

Zeqi Hu , Yongshuo She , Lin Hua , Kang Dong , Mingzhang Chen , Yitong Wang , Xunpeng Qin

The conventional planar layering paradigm of additive manufacturing (AM) has become a critical bottleneck, hindering the fabrication of high-performance components due to its inherent stair-stepping effect, mechanical anisotropy, and heavy reliance on support structures. Non-planar additive manufacturing (NPAM), by leveraging multi-axis motion systems and non-planar path planning, fundamentally overcomes these limitations, offering a transformative approach for the direct fabrication of parts with complex surfaces and optimized mechanical properties. This paper provides a comprehensive and systematic review of the latest research advancements in the NPAM field and innovatively establishes a core technology chain encompassing algorithm-system-process-quality. We delve into four key links: first, the non-planar slicing and path planning algorithms that form the technological core, covering strategies from support-free fabrication and performance enhancement to synergistic design with topology optimization; second, the multi-axis hardware systems that enable path execution, including robotic platforms, hybrid systems, specialized equipment, and their kinematic and dynamic control; third, the process physics and material behavior across polymers, composites, metals, ceramics, and functional inks; and finally, quality control to ensure manufacturing reliability, focusing on melt pool dynamics, geometric accuracy, microstructural evolution, and the crucial aspects of in-situ monitoring and closed-loop control. Furthermore, this paper systematically showcases the transformative applications of NPAM in aerospace, biomedical engineering, and conformal electronics. By elucidating the intrinsic connections between these technological links, this review aims to provide researchers with a structured knowledge framework, and prospect the future of intelligent design and manufacturing driven by artificial intelligence and digital twins.

传统的平面分层增材制造（AM）模式由于其固有的阶梯效应、力学各向异性和对支撑结构的严重依赖，已经成为阻碍高性能部件制造的关键瓶颈。非平面增材制造（NPAM）通过利用多轴运动系统和非平面路径规划，从根本上克服了这些限制，为直接制造具有复杂表面和优化机械性能的零件提供了一种变革性的方法。本文对NPAM领域的最新研究进展进行了全面系统的综述，并创新性地建立了包含算法-系统-过程-质量的核心技术链。我们深入研究了四个关键环节：首先，构成技术核心的非平面切片和路径规划算法，涵盖了从无支撑制造和性能增强到拓扑优化协同设计的策略；第二，实现路径执行的多轴硬件系统，包括机器人平台、混合系统、专用设备及其运动学和动态控制；第三，聚合物、复合材料、金属、陶瓷和功能油墨的工艺物理和材料行为；最后是质量控制，以确保制造可靠性，重点关注熔池动力学，几何精度，微观组织演变，以及现场监测和闭环控制的关键方面。此外，本文系统地展示了NPAM在航空航天、生物医学工程和共形电子领域的变革性应用。本文旨在通过阐明这些技术环节之间的内在联系，为研究人员提供一个结构化的知识框架，并展望人工智能和数字孪生驱动的智能设计和制造的未来。

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引用次数: 0

Deformation and stress evolution during laser powder bed fusion of semi-crystalline polyamide-12 半晶聚酰胺-12激光粉末床熔接过程中的变形与应力演化

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-19 DOI: 10.1016/j.addma.2025.105061

Zhongfeng Xu , Wei Zhu , Lionel Freire , Noëlle Billon , Jean-Luc Bouvard , Yancheng Zhang

Laser powder bed fusion (L-PBF) of semi-crystalline polymers such as polyamide-12 (PA12) has found increasing use in various industrial applications. However, achieving high dimensional accuracy remains a significant challenge. Despite the seemingly straightforward layer-by-layer manufacturing concept, the L-PBF process involves complex thermal histories and strongly coupled multiphysics, making the evolution of stress and deformation mechanisms still not fully understood. To address this, a comprehensive three-dimensional thermo-mechanical modeling framework is developed to simulate the L-PBF process of PA12. The model for the first time incorporates transient heat transfer, phase transformation induced volumetric shrinkage, thermo-viscoelasticity, and a modified non-isothermal crystallization kinetics. To alleviate the computational burden of part-scale simulations, a dual-mesh strategy is employed to efficiently couple thermal and mechanical fields without compromising numerical accuracy, which also enables the framework to handle L-PBF simulations of arbitrarily complex three-dimensional geometries. Particular attention is paid to the role of mechanical and thermal boundary conditions. Specifically, the underlying powder bed is modeled as a fictitious viscous medium, providing support while permitting upward displacement. Additionally, a radiative heat loss boundary condition, which more closely approximates the actual physical process, is applied to the top powder surface. The incorporation of this radiation effect significantly enhances the crystallization rate and improves the agreement with experimentally measured warpage. The model is validated against experimental warpage data under various preheating temperatures. Furthermore, strain decoupling analysis for the first time reveals that displacement induced by phase transformation is approximately 10 times greater than that caused by thermal expansion, highlighting the dominant role of crystallization-induced shrinkage in warpage formation. Numerical tests also indicate that warpage is highly sensitive to the preheating target temperature of the PA12 powder bed, while the temperature of the newly recoated powder within the tested range has a limited effect. This work provides a predictive modeling foundation for future optimization of polymer L-PBF processes at part-scale, particularly in controlling deformation and improving dimensional accuracy.

半结晶聚合物如聚酰胺-12 （PA12）的激光粉末床熔融（L-PBF）在各种工业应用中得到了越来越多的应用。然而，实现高尺寸精度仍然是一个重大挑战。尽管看似简单的分层制造概念，但L-PBF过程涉及复杂的热历史和强耦合的多物理场，使得应力和变形机制的演变仍未完全了解。为了解决这个问题，开发了一个综合的三维热-力学建模框架来模拟PA12的L-PBF过程。该模型首次纳入了瞬态传热、相变引起的体积收缩、热粘弹性和改进的非等温结晶动力学。为了减轻部分尺度模拟的计算负担，采用双网格策略在不影响数值精度的情况下有效地耦合热场和力学场，这也使框架能够处理任意复杂三维几何形状的L-PBF模拟。特别注意的是机械和热边界条件的作用。具体来说，下面的粉末床被建模为一个虚构的粘性介质，在允许向上位移的同时提供支撑。此外，在粉末顶部表面应用了更接近实际物理过程的辐射热损失边界条件。这种辐射效应的加入大大提高了结晶速率，并改善了与实验测量翘曲的一致性。利用不同预热温度下的实验翘曲数据对模型进行了验证。此外，应变解耦分析首次揭示了相变引起的位移约为热膨胀引起的位移的10倍，突出了结晶引起的收缩在翘曲形成中的主导作用。数值试验还表明，翘曲对PA12粉末床的预热目标温度高度敏感，而在测试范围内新涂覆粉末的温度影响有限。该工作为今后在局部尺度上优化聚合物L-PBF工艺，特别是在控制变形和提高尺寸精度方面提供了预测建模基础。

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引用次数: 0

Probing melt pool dynamics in laser-directed energy deposition via optical metrology: Simultaneous mapping of 3D morphology and surface flow 通过光学计量学探测激光定向能量沉积中的熔池动力学：三维形貌和表面流动的同时映射

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-17 DOI: 10.1016/j.addma.2025.105053

Chenghao Zhang , Zhanfei Zhang , Bo Zheng , Qixian Zhong , Fenghao Zhou , Huimin Xie , Zhanwei Liu

During laser-directed energy deposition (L-DED), the three-dimensional morphology and surface flow behavior of the melt pool is considered as critical physical fields which fundamentally determine the quality of fabricated components. Nevertheless, conventional in-situ monitoring systems have limitations in achieving synchronized observation of both morphological and flow characteristics. In this study, we develop an in-situ optical measurement system based on four-mirror module, enabling binocular vision imaging of the melt pool using a single high-speed camera. By incorporating deep learning-assisted feature extraction and matching algorithms, three-dimensional reconstruction of the melt pool morphology is accomplished. Simultaneously, digital image correlation techniques are employed to quantify surface flow fields. The dynamics evolution of melt pool morphology and surface flow are characterized under different process parameter combinations. On this basis, surrogate models correlating process parameters with melt pool characteristics are established. Sobol sensitivity analysis further reveals the influence of process parameters on the characteristics of melt pool. The obtained results demonstrate that the melt pool height is predominantly regulated by scanning speed and powder feed rate, whereas the melt pool width exhibits stronger dependence on laser power and scanning speed. The melt pool surface flow exhibits unsteady state, with turbulent kinetic energy concentrating predominantly in the central region. Marangoni convection is identified as the dominant mechanism governing melt transport along the scanning direction. This work provides a robust experimental framework for investigating multi-physics coupling phenomena in L-DED melt pools, offering technical support for process optimization and closed-loop control strategies of L-DED process.

在激光定向能沉积（L-DED）过程中，熔池的三维形貌和表面流动行为是决定零件质量的关键物理场。然而，传统的原位监测系统在实现形态和流动特征的同步观测方面存在局限性。在这项研究中，我们开发了一个基于四镜模块的原位光学测量系统，实现了使用单个高速相机对熔池进行双目视觉成像。通过结合深度学习辅助特征提取和匹配算法，实现了熔池形态的三维重建。同时，采用数字图像相关技术对表面流场进行量化。研究了不同工艺参数组合下熔池形态和表面流动的动态演变。在此基础上，建立了工艺参数与熔池特征之间的代理模型。Sobol灵敏度分析进一步揭示了工艺参数对熔池特性的影响。结果表明，熔池高度主要受扫描速度和粉末进给量的影响，而熔池宽度受激光功率和扫描速度的影响较大。熔池表面流动呈现非定常状态，湍流动能主要集中在中心区域。马兰戈尼对流是控制熔体沿扫描方向输运的主要机制。本研究为研究L-DED熔池中多物理场耦合现象提供了可靠的实验框架，为L-DED工艺优化和闭环控制策略提供了技术支持。

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引用次数: 0

Enhancing processability and performance of laser powder bed fusion-fabricated poly-ether-ether-ketone composites: Influence of glass fiber length and content 提高激光粉末床熔融法制备聚醚-醚-酮复合材料的可加工性和性能：玻璃纤维长度和含量的影响

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-16 DOI: 10.1016/j.addma.2025.105058

Haoze Wang , Yuheng Tian , Yuxin Li , Leiyi Qi , Peng Chen , Chunze Yan , Yusheng Shi

Incorporating glass fibers (GF) into LPBF-printed PEEK enhances its mechanical and high-temperature load-bearing capacity while preserving the polymer’s electromagnetic transparency, enabling use in demanding environments that require heat resistance, heavy loads and excellent electrical insulation. This study investigates the effects of fiber length and content on the processability and mechanical properties of GF-reinforced PEEK composites. The results demonstrate that increasing GF content expanded the sintering window by up to 18 % and raised thermal degradation temperatures, thereby improving LPBF processability. The tensile modulus peaked at 4.80 GPa (31 % increase at 20 wt% for 250-mesh fibers), while longer fibers (125-mesh) exhibited better flexural modulus (5.21 GPa, 43 % increase at 20 wt% for 125-mesh fibers), as longer fibers help prevent crack propagation and reduce defect impact in bending. The storage modulus increased with both fiber content and length, reaching up to 182 % higher at 50 °C for 125-mesh fibers at 20 wt%. The dielectric constants of the PEEK/GF composites ranged from 2.48 to 3.53, with low dielectric losses, indicating excellent stability across 1–40 GHz, confirming suitability for lightweight insulation and radome applications.

将玻璃纤维（GF）加入到lpbf打印的PEEK中，可以增强其机械和高温承载能力，同时保持聚合物的电磁透明度，使其能够在要求耐热、重载荷和优异电绝缘的苛刻环境中使用。研究了纤维长度和含量对gf增强PEEK复合材料加工性能和力学性能的影响。结果表明，增加GF含量可使烧结窗口扩大18 %，提高热降解温度，从而改善LPBF的可加工性。拉伸模量峰值为4.80 GPa(250目纤维在20 wt%时增加31 %)，而较长的纤维（125目）表现出更好的弯曲模量（5.21 GPa， 125目纤维在20 wt%时增加43 %），因为较长的纤维有助于防止裂纹扩展并减少弯曲时的缺陷影响。存储模量随纤维含量和长度的增加而增加，对于125目纤维，在20 wt%时，在50°C时达到182 %。PEEK/GF复合材料的介电常数范围为2.48至3.53，介电损耗低，在1-40 GHz范围内具有优异的稳定性，适用于轻型绝缘和天线罩应用。

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引用次数: 0

Stereolithography 3D printing of PTFE-filled photopolymer composites with enhanced THz transparency 增强太赫兹透明度的聚四氟乙烯填充光聚合物复合材料的立体光刻3D打印

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-16 DOI: 10.1016/j.addma.2025.105057

Luke Phillips , Harry J. Godden , John Kendrick , Nathan R. Fox , Alexander Valavanis , Andrew D. Burnett , Robert Kay , Ehab Saleh

Quasi-optics are essential components of terahertz (THz) systems, used to direct and manipulate THz radiation. High-resolution additive manufacturing (AM) techniques, such as vat photopolymerization (VP), enable the low-cost production of complex quasi-optical components with optically smooth surfaces and fine geometric features with dimensions comparable to wavelengths in the THz region. However, VP-produced quasi-optics are often inefficient owing to significant absorption losses, with commercially available photopolymers exhibiting absorption coefficients ranging between 19 – 27 cm^–1 at 1 THz. Polytetrafluoroethylene (PTFE) is highly transparent in the THz region, making it a promising filler material to reduce the absorption of photopolymers. However, no previous studies have reported the development of a PTFE composite suitable for processing via VP. In this study, PTFE powder-filled composites were formulated containing PTFE-to-photocurable-resin ratios ranging from 1:10–4:10, corresponding to approximately 9.0 % and 28.5 % by weight, respectively. Samples were manufactured via VP and characterised from 0.5 to 2.0 THz using a THz time-domain spectroscopy system. The results demonstrated a correlation between higher PTFE ratios and a reduction in the absorption coefficient of the samples from 0.5 to 2.0 THz, with the 4:10 sample having an absorption coefficient of 15.3 ± 0.3 cm^–1 at 1 THz, 27.8 % lower than that of the neat resin (21.2 ± 0.4 cm^–1). Additionally, experimental results were shown to agree well with a Maxwell Garnett effective medium approximation-based calculation of the THz optical properties of AM composites. These findings highlight the potential of non-polar polymer fillers to enhance the transparency of photopolymers to THz radiation, potentially supporting the future development of more efficient VP-produced quasi-optical components.

准光学是太赫兹（THz）系统的重要组成部分，用于指导和操纵太赫兹辐射。高分辨率增材制造（AM）技术，如还原光聚合（VP），可以低成本生产具有光学光滑表面和精细几何特征的复杂准光学元件，其尺寸可与太赫兹区域的波长相媲美。然而，由于显著的吸收损失，vp产生的准光学器件通常效率低下，商业上可用的光聚合物的吸收系数在19 - 27 cm-1和1 太赫兹之间。聚四氟乙烯（PTFE）在太赫兹区是高度透明的，使其成为一种有前途的填充材料，以减少光聚合物的吸收。然而，目前还没有研究报道开发出一种适合VP加工的PTFE复合材料。在本研究中，PTFE粉末填充复合材料的配方中，PTFE与光固化树脂的比例为1:10-4:10，重量分别约为9.0 %和28.5 %。样品通过VP制造，并使用太赫兹时域光谱系统在0.5至2.0 太赫兹范围内进行表征。结果显示出更高的聚四氟乙烯比率之间的相关性,减少样品的吸收系数从0.5到2.0 太赫兹,叫样本有一个吸收系数为15.3 ±0.3  cm - 1 1 太赫兹,低27.8 %比纯树脂(21.2 ±0.4  cm - 1)。此外，实验结果与基于Maxwell Garnett有效介质近似的增材复合材料太赫兹光学特性计算结果一致。这些发现强调了非极性聚合物填料在提高光聚合物对太赫兹辐射的透明度方面的潜力，可能支持未来开发更高效的vp生产的准光学元件。

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引用次数: 0

A framework for process anomaly detection in 3D concrete printing 三维混凝土打印过程异常检测框架

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-16 DOI: 10.1016/j.addma.2025.105056

Abdallah Kamhawi , Yuxin Lin , Christopher Watson , Kira Barton , Mania Aghaei Meibodi

Extrusion-based 3D concrete printing offers a transformative opportunity for waste-free fabrication of complex and materially optimized building components. However, the current reliance on manual observation and ad-hoc parameter tuning introduces significant variability into the process and limits the scalability of 3D concrete printing. Existing systems offer no predictive insight into failure events and remain dependent on trial-and-error methods, resulting in increased material consumption, higher costs, and prolonged production times. To address this, the paper introduces a comprehensive framework for process anomaly detection tailored to two-component extrusion-based 3D concrete printing systems. The proposed framework integrates systematic sensor instrumentation, heterogeneous data acquisition, and signal feature characterization to enable real-time monitoring of system health. Non-destructive sensors are deployed to measure environmental conditions, slurry pumpability, hydration behavior, and workability. Collected signals are analyzed using a suite of processing techniques — including frequency analysis, amplitude envelope detection, curve fitting, and magnitude deviation analysis — to extract critical features indicative of emerging anomalies. The methodology presented in this paper establishes a generalizable framework for anomaly detection, using data collected from physical experiments, where the specific metric values derived from the data are tied to the feedstock used in this study for validation. The paper results demonstrate the ability of the proposed methods to detect failure modes — such as pump clogging, material segregation, and two-component mixing head clogging — ahead of human operator detection. These findings confirm the viability of the proposed framework for anomaly detection.

基于挤压的3D混凝土打印为无废物制造复杂和材料优化的建筑构件提供了一个变革性的机会。然而，目前对人工观察和临时参数调整的依赖给过程带来了显著的可变性，并限制了3D混凝土打印的可扩展性。现有的系统无法预测故障事件，仍然依赖于试错方法，导致材料消耗增加，成本增加，生产时间延长。为了解决这个问题，本文介绍了一个针对基于双组分挤出的3D混凝土打印系统的过程异常检测的综合框架。提出的框架集成了系统传感器仪器、异构数据采集和信号特征表征，以实现对系统健康状况的实时监控。非破坏性传感器可用于测量环境条件、泥浆泵送性、水化行为和可加工性。收集到的信号使用一套处理技术进行分析，包括频率分析、幅度包络检测、曲线拟合和幅度偏差分析，以提取指示新出现异常的关键特征。本文提出的方法建立了一个可推广的异常检测框架，使用从物理实验中收集的数据，其中从数据中获得的特定度量值与本研究中使用的原料相关联以进行验证。本文的结果表明，所提出的方法能够在人工操作人员检测之前检测故障模式，如泵堵塞、材料离析和双组分混合头堵塞。这些发现证实了所提出的异常检测框架的可行性。

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引用次数: 0