Additive manufacturing最新文献_第5页

Measuring thermomechanical response of large-format printed polymer composite structures via digital image correlation 通过数字图像相关性测量大幅面印刷聚合物复合结构的热机械响应

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104479

Tyler M. Corum , Johnna C. O’Connell , James C. Brackett , Ahmed Arabi Hassen , Chad E. Duty

Large-format additive manufacturing (LFAM) is a branch of additive manufacturing (AM) research with the ability to create large structures typically measuring several meters in scale. LFAM is advantageous for tooling applications, not only because it offers the ability to create complex geometries not easily made using subtractive manufacturing processes, but the cost savings of pelletized feedstock used by these systems result in larger parts printed at faster speeds than traditional AM systems. Fiber reinforced polymer (FRP) is a commonly used feedstock material in LFAM structures because it reduces the distortion experienced during printing. However, FRP introduces highly anisotropic thermomechanical properties and contributes to a nonhomogeneous microstructure that can result in critical distortion of dimensions during tooling. Measuring the global thermomechanical response of LFAM structures requires a more representative method that accounts for not only anisotropic properties but also the nonhomogeneous nature of the final part. This is where traditional techniques to measure thermomechanical response, such as thermomechanical analysis (TMA), fall short as they assume homogeneity. This study evaluated the coefficient of thermal expansion (CTE) of LFAM structures as measured by TMA as compared to a novel digital image correlation oven (DIC Oven) system. The LFAM structures were made from 20 % by weight carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS). TMA measurements showed significant variations in CTE across a single LFAM bead, confirming the need for a global technique that captures overall thermomechanical response. The CTE values measured using the DIC Oven compared well to average TMA values obtained from localized measurements across the sample. The DIC Oven was also used to quantify the effects of different layer orientations on thermomechanical properties, which cannot be easily captured using TMA. A predictive model was also developed by using localized TMA values across an LFAM bead to predict the overall thermomechanical response of an LFAM structure.

大型增材制造（LFAM）是增材制造（AM）研究的一个分支，能够制造出通常为几米的大型结构。LFAM 在模具应用方面具有优势，这不仅是因为它能够制造出不易用减法制造工艺制造的复杂几何形状，还因为这些系统使用的颗粒化原料节省了成本，因此能以比传统 AM 系统更快的速度打印出更大的部件。纤维增强聚合物（FRP）是 LFAM 结构中常用的原料材料，因为它可以减少打印过程中的变形。然而，玻璃纤维增强聚合物具有高度各向异性的热机械特性，会产生非均质的微观结构，从而导致模具加工过程中出现严重的尺寸变形。测量 LFAM 结构的整体热机械响应需要一种更具代表性的方法，这种方法不仅要考虑各向异性，还要考虑最终零件的非均质性。这正是传统的热机械响应测量技术（如热机械分析 (TMA)）的不足之处，因为它们假定了均匀性。本研究评估了 LFAM 结构的热膨胀系数 (CTE)，并将 TMA 与新型数字图像相关烤箱 (DIC Oven) 系统进行了比较。LFAM 结构由 20% 重量百分比的碳纤维增强丙烯腈-丁二烯-苯乙烯（CF-ABS）制成。TMA 测量结果表明，单个 LFAM 珠的 CTE 存在显著差异，这证明需要一种能够捕捉整体热机械响应的全局技术。使用 DIC 烘箱测得的 CTE 值与通过对样品进行局部测量获得的平均 TMA 值进行了很好的比较。DIC 烘炉还用于量化不同层取向对热机械性能的影响，而 TMA 无法轻松捕捉这些影响。通过使用整个 LFAM 珠的局部 TMA 值来预测 LFAM 结构的整体热机械响应，还建立了一个预测模型。

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引用次数: 0

4D Printed shape memory polymers in focused ultrasound fields 聚焦超声场中的 4D 印刷形状记忆聚合物

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104465

Hrishikesh Kulkarni , Jiaxin Xi , Ahmed Sallam , Phoenix Lee , David Safranski , Reza Mirzaeifar , Shima Shahab

4D Printing is a new area of additive manufacturing that extends the possibilities of 3D printing by including the dimension of time. This cutting-edge technique entails creating elaborate structures out of intelligent materials, specifically shape memory polymers (SMPs), which may dynamically change shape or functionality in response to external inputs. The purpose of this study is to conduct a rigorous spatiotemporal characterization into the potential of focused ultrasound (FUS) in actuating 4D-printed SMPs as well as to evaluate the impacts of different printing parameters on shape recovery. Experiments demonstrate that FUS is a unique and non-invasive method that can cause localized heating, activate several intermediate shapes, and accomplish full shape recovery in SMPs. Moreover, by optimizing sample size, ultrasound frequency, exposure time, intensity, and the location of ultrasound focusing, FUS possesses an enhanced capacity for temporal and spatial control of shape recovery. We determine the effects of various 3D printing parameters, including printing temperature, printing speed, infill density, and infill structures, on the thermo-mechanical shape recovery properties of a thermoplastic polyurethane. Shape recovery ratios ranged from 50% to 80% across different printing parameters. The study demonstrated that increasing acoustic field intensity can maximize shape recovery to over 95%, although this may cause to material degradation depending on sample thickness. The findings also revealed that these printing parameters significantly influence storage modulus, loss modulus, and glass transition temperature, highlighting their impact on thermo-mechanical properties. Furthermore, this study uses acoustical principles and thermo-mechanical experimental data to show a systematic relationship between additive manufacturing settings and SMP viscoelastic deformation properties. Lastly, a dynamic transition of a 4D-printed functional gripper-like structure, exhibiting both opening and closing motions upon exposure to FUS irradiation, was demonstrated using the optimized parameters. This research paves the way for FUS to accurately spatiotemporal and localized actuation of SMPs, particularly in medical applications.

4D 打印是增材制造的一个新领域，它将时间维度纳入其中，从而扩展了 3D 打印的可能性。这项前沿技术需要用智能材料，特别是形状记忆聚合物（SMP）来创建精细的结构，这种材料可以根据外部输入动态地改变形状或功能。本研究旨在对聚焦超声（FUS）在驱动 4D 打印 SMP 方面的潜力进行严格的时空表征，并评估不同打印参数对形状恢复的影响。实验证明，聚焦超声是一种独特的非侵入式方法，它可以引起局部加热，激活多个中间形状，并实现 SMP 的完全形状恢复。此外，通过优化样品大小、超声频率、曝光时间、强度和超声聚焦位置，FUS 还能增强形状恢复的时间和空间控制能力。我们确定了各种三维打印参数（包括打印温度、打印速度、填充密度和填充结构）对热塑性聚氨酯热机械形状恢复特性的影响。在不同的打印参数下，形状恢复率从 50% 到 80% 不等。研究表明，增加声场强度可最大限度地提高形状恢复率，使其达到 95% 以上，但这可能会导致材料降解，具体取决于样品厚度。研究结果还显示，这些印刷参数对存储模量、损耗模量和玻璃化转变温度有显著影响，凸显了它们对热机械性能的影响。此外，本研究还利用声学原理和热机械实验数据，展示了增材制造设置与 SMP 粘弹性变形特性之间的系统关系。最后，利用优化参数展示了 4D 打印的功能性类抓手结构的动态转变，该结构在受到 FUS 辐照后表现出张开和闭合运动。这项研究为 FUS 准确地对 SMP 进行时空和局部致动铺平了道路，尤其是在医疗应用中。

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引用次数: 0

A heterogeneous pore design algorithm for material extrusion additive manufacturing 用于材料挤压增材制造的异质孔隙设计算法

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104449

Huawei Qu , Kaizheng Liu , Juan Liu , Chongjian Gao , Changshun Ruan

Material extrusion additive manufacturing offers great potential for customizing matters with complex external contours, and filament diameter-adjustable 3D (FDA-3D) printing strategy provides fresh impetus to create heterogeneous porous structures inside these complex matters. However, the absence of supporting algorithms to implement FDA-3D printing severely hinders its widespread use. In this paper, we develop a heterogeneous pore design (HPD) algorithm aimed at advancing the development of FDA-3D printing for producing heterogeneous porous matters. The HPD algorithm consists of three sub-algorithms: model design, collapse compensation, and fabrication file (G-codes) generation. As proofs of concept, we utilize this algorithm to 3D print radial gradient and letter-embedded gradient materials following specific steps: (1) designing the heterogeneous porous models with collapse compensation in Grasshopper® and displaying them in Rhinocores®; (2) customizing and writing the corresponding G-codes files by following the material extrusion 3D printer's control rules; (3) upgrading a commercial extrusion printer to FDA-3D print the design models via the customized G-codes. Micro-computed tomography-based 3D reconstruction and quantified pore size maps for the fabricated objects demonstrate the high capability of this HPD algorithm. Overall, the HPD algorithm holds the potential to revolutionize material extrusion 3D printers cost-effectively, creating new possibilities for material extrusion of heterogeneous materials.

材料挤压增材制造为定制具有复杂外部轮廓的物质提供了巨大潜力，而长丝直径可调三维（FDA-3D）打印策略为在这些复杂物质内部创建异质多孔结构提供了新的动力。然而，由于缺乏实现 FDA-3D 打印的辅助算法，严重阻碍了其广泛应用。在本文中，我们开发了一种异质孔隙设计（HPD）算法，旨在推动 FDA-3D 打印技术在生产异质多孔物质方面的发展。HPD 算法包括三个子算法：模型设计、塌陷补偿和制造文件（G 代码）生成。作为概念验证，我们利用该算法按照具体步骤三维打印径向梯度和字母嵌入梯度材料：(1) 在 Grasshopper® 中设计具有塌陷补偿功能的异质多孔模型，并将其显示在 Rhinocores® 中；(2) 按照材料挤压三维打印机的控制规则，定制并编写相应的 G 代码文件；(3) 通过定制的 G 代码，将商用挤压打印机升级为 FDA-3D 打印设计模型。基于微型计算机断层扫描的三维重建和制造物体的量化孔径图证明了 HPD 算法的高能力。总之，HPD 算法有望以经济高效的方式彻底改变材料挤压三维打印机，为异质材料的材料挤压创造新的可能性。

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引用次数: 0

Multi-fidelity surrogate with heterogeneous input spaces for modeling melt pools in laser-directed energy deposition 采用异质输入空间的多保真度替代物，为激光引导能量沉积过程中的熔池建模

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104440

Nandana Menon, Amrita Basak

Multi-fidelity (MF) modeling is a powerful statistical approach that can intelligently blend data from varied fidelity sources. This approach finds a compelling application in predicting melt pool geometry for laser-directed energy deposition (L-DED). One major challenge in using MF surrogates to merge a hierarchy of melt pool models is the variability in input spaces. To address this challenge, this paper introduces a novel approach for constructing an MF surrogate for predicting melt pool geometry by integrating models of varying complexity, that operate on heterogeneous input spaces. The first thermal model incorporates five input parameters i.e., laser power, scan velocity, powder flow rate, carrier gas flow rate, and nozzle height. In contrast, the second thermal model can only handle laser power and scan velocity. A mapping is established between the heterogeneous input spaces so that the five-dimensional space can be morphed into a pseudo two-dimensional space. Predictions are then blended using a Gaussian process-based co-kriging method. The resulting heterogeneous multi-fidelity Gaussian process (Het-MFGP) surrogate not only improves predictive accuracy but also offers computational efficiency by reducing evaluations required from the high-dimensional, high-fidelity thermal model. The tested Het-MFGP yields an

R^{2}

of 0.975 for predicting melt pool depth. This surpasses the comparatively modest

R^{2}

of 0.592 achieved by a GP trained exclusively on high-dimensional, high-fidelity data. Similarly, in the prediction of melt pool width, the Het-MFGP excels with an

R^{2}

of 0.943, outshining the GP's performance, which registers a lower

R^{2}

of 0.588. The results underscore the benefits of employing Het-MFGP for modeling melt pool behavior in L-DED. The framework successfully demonstrates how to leverage multimodal data and handle scenarios where certain input parameters may be difficult to model or measure.

多保真度（MF）建模是一种强大的统计方法，可以智能地混合来自不同保真度来源的数据。这种方法在预测激光直接能量沉积 (L-DED) 的熔池几何形状方面有着引人注目的应用。使用 MF 代理来合并熔池模型层次的一个主要挑战是输入空间的可变性。为了应对这一挑战，本文介绍了一种新颖的方法，通过整合不同复杂度的模型，构建用于预测熔池几何形状的 MF 代理，这些模型在不同的输入空间中运行。第一个热模型包含五个输入参数，即激光功率、扫描速度、粉末流速、载气流速和喷嘴高度。相比之下，第二个热模型只能处理激光功率和扫描速度。在异构输入空间之间建立映射，从而将五维空间变形为伪二维空间。然后使用基于高斯过程的共轭方法对预测结果进行混合。由此产生的异构多保真度高斯过程（Het-MFGP）代理不仅提高了预测精度，还通过减少高维高保真热模型所需的评估来提高计算效率。测试的 Het-MFGP 预测熔池深度的 R2 值为 0.975。这超过了完全基于高维、高保真数据训练的 GP 所达到的相对较低的 R2（0.592）。同样，在预测熔池宽度时，Het-MFGP 的 R2 值为 0.943，超过了 GP 的表现，后者的 R2 值为 0.588。这些结果凸显了采用 Het-MFGP 对 L-DED 中的熔池行为进行建模的优势。该框架成功展示了如何利用多模态数据和处理某些输入参数可能难以建模或测量的情况。

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引用次数: 0

Inhibition of interfacial cracks in 304L-Inconel718 bimetal fabricated via laser powder bed fusion 抑制通过激光粉末床融合制造的 304L-Inconel718 双金属中的界面裂纹

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104463

Yinghui Li , Zhuangzhuang Liu , Zhengyu Wei , Pengfei Hu , Jiawang Chen , Lijing Liu , Guogang Shu , Jianxin Xie

Multi-material additive manufacturing is crucial for intricate component fabrication, yet challenges, such as interfacial cracks and weak bonding, persist. This work investigated the laser powder bed fusion (L-PBF) of bimetallic components (stainless steel 304L-nickel-based alloy Inconel718) crucial in aerospace and nuclear applications. It is found that the interfacial cracks predominantly occur within the compositional transition zone where the proportion of 304 L is between 45 wt% and 75 wt%, characterized by brittle Laves phases along grain boundaries. Experimental and finite element simulations of melt pool reveal that a higher ratio of temperature gradient (

\overset{̅}{G}

) to the grain growth rate (

\overset{̅}{R}

) (

\overset{̅}{G}

/

\overset{̅}{R}

) results in straight grain boundaries with underdeveloped secondary dendrites. This leads to the formation of continuous liquid film and strip-like Laves phase at grain boundaries, causing interfacial cracks during L-PBF. To suppress these cracks, this work proposes manipulating grain boundaries into a tortuous morphology through promoting the growth of secondary dendrites. By controlling the

\overset{̅}{G}

/

\overset{̅}{R}

ratios below the critical value (<147.9×10⁶ K∙s/m²) and combining with a high cooling rate (

\overset{̅}{G}

×

\overset{̅}{R}

) during L-PBF, a well-developed secondary dendritic structure and grain refinement are achieved, significantly enhancing grain boundary tortuosity and forming discretely distributed Laves phases. As a result, interfacial cracks are completely suppressed, enabling the successful manufacturing of crack-free 304L-Inconel718 bimetallic components. The approach of tailoring the distribution of brittle precipitates through manipulating grain boundary morphology proposed in this work provides a novel and practical pathway for inhibiting cracks in multi-material additive manufacturing.

多材料增材制造对于复杂部件的制造至关重要，但界面裂纹和弱粘合等挑战依然存在。这项工作研究了航空航天和核应用中至关重要的双金属部件（不锈钢 304L-镍基合金 Inconel718）的激光粉末床熔融（L-PBF）。研究发现，界面裂纹主要发生在 304 L 的比例介于 45 wt% 和 75 wt% 之间的成分过渡区，其特征是沿晶界的脆性 Laves 相。熔池的实验和有限元模拟显示，温度梯度（G̅）与晶粒生长率（R̅）之比（G̅/R̅）越高，晶粒边界越直，次生枝晶不发达。这导致在晶界处形成连续液膜和条状 Laves 相，从而在 L-PBF 过程中产生界面裂纹。为了抑制这些裂纹，本研究提出通过促进次生枝晶的生长，将晶界操纵成迂回形态。通过将 G̅/R̅ 比值控制在临界值（<147.9×106 K∙s/m2 ）以下，并结合 L-PBF 期间的高冷却速率 (G̅×R̅)，实现了发达的次生树枝状结构和晶粒细化，显著提高了晶界曲折性，并形成了离散分布的 Laves 相。因此，界面裂纹被完全抑制，从而成功制造出无裂纹的 304L-Inconel718 双金属部件。这项工作中提出的通过操纵晶界形态来定制脆性沉淀分布的方法，为在多材料增材制造中抑制裂纹提供了一种新颖实用的途径。

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引用次数: 0

A mechanical characteristic capture method considering printing configurations for buildability modeling in concrete 3D printing 一种考虑到打印配置的力学特征捕捉方法，用于混凝土三维打印中的可建性建模

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104462

Yuning Chen , Kailun Xia , Enlai Dong , Ruilin Cao , Yueyi Gao , Yamei Zhang

The structure failure modeling of 3D printing concrete (3DPC) during production is crucial for structure design, manufacturing process control and optimization. Serving as model inputs, the accuracy of 3DPC fresh material properties measurement highly affects the model prediction performance. The measured mechanical properties of freshly printed concrete strongly depend on the geometry, deformation and hardening process of used samples in testing. Herein, we propose an all-in-one method (AIOM) that synchronously considers these key factors (layer geometry, deformation, and hardening process) to more accurately capture the early-age mechanical performance distribution in printed structures. Different parametric-mechanical buckling models and two printable cementitious materials with distinct hardening characteristics (printable cement and printable geopolymer) were used to validate the performance of AIOM, with the traditional testing method, uniaxial unconfined compression test (UUCT), as the reference. Compared with UUCT, AIOM can improve the buildability prediction accuracy by 11.9 % to 50.8 % for different validation scenarios. This novel testing method for 3DPC fresh material properties contributes to improving the accuracy of 3DPC structure failure models, thereby facilitating a better production phase control for 3DPC.

三维打印混凝土（3DPC）生产过程中的结构失效建模对于结构设计、生产过程控制和优化至关重要。作为模型输入，3DPC 新材料性能测量的准确性对模型预测性能影响很大。新打印混凝土的测量力学性能与测试中所用样品的几何形状、变形和硬化过程密切相关。在此，我们提出一种多合一方法（AIOM），同步考虑这些关键因素（层几何形状、变形和硬化过程），以更准确地捕捉打印结构的早期力学性能分布。以传统的测试方法--单轴无约束压缩试验（UUCT）为参考，使用不同的参数力学屈曲模型和两种硬化特性不同的可印刷胶凝材料（可印刷水泥和可印刷土工聚合物）来验证 AIOM 的性能。与单轴无约束压缩试验相比，在不同的验证情况下，AIOM 可将可建性预测精度提高 11.9% 至 50.8%。这种新型的 3DPC 新材料性能测试方法有助于提高 3DPC 结构失效模型的准确性，从而更好地控制 3DPC 的生产阶段。

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引用次数: 0

Obtaining excellent mechanical properties with additively manufactured short fiber reinforced polyether-ether-ketone thermoplastics through simultaneous vacuum and infrared heating 通过同时真空和红外加热，用添加式制造的短纤维增强聚醚醚酮热塑性塑料获得优异的机械性能

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104491

Recep Gümrük , Bahri Barış Vatandaş , Altuğ Uşun

Additive manufacturing of short fiber reinforced thermoplastic composite with high-performance engineering thermoplastics is important in various industrial sectors because of their ability to manufacture complex and lightweight products. Although extensive studies in the literature are aimed at enhancing the mechanical performance of additively manufactured short fiber reinforced thermoplastics through methods like refining printing parameters, enhancing fiber fractions, and optimizing printing parameters, their mechanical performance remains limited. In this study, the individual effects of vacuum-assisted printing and infrared pre-heater-assisted printing and their combined effects were investigated to substantially increase the mechanical properties, interlaminar performance, and crystallinity ratios. The polyether ether ketone (PEEK) samples were printed with vacuum-assisted, infrared-assisted, and a combination of vacuum and infrared-assisted environments were subjected to three-point bending tests to evaluate their mechanical properties. Synergistic vacuum and infrared-assisted printing significantly enhanced the mechanical properties as the flexural strength increased by 54.58 % compared to printing under vacuum alone. Moreover, the flexural strength and elasticity modulus of samples printed with vacuum-infrared-assisted manufacturing increased by 324.48 % and 239.77 %, respectively, when compared to printing under atmospheric pressure without additional heating. Thermal and structural characterizations of the printed parts revealed that this significant improvement was attributed to reduced porosity ratios and increased crystallinity.

采用高性能工程热塑性塑料对短纤维增强热塑性复合材料进行快速成型制造，因其能够制造复杂、轻质的产品而在各个工业领域发挥着重要作用。尽管文献中的大量研究旨在通过细化打印参数、提高纤维分数和优化打印参数等方法来提高增材制造短纤维增强热塑性塑料的机械性能，但其机械性能仍然有限。在本研究中，研究了真空辅助印刷和红外预热器辅助印刷的单独效果及其组合效果，以大幅提高机械性能、层间性能和结晶度比。聚醚醚酮（PEEK）样品分别在真空辅助、红外辅助以及真空和红外辅助相结合的环境下进行了印刷，并在三点弯曲试验中对其机械性能进行了评估。真空和红外辅助印刷协同作用显著提高了机械性能，与单独在真空环境下印刷相比，弯曲强度提高了 54.58%。此外，与在常压下印刷而不额外加热相比，用真空-红外辅助制造工艺印刷的样品的抗弯强度和弹性模量分别提高了 324.48 % 和 239.77 %。对印刷部件的热学和结构特性分析表明，这一显著改善归因于孔隙率的降低和结晶度的提高。

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引用次数: 0

Near-surface microstructures convolute mechanical properties in additively manufactured metals 近表面微观结构影响快速成型金属的机械性能

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104477

Kaitlynn M. Fitzgerald , Jay D. Carroll , Dale E. Cillessen , Anthony Garland , Timothy J. Ruggles , Kyle L. Johnson , Brad L. Boyce

Kovar specimens were additively manufactured with 180 variations in process conditions. Three distinct geometries (two tensile geometries and a Charpy specimen) were evaluated for each set of process conditions. Tensile specimens additively manufactured to net shape had less porosity, more uniform material properties, higher average ductility, and they consistently failed via ductile rupture. Tensile specimens harvested via electric discharge machining from larger additively manufactured blocks often contained lack of fusion voids throughout the cross section - those pre-existing pores drove pre-mature failure. As-printed specimens, on the other hand, were more representative of the outer border properties rather than the interior of large printed parts. The properties of the specimens cut from the larger block of additively manufactured material were more representative of the inner hatch properties but were stochastic, depending on the size and location of present voids. Using a high-throughput methodology, the results from over 800 tensile tests are reported here. This extensive statistical sampling allows the effects of specimen type and location to be clearly distinguished from other intentional variables (process parameter variations) and stochastic material variability.

科瓦试样是在 180 种不同工艺条件下添加制造的。针对每组工艺条件评估了三种不同的几何形状（两种拉伸几何形状和一种夏比试样）。根据净形添加剂制造的拉伸试样孔隙率更小、材料特性更均匀、平均延展性更高，并且始终通过延展断裂失效。通过电火花加工从较大的添加剂制造块中获得的拉伸试样往往在整个横截面上缺乏熔融空隙--这些预先存在的孔隙会导致过早失效。另一方面，直接打印的试样更能代表外部边界的特性，而不是大型打印部件的内部。从更大的加成制造材料块上切割下来的试样的特性更能代表内部舱口的特性，但其随机性取决于存在空隙的大小和位置。本文采用高通量方法，报告了 800 多项拉伸试验的结果。通过这种广泛的统计取样，可以将试样类型和位置的影响与其他有意变量（工艺参数变化）和随机材料变化明确区分开来。

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引用次数: 0

Data-driven reliability-oriented buildability analysis of 3D concrete printed curved wall 以可靠性为导向的三维混凝土打印曲面墙可建性数据驱动分析

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104459

Baixi Chen, Xiaoping Qian

The inherent uncertainties, particularly material uncertainties, significantly impact the buildability of 3D concrete-printed curved walls, leading to substantial variations that complicate quality control. To address this, a data-driven stochastic analysis framework is proposed for reliability-oriented buildability evaluation. Material uncertainties are quantified using a maximum likelihood-based stochastic parameter estimation method and considered as the uncertainty sources. Subsequently, a data-driven model, namely sparse Gaussian process regression (SGPR) model, is trained and combined with Monte Carlo simulation to assess the stochastic behavior of curved wall buildability. The influences of print speed, layer height, and horizontal curvature on buildability are analyzed under varying reliability levels. Additionally, an empirical model is proposed for the rapid evaluation of maximum buildability at specified horizontal curvature and reliability levels, providing significant practical value for 3D concrete printing designers. The impact of other uncertainty sources including the model error on reliability-oriented buildability is also discussed. These sources exhibit negligible influence when their intensities are less than 30 % of that caused by material uncertainty. Furthermore, the feasibility of the data-driven reliability-oriented buildability analysis for more complex geometry is also demonstrated.

固有的不确定性，尤其是材料的不确定性，会对三维混凝土打印曲面墙的可建性产生重大影响，从而导致巨大的差异，使质量控制变得更加复杂。为此，我们提出了一个数据驱动的随机分析框架，用于以可靠性为导向的可建性评估。使用基于最大似然法的随机参数估计方法对材料不确定性进行量化，并将其视为不确定性源。随后，训练了一个数据驱动模型，即稀疏高斯过程回归（SGPR）模型，并将其与蒙特卡罗仿真相结合，以评估曲面墙可构建性的随机行为。在不同的可靠性水平下，分析了打印速度、层高和水平曲率对可构建性的影响。此外，还提出了一个经验模型，用于快速评估指定水平曲率和可靠性水平下的最大可建性，为三维混凝土打印设计人员提供了重要的实用价值。此外，还讨论了其他不确定性来源（包括模型误差）对以可靠性为导向的可构建性的影响。当这些来源的强度小于材料不确定性的 30% 时，其影响可忽略不计。此外，数据驱动的以可靠性为导向的可构建性分析对于更复杂几何形状的可行性也得到了证明。

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引用次数: 0

Additive manufacturing of heterogeneous combinatorial functional surface by plasmonic hierarchical sintering of silicon particles for active manipulation of rheological liquid motion 通过等离子体分层烧结硅颗粒增材制造异质组合功能表面，主动操纵流变液体运动

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2024-08-25 DOI: 10.1016/j.addma.2024.104474

Sung Jin Park, Seunghyun Back, Bongchul Kang

We present a sustainable and efficient additive manufacturing method of silicon-based heterogeneous combinatorial functional surfaces designed to actively manipulate liquid droplet motion dynamics to address advanced rheological engineering challenges and applications. This additive manufacturing enables the instantaneous formation and control of hierarchical multiscale structures with tunable wettability through instantaneous plasmonic thermophysical sintering between laser and Si particles, eliminating the need for additional masks and subsequent processing steps. Furthermore, this fabrication approach can selectively implement heterogeneous combinatorial functional surfaces in a single domain by reversibly switching extreme wettability modes (e.g., from superhydrophobic to superhydrophilic) upon laser irradiation. Continuous superhydrophilic channels in a superhydrophobic background created by selective laser re-irradiation provide sufficient local attraction to manipulate droplet motion along the channel due to van der Waals forces and Laplace pressure fields generated by the difference in wettability. Active manipulation of droplet dynamic motion, such as trajectory tracking and antigravity self-propulsion, can be realized by simply designing a laser scanning path that determines the geometry of the local channel. The manipulation platform for liquid motion dynamics can be applied to active microfluidic channels with no cavity, without the need for an external power source. This advancement has important implications for broad fluid and rheological engineering applications.

我们提出了一种可持续、高效的硅基异质组合功能表面快速成型制造方法，旨在主动操纵液滴运动动力学，以应对先进的流变工程挑战和应用。这种快速成型制造方法通过激光与硅颗粒之间的瞬时等离子体热物理烧结，实现了具有可调润湿性的分层多尺度结构的瞬时形成和控制，无需额外的掩膜和后续加工步骤。此外，这种制造方法还能在激光照射时可逆地切换极端润湿性模式（例如从超疏水到超亲水），从而有选择性地在单个域中实现异质组合功能表面。通过选择性激光再照射，在超疏水背景中形成连续的超亲水通道，由于润湿性差异产生的范德华力和拉普拉斯压力场，为操纵液滴沿通道运动提供了足够的局部吸引力。只需设计一条决定局部通道几何形状的激光扫描路径，就能实现液滴动态运动的主动操纵，如轨迹跟踪和反重力自推进。液体动态运动操纵平台可应用于无空腔的主动微流体通道，无需外部动力源。这一进步对广泛的流体和流变工程应用具有重要意义。

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