Additive manufacturing最新文献_第5页

Metastable phase transformations are key to graded immiscible multi-materials via additive manufacturing 亚稳态相变是通过增材制造实现梯度非混相复合材料的关键

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.104999

I. Basu , L. Deillon , R.E. Schäublin , M. Bambach , J.F. Löffler

Additive manufacturing of immiscible materials by laser-based technology offers a unique opportunity to design property-graded structures. The CuCrZr–316L system serves as a prime example of this approach, combining the benefits of the superior thermal/electrical properties of the former and the robust mechanical characteristics of the latter. However, to understand the resulting properties, insights into the microstructure transformations induced by the laser-induced extreme processing conditions are needed. Correlative characterization using transmission electron backscattered diffraction, transmission electron microscopy and nanoscale energy-dispersive X-ray spectroscopy analyses was implemented to assess the microstructural and chemical landscape across the multiple length scales of a laser-powder bed fusion (PBF-LB) processed CuCrZr–316L multi-material. Micron-scale residual stress measurements were performed by focused ion beam-digital image correlation technique to obtain spatially resolved stress gradients across the CuCrZr–316L interface. The findings were utilized to establish an intricate correlation between the structural/compositional hierarchy and the local stress states of the material; they reveal unusual phase transformation pathways that can generally act in materials solidified under extreme and metastable conditions. Multiscale phase separation into Cu- and Fe-rich regions occurred both within the melt and spinodally within the solid state. While the Cu-rich regions exhibited an FCC structure, the Fe-rich regions comprised FCC and the unexpected formation of BCC phases. A novel phase decomposition-mediated structural transformation was observed in the CuCrZr–316L interfacial zone, resulting from nanoscale compositional fluctuations and straddling the boundary of a spinodal-binodal transition. Moreover, this work reveals the correlation between local stress heterogeneities in additively manufactured (AM) multi-material microstructures and the associated local dislocation-mediated strengthening mechanisms. Such microstructural mechanisms, enabled by PBF-LB, can be utilized to generate materials with contrasting property combinations, such as a simultaneous strength-ductility enhancement.

基于激光技术的非混相材料增材制造为设计性能分级结构提供了独特的机会。CuCrZr-316L系统是这种方法的一个典型例子，它结合了前者优越的热/电性能和后者强大的机械特性。然而，为了了解最终的性能，需要深入了解激光诱导的极端加工条件下引起的微观结构转变。利用透射电子背散射衍射、透射电子显微镜和纳米尺度能量色散x射线能谱分析对激光-粉末床熔合（PBF-LB）加工的CuCrZr-316L复合材料在多个长度尺度上的微观结构和化学景观进行了相关表征。利用聚焦离子束-数字图像相关技术进行微米尺度的残余应力测量，获得CuCrZr-316L界面上的空间分辨应力梯度。这些发现被用来建立结构/成分层次与材料局部应力状态之间的复杂关联；他们揭示了不寻常的相变途径，通常可以在极端和亚稳态条件下固化的材料中起作用。熔体内部和固态内部都发生了富Cu和富fe区域的多尺度相分离。富cu区表现为FCC结构，而富fe区则由FCC和意外形成的BCC相组成。在CuCrZr-316L界面区观察到一种新的相分解介导的结构转变，这种转变是由纳米级成分波动引起的，并且跨越了双节-双节过渡的边界。此外，这项工作揭示了增材制造（AM）多材料微观结构中的局部应力非均质性与相关的局部位错介导的强化机制之间的相关性。由PBF-LB实现的这种微观结构机制可以用来生成具有不同性能组合的材料，例如同时增强强度和延性。

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引用次数: 0

Improved laser beam shapes for DED-LB/M: low-fidelity Monte-Carlo design and high-fidelity verification 改进的d - lb /M激光束形状：低保真蒙特卡罗设计和高保真验证

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105016

Lova Chechik , Mohammad Sattari , Gert-willem R.B.E. Römer , Michael Schmidt

Complex beam shapes, i.e. laser beam intensity distributions, have shown great potential in laser processing technologies, with ring-profiles being widely investigated for additive manufacturing (AM), aiming to improve productivity, reduce defects and improve process stability. The question arises, however, whether the ring-profile is optimal, or rather, what laser beam intensity distribution could optimise different aspects of AM? Laser-directed energy deposition (DED-LB/M) is used in applications such as turbine blade repair, but is expensive and struggles with microstructural inhomogeneity. Recently, computationally-intensive simulations have been tested to design complex beam shapes for laser-powder bed fusion (PBF), only a few beam shapes, however, have been tested in DED-LB/M. This work focusses on DED-LB/M and proposes a novel methodology, using a Monte-Carlo approach to establish new improved laser beam intensity distributions. A low-fidelity model is subsequently used to calculate the resulting temperature fields. Example beam shapes are shown, aiming to improve process stability, to control the microstructure (through the thermal gradient) and to increase the process productivity. Next, validated high-fidelity simulations are used to verify the newly designed intensity distributions and show that the trends in peak temperature as well as melt-pool length and width are accurately captured by the low-fidelity model. The improved beam shapes predicted by the low-fidelity model will be used to direct future work, providing a starting point for intensity distributions to be experimentally tested. The low computational complexity of the low-fidelity model makes this methodology time-feasible, and its flexibility allows for new melt pool features to be improved. Consequently, this methodology can be transferred to further laser processes, such as surface-hardening or PBF, allowing for step-change improvements across the breadth of laser processing techniques.

复杂的光束形状，即激光束强度分布，在激光加工技术中显示出巨大的潜力，环形轮廓被广泛研究用于增材制造（AM），旨在提高生产率，减少缺陷和提高工艺稳定性。然而，问题出现了，环形轮廓是否是最佳的，或者更确切地说，什么样的激光束强度分布可以优化AM的不同方面？激光定向能量沉积（d - lb /M）用于涡轮叶片修复等应用，但价格昂贵且存在微观结构不均匀的问题。最近，为了设计激光粉末床熔合（PBF）的复杂光束形状，已经进行了大量的计算模拟测试，然而，在d - lb /M中只测试了几种光束形状。这项工作的重点是d - lb /M，并提出了一种新的方法，使用蒙特卡罗方法建立新的改进的激光束强度分布。随后使用低保真模型计算得到的温度场。示例梁形状显示，旨在提高工艺稳定性，控制微观结构（通过热梯度），并提高工艺生产率。然后，利用经过验证的高保真度模拟来验证新设计的强度分布，并表明低保真度模型准确地捕获了峰值温度以及熔池长度和宽度的变化趋势。低保真模型预测的改进光束形状将用于指导未来的工作，为实验测试的强度分布提供一个起点。低保真模型的低计算复杂度使得该方法在时间上可行，并且其灵活性允许改进新的熔池特征。因此，这种方法可以转移到进一步的激光工艺，如表面硬化或PBF，允许跨激光加工技术广度的阶跃变化改进。

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引用次数: 0

Tailored microstructures in laser-based powder bed fusion of 316L using beam shaping: From microstructure formation in individual specimens to their transition in segmented parts 使用光束整形的激光粉末床熔合316L的定制微观结构：从单个样品的微观结构形成到它们在分段部分的转变

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105026

Jonas Grünewald , Raphaela Pfund , Daniel Röhrer , Leonhard Hitzler , Jan Torgersen , Katrin Wudy

Ring-shaped beam profiles are increasingly being used in laser-based powder bed fusion of metals (PBF-LB/M). Due to a changed temperature distribution and progression during processing, the ring-shaped beam profiles have the potential to adjust the solidification behavior and can therefore affect the microstructure formation. This publication shows first how the use of different ring-shaped beam profiles influences the as-built microstructure of AISI 316L. Secondly, it demonstrates how this can be used to tailor the microstructure locally. In order to investigate the emerging microstructure in the transition zone of locally different microstructures, two parameter sets are combined to manufacture different segments within a single component. The results show that using state-of-the-art strategies with Gaussian beam profiles can result in strong <100> || BD textures, like reported in the state of the art. In comparison, it is possible to rotate the texture to <111> || BD when using ring-shaped beam profiles. Moreover, a correlation between the grain size and the spot size of the beam profile used is employed. When combining two parameter sets within one part, the height of the transition zone and the emerging microstructure in subsequently manufactured layers strongly depend on the microstructure of previously manufactured layers. If a fine-grained microstructure is initially formed, only a small transition zone (< 5 layers) is created. Resulting grains in subsequent layers tend to be smaller. The resulting grains in the subsequent manufactured layers are significantly larger, and a long transition zone (≈ 30 layers) is created if the microstructure of the previously manufactured layers is coarse. The results demonstrate that microstructure tailoring is possible using alternative beam profiles. However, for precise control, the microstructure of the underlying layers must be considered in the design. The systematic investigation of the transition zone between two distinct microstructures is a key novelty of this study. The newly revealed findings on the interaction between initially formed and subsequently developing microstructures can also be applied to further additive manufacturing and joining processes.

环形光束轮廓越来越多地应用于激光粉末床金属熔接（PBF-LB/M）。由于在加工过程中温度分布和进程的改变，环形束廓形具有调节凝固行为的潜力，因此可以影响微观组织的形成。该出版物首先展示了不同环形梁廓形的使用如何影响AISI 316L的建成微观结构。其次，它演示了如何使用它来定制局部微观结构。为了研究局部不同显微组织过渡区新出现的微观组织，将两个参数组合在一起，在单个部件内制造不同的段。结果表明，使用最先进的高斯光束轮廓策略可以产生强的<；100>； || BD纹理，就像目前最先进的报道一样。相比之下，当使用环形光束轮廓时，可以将纹理旋转到<；111>； || BD。此外，晶粒尺寸和光束轮廓光斑尺寸之间的相关性被采用。当将两个参数集组合在一个零件内时，过渡区高度和后续制备层中出现的微观结构强烈依赖于先前制备层的微观结构。如果最初形成细晶粒的微观结构，则只形成一个小的过渡区（<； 5层）。在随后的层中产生的颗粒往往更小。如果先前制造的层的微观结构粗糙，则在随后制造的层中产生的晶粒明显更大，并且产生长过渡区（≈30层）。结果表明，使用不同的光束轮廓可以实现微结构裁剪。然而，为了精确控制，在设计中必须考虑底层的微观结构。系统地研究两种不同微观结构之间的过渡区是本研究的一个关键新颖之处。关于初始形成和随后发展的微观结构之间相互作用的新发现也可以应用于进一步的增材制造和连接工艺。

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引用次数: 0

Using nonlinear lead filtering for real-time accurate extrusion control in large format additive manufacturing 采用非线性先导滤波技术实现大幅面增材制造的实时精确挤出控制

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105005

Jutang Gao, Pinyi Wu, Chinedum E. Okwudire, Wes McGee

Large format additive manufacturing (LFAM) systems can produce large-scale parts by melting and depositing granulated thermoplastic feedstock through an extrusion process. Yet, LFAM applications with extrusion variations or complex geometry are usually hindered by sluggish extrusion responses, which cause inaccurate bead widths and printing defects during material deposition. This study presents a feedforward control strategy that employs a model-based, time-varying lead filter to address such extrusion defects without requiring additional sensors or major hardware modifications. By continuously estimating the extrusion system’s time constant based on operating conditions, the proposed control method compensates for nonlinear first-order extrusion dynamics. Experiments on a robot-assisted LFAM setup demonstrate improvements in deposition accuracy across multiple scenarios, including consistent bead width with dynamic motion velocity, rapid bead width variation, and fast material transitions with dual-screw dual-material configuration. The method’s reliance on a generic extrusion model and feedforward controller implementation suggests potential applicability to other LFAM setups with different motion systems. As a result, the approach offers a practical route to enhanced deposition consistency and greater flexibility in LFAM processes.

大型增材制造（LFAM）系统可以通过挤压工艺熔化和沉积粒状热塑性原料来生产大型零件。然而，具有挤压变化或复杂几何形状的LFAM应用通常受到缓慢的挤压响应的阻碍，这会导致不准确的头宽度和材料沉积过程中的打印缺陷。本研究提出了一种前馈控制策略，该策略采用基于模型的时变先导滤波器来解决此类挤压缺陷，而无需额外的传感器或重大的硬件修改。该控制方法通过对挤出系统运行状态的时间常数进行连续估计，对一阶非线性挤出动力学进行补偿。在机器人辅助下的LFAM装置上进行的实验表明，在多种情况下，包括动态运动速度下的一致磁珠宽度、快速磁珠宽度变化以及双螺杆双材料配置下的快速材料过渡，沉积精度都得到了提高。该方法依赖于通用的挤压模型和前馈控制器实现，这表明该方法可能适用于其他具有不同运动系统的LFAM设置。因此，该方法为增强LFAM工艺的沉积一致性和更大的灵活性提供了一条实用的途径。

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引用次数: 0

A numerical framework for modeling the Xolography additive manufacturing method Xolography增材制造方法建模的数值框架

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105006

Roozbeh Salajeghe , Yves Garmshausen , Yousef Arzhangnia , Cyrille Boyer , Nathaniel Corrigan , Martin Herder , Berin Šeta , Jon Spangenberg

Despite significant advancements in the Xolography technique, a numerical framework to digitally define the process window and optimize parameters for different setups is still lacking. This study addresses this gap by introducing the first numerical model of Xolography, simultaneously solving UV and visible light intensities while computing reaction rates. A governing reaction set is proposed, and a finite difference–based algorithm is implemented to solve the equations. Experimental characterization, numerical modeling, and optimization are combined to determine the unknown parameters. The framework is then applied to study conversion-field variations inside and outside printed regions. Results show that, for a given laser scanning velocity, intensity values closer to the minimum threshold yield more uniform conversion within the part. However, low intensities increase the risk of under-curing along the print direction. To mitigate this, adjustments in the initial laser position and projector illumination time are suggested to improve dimensional fidelity. The study further demonstrates that both under- and over-curing can occur where the cross-section changes within a geometry. Practical adjustments are proposed to reduce these effects. Overall, the proposed numerical framework enables analysis and optimization of the Xolography process across different setups, offering guidelines to improve accuracy and print quality.

尽管Xolography技术取得了重大进步，但仍然缺乏数字框架来数字定义工艺窗口并优化不同设置的参数。本研究通过引入第一个Xolography数值模型，在计算反应速率的同时求解紫外线和可见光强度，解决了这一差距。提出了控制反应集，并实现了基于有限差分的方程求解算法。实验表征，数值模拟和优化相结合，以确定未知参数。然后将该框架应用于研究印刷区域内外的转换场变化。结果表明，对于给定的激光扫描速度，强度值越接近最小阈值，工件内部的转换越均匀。然而，低强度增加了沿印刷方向欠固化的风险。为了缓解这种情况，建议调整初始激光位置和投影仪照明时间以提高尺寸保真度。研究进一步表明，在一个几何形状的截面发生变化的地方，都可能发生过固化和过固化。为减少这些影响，提出了切实可行的调整措施。总体而言，所提出的数值框架可以对不同设置的Xolography过程进行分析和优化，为提高准确性和打印质量提供指导。

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引用次数: 0

In-process polymer laser ablation for carbon functional gradience in metal additive manufacturing 金属增材制造过程中聚合物激光烧蚀碳功能梯度

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105011

Arnoldas Sasnauskas , Jamie Bell , Kaka Cheng , Shaocong Qin , Apostolos Koutsiouks , Valeria Nicolosi , Paul A. Hooper , Shuo Yin , Minh-Son Pham , Rocco Lupoi

Metal Additive manufacturing using Powder Sheets (MAPS) is an emerging approach in addressing various challenges in powder based additive manufacturing. Recent studies noted drawbacks in the MAPS process such as intense plume generation, irregular applied melt pool energies and carbon contamination. Therefore, this study presents a new process where the polymer is ablated by a low energy laser scan before a high energy laser melt to mitigate the drawbacks of MAPS. Optimised parameters of this process can increase deposition efficiency up to 60 ± 7 % by mitigating spatter effects. In addition, majority of the carbon (in the form of the polymer binder) can be removed to greatly reduce the hardness of the material from 353 ± 5 HV1 to a softer 241 ± 7 HV1. On average there is a 51.5 ± 16.3 % reduction in carbon content in the alloy depending on the volumetric energy density and spot size utilised. Underlying mechanisms responsible for these changes were studied by conducting simulations of the applied spot temperature and high-speed imaging of the plume and spatter generation. The ablation offers an opportunity to manufacture a functionally gradient material (FGM) with a minimal bleed zone. Applications for this can be realized in high performance components that require varied mechanical properties such as hard on outer surfaces and ductile core.

使用粉末板材的金属增材制造（MAPS）是解决粉末增材制造中各种挑战的一种新兴方法。最近的研究指出了MAPS过程的缺点，如强烈的羽流产生，不规则的熔池能量和碳污染。因此，本研究提出了一种新的工艺，在高能激光熔化之前，用低能激光扫描烧蚀聚合物，以减轻MAPS的缺点。优化后的工艺参数可以通过减轻飞溅效应，将沉积效率提高到60% ± 7 %。此外，大部分碳（以聚合物粘结剂的形式）可以被去除，从而大大降低材料的硬度，从353 ± 5 HV1降至较软的241 ± 7 HV1。平均而言，合金中的碳含量降低51.5 ± 16.3 %，具体取决于所使用的体积能量密度和光斑尺寸。对这些变化的潜在机制进行了研究，通过模拟应用点温度和羽流和飞溅产生的高速成像。烧蚀提供了制造具有最小出血区的功能梯度材料（FGM）的机会。这种方法的应用可以在高性能部件中实现，这些部件需要不同的机械性能，如坚硬的外表面和延展性的芯。

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引用次数: 0

Resolving hydrophilic–hydrophobic resin mismatch for single-step volumetric additive manufacturing of cell-adhesive polyesters 解决单步体积增材制造细胞粘接聚酯的亲疏水树脂错配问题

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105009

Quinten Thijssen , Britt Dierck , Laurens Parmentier , Hyunseok Kwon , Silvia Rodriguez-Fernandez , Astrid Quaak , Kevin Van holsbeeck , Charlotte Martin , Steven Ballet , Heungsoo Shin , Diego Mantovani , Sandra Van Vlierberghe

Volumetric additive manufacturing (VAM) can fabricate complex geometries within tens of seconds, yet its resin palette is constrained by materials incompatibilities. In particular, embedding hydrophilic bioactive peptides into hydrophobic polyester resins remains elusive due to severe polarity mismatch and the need for specific co-solvents that complicate resin development for additive manufacturing. Here, we resolve this mismatch and demonstrate single-step VAM of cell-adhesive poly(ε-caprolactone) (PCL) networks. A dimethylformamide–formulated resin co-dissolves a cysteine-terminated RGD peptide and alkene-functionalized PCL; during printing, thiol–ene crosslinking with a tetrathiol covalently integrates the peptide throughout the part. Formulation parameters were tuned to balance peptide solubility, radical inhibition, viscosity, and optical attenuation while preserving rapid VAM printability, enabling porous architectures to be produced in tens of seconds at peptide loadings up to 0.3 wt%. Peptide incorporation and surface availability on VAM objects were confirmed by ninhydrin staining, static contact-angle measurements, and X-ray photoelectron spectroscopy. With adipose-derived stem cells and SaOS-2 cells, RGD-dependent adhesion, spreading, and polarization were observed, whereas scrambled RDG controls showed minimal adhesion, indicating sequence specificity. Results were independently reproduced across three laboratories. By converting a previously incompatible peptide–polyester system into a printable resin for VAM, this study expands the materials space for VAM and provides a general route to directly manufacture bioactive polyesters.

体积增材制造（VAM）可以在几十秒内制造复杂的几何形状，但其树脂调色板受到材料不兼容性的限制。特别是，由于严重的极性不匹配和对特定助溶剂的需求，将亲水性生物活性肽嵌入疏水性聚酯树脂中仍然难以实现，这使得增材制造的树脂开发复杂化。在这里，我们解决了这种不匹配，并演示了细胞粘附聚（ε-己内酯）（PCL）网络的单步VAM。二甲基甲酰胺配制的树脂共溶半胱氨酸端RGD肽和烯烃功能化PCL；在打印过程中，巯基烯交联与四硫醇共价整合整个部分的肽。调整配方参数以平衡肽溶解度，自由基抑制，粘度和光学衰减，同时保持快速VAM打印性，使多孔结构能够在肽负载高达0.3 wt%的情况下在数十秒内产生。通过茚三酮染色、静态接触角测量和x射线光电子能谱证实了肽在VAM物体上的掺入和表面可用性。在脂肪来源的干细胞和SaOS-2细胞中，观察到rgd依赖性的粘附、扩散和极化，而混乱的RDG对照显示最小的粘附，表明序列特异性。结果在三个实验室独立再现。通过将先前不相容的肽-聚酯体系转化为VAM的可打印树脂，本研究扩大了VAM的材料空间，并提供了直接制造生物活性聚酯的一般途径。

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引用次数: 0

A sand-fixing method inspired by additive manufacturing 一种受增材制造启发的固沙方法

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-09-05 DOI: 10.1016/j.addma.2025.105017

Minglong Wang , Long Xu , Xiaozhen Li, Hui Li, Chunguang Wang, Zhandong Huang, Xiaobing Cai

The human living environment is being substantially threatened by desertification deteriorated by wind-blown sand erosion. However, most current sand-fixing techniques suffer from issues such as low efficiency, high costs, and short lifespan. Here, inspired by selective laser sintering based 3D printing, we present a method for sand-fixing by sintering micro-sized checkerboard barriers (MCBs) onto the surface of a desert using the laser. The reduction in sand transport rate and particle velocity at various heights suggests that the MCBs play a significant role in blocking the wind-sand transport and stabilizing the sand. We identified two primary mechanisms through which MCBs enhance sand fixation: (1) MCBs substantially weaken the airflow velocity in the near-surface field and increase the thickness of the boundary layer, thus decreasing the effect of airflow traction on the sand granules. (2) MCBs stabilize the surface layer of sand granules, counteracting the traction effect of the airflow. Additionally, a stable force system is established among the granules by analyzing the force chain. The method described in this paper is expected to offer a promising solution for smart and effective wind-sand control.

风沙侵蚀导致的沙漠化严重威胁着人类的生存环境。然而，目前大多数固砂技术都存在效率低、成本高、寿命短等问题。在这里，受基于选择性激光烧结的3D打印的启发，我们提出了一种利用激光在沙漠表面烧结微尺寸棋盘屏障（mcb）的固沙方法。不同高度风沙输沙速率和沙粒速度的减小表明MCBs在阻挡风沙输沙和稳定风沙方面发挥了重要作用。研究发现，mcb增强固沙的主要机制有两个：(1)mcb显著减弱近地表气流速度，增加边界层厚度，从而降低气流对沙粒的牵引作用；(2) mcb稳定了沙粒的表层，抵消了气流的牵引作用。通过对力链的分析，建立了颗粒间稳定的力系统。本文所描述的方法有望为智能有效的风沙治理提供一种有前途的解决方案。

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引用次数: 0

Vector-level feedforward control of LPBF melt pool area using a physics-based thermal model 基于物理热模型的LPBF熔池面积矢量级前馈控制

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-08-25 DOI: 10.1016/j.addma.2025.104981

Nicholas Kirschbaum , Nathaniel Wood , Chang-Eun Kim , Thejaswi U. Tumkur , Chinedum Okwudire

Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and geometric inaccuracies, stemming in part from variations in the melt pool. This paper proposes a novel vector-level feedforward control framework for regulating melt pool area in LPBF. By decoupling part-scale thermal behavior from small-scale melt pool physics, the controller provides a scale-agnostic prediction of melt pool area and efficient optimization over it. This is done by operating on two coupled lightweight models: a finite-difference thermal model that efficiently captures vector-level temperature fields and a reduced-order, analytical melt pool model. Each model is calibrated separately with minimal single-track and 2D experiments, and the framework is validated on a complex 3D geometry in both Inconel 718 and 316L stainless steel. Results showed that feedforward vector-level laser power scheduling reduced geometric inaccuracy in key dimensions by 62%, overall porosity by 16.5%, and photodiode root-mean-squared deviation by 38.5% on average. Overall, this modular, data-efficient approach demonstrates that proactively compensating for known thermal effects can significantly improve part quality while remaining computationally efficient and readily extensible to other materials and machines.

激光粉末床熔融（LPBF）是一种增材制造技术，由于其能够生产几何复杂、全致密的金属零件而受到欢迎。然而，这些部件容易出现内部缺陷和几何不精确，部分原因是熔池的变化。本文提出了一种新的矢量级前馈控制框架，用于调节LPBF熔池面积。通过将部分尺度热行为与小尺度熔池物理解耦，该控制器提供了熔池面积的尺度不可知预测和有效优化。这是通过对两个耦合轻量级模型进行操作来实现的：一个是有效捕获矢量级温度场的有限差分热模型，另一个是降阶的分析熔池模型。每个模型都通过最小的单轨道和2D实验单独校准，框架在Inconel 718和316L不锈钢的复杂3D几何结构上进行验证。结果表明，前馈矢量级激光功率调度将关键尺寸几何误差降低62%，整体孔隙度降低16.5%，光电二极管均方根偏差平均降低38.5%。总体而言，这种模块化、数据高效的方法表明，主动补偿已知的热效应可以显著提高零件质量，同时保持计算效率，并易于扩展到其他材料和机器。

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引用次数: 0

Interplay mechanism between molten pool, spatter, vapor and melt defects in laser beam powder bed fusion via In-situ schlieren monitoring and deep learning methods 基于现场纹影监测和深度学习方法的激光粉末床熔合熔池、飞溅、蒸汽和熔体缺陷的相互作用机理

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-08-25 DOI: 10.1016/j.addma.2025.104997

Xin Lin , Haodong Chen , Yangkun Mao , Dawei Ni , Kunpeng Zhu

Melt track defects (e.g., internal porosity, surface defects) can significantly affect printing quality. However, the correlation between these defects and molten pool variations, as well as their underlying formation mechanisms, remains unclear. This study investigates sequential molten pool variations in Laser Beam Powder Bed Fusion (PBF-LB) process. A Feature Pyramid CBAM Network (FP-CBAM Network) machine learning approach and t-SNE method are proposed to identify correlation patterns between molten pool morphological changes and the morphology of melt tracks. The overall accuracy of the proposed network for classifying melt track defects is 97.33 %. Through schlieren imaging, spatter dynamics, vaporization phenomena, and molten pool are captured. Furthermore, the interplay coupling mechanism among molten pools, spatter, and vapor are analyzed, which mutually validates the feasibility of FP-CBAM Network. The quick transitions between molten pool (MP) lead mode and MP lag mode in molten pool motion induced abrupt, changes in the molten pool's overall moving velocity, which is associated with necking defects. The high-velocity aerial spatter deposition phenomenon is caused by spatters re-entering the laser beam, remelted and evaporated, which contributes to edge protrusion. The vapor jet angles near 90°, which simultaneously impacts both front and rear melt regions, generates spatters with dispersion areas significantly larger than the vapor coverage zone, resulting in increasing the probability of spatter deposition on melt track. This study provides a solution of enabling dynamic adjustment of processing parameters based on the melt surface defect prediction to improve melt quality.

熔体轨迹缺陷（如内部孔隙、表面缺陷）会显著影响印刷质量。然而，这些缺陷与熔池变化之间的相关性及其潜在的形成机制仍不清楚。本文研究了激光粉末床熔融（PBF-LB）过程中熔池的顺序变化。提出了一种特征金字塔型CBAM网络（FP-CBAM网络）机器学习方法和t-SNE方法来识别熔池形态变化与熔体轨迹形态之间的关联模式。所提出的熔体轨迹缺陷分类网络的总体准确率为97.33 %。通过纹影成像，溅射动力学，汽化现象，和熔池被捕获。分析了熔池、飞溅和蒸汽之间的相互耦合机制，相互验证了FP-CBAM网络的可行性。熔池运动在超前模式和滞后模式之间的快速转换导致熔池整体运动速度的突然变化，这与颈缩缺陷有关。高速空中溅射沉积现象是由于溅射物重新进入激光束，重新熔化和蒸发，导致边缘突出。当蒸汽喷射角度接近90°时，同时影响熔体前后区域，产生的飞溅物弥散面积明显大于蒸汽覆盖区域，导致飞溅物在熔体轨迹上沉积的概率增加。本研究提供了一种基于熔体表面缺陷预测的工艺参数动态调整的解决方案，以提高熔体质量。

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