Pub Date : 2025-12-05DOI: 10.1016/j.addlet.2025.100348
Filip Seidler, Jakub Slavíček, Daniel Koutný
This study investigates the impact of various deposition strategies on the microstructure of volumetric components fabricated from AZ61 magnesium alloy using Wire Arc Direct Energy Deposition (WADED), also referred to as Wire Arc Additive Manufacturing (WAAM). Because coarse grains can significantly reduce mechanical performance, thermal simulations were performed to identify low-cooling-rate regions associated with different deposition trajectories. Three deposition strategies were analysed: ZigZag, Spiral, and S-pattern. The simulated thermal profiles were validated by optical grain size analysis and hardness measurements. In the selected critical regions, where the largest grains are expected, the S-pattern achieved the narrowest range in grain size and hardness distribution. This trajectory also exhibited the finest microstructure in most critical region, with the smallest average grain size. Additionally, it maintained good geometrical accuracy, indicating that it offers a promising route for producing high-quality magnesium-alloy components via WADED.
{"title":"Influence of deposition strategy on the microstructure of volumetric WADED-fabricated AZ61 magnesium alloy components","authors":"Filip Seidler, Jakub Slavíček, Daniel Koutný","doi":"10.1016/j.addlet.2025.100348","DOIUrl":"10.1016/j.addlet.2025.100348","url":null,"abstract":"<div><div>This study investigates the impact of various deposition strategies on the microstructure of volumetric components fabricated from AZ61 magnesium alloy using Wire Arc Direct Energy Deposition (WADED), also referred to as Wire Arc Additive Manufacturing (WAAM). Because coarse grains can significantly reduce mechanical performance, thermal simulations were performed to identify low-cooling-rate regions associated with different deposition trajectories. Three deposition strategies were analysed: ZigZag, Spiral, and S-pattern. The simulated thermal profiles were validated by optical grain size analysis and hardness measurements. In the selected critical regions, where the largest grains are expected, the S-pattern achieved the narrowest range in grain size and hardness distribution. This trajectory also exhibited the finest microstructure in most critical region, with the smallest average grain size. Additionally, it maintained good geometrical accuracy, indicating that it offers a promising route for producing high-quality magnesium-alloy components via WADED.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"16 ","pages":"Article 100348"},"PeriodicalIF":4.7,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145712242","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-02DOI: 10.1016/j.addlet.2025.100343
Adam G. Stevens , Vanshika Singh , Rangasayee Kannan , David Hebble , Sarah Graham , Paritosh Mhatre , Kevin Zinn , Christopher Masuo , William Carter , Jesse Heineman , Andres Marquez Rossy , Alexandra B. Shanafield , Charles Savage , Alex Roschli , Brian Hicks , Peeyush Nandwana , S.S. Babu , Brian K. Post
Electroslag Additive Manufacturing (ESAM), a new high-throughput additive manufacturing (AM) method that combines Electroslag Strip Cladding (ESC) and wire arc AM (WAAM) is introduced. This combination enables the high deposition rate of ESC (more than 20 kg/h with a 60 mm strip electrode) to benefit from the precise geometric control of WAAM. As a precursor to ESAM, the ESC process is investigated in an AM context independently by evaluating both direct and staggered bead-stacking strategies and analyzing the microstructural and mechanical properties of each. This is followed by an ESAM demonstration producing an annular geometry by pairing ESC with gas tungsten arc welding (GTAW), wherein GTAW is utilized to construct annular walls that are subsequently infilled via ESC. The microstructure and mechanical properties of ESC-only AM are compared with that of the ESAM method and it is shown that printed integral retaining walls do not impact the resulting mechanical properties of ESAM. Furthermore, results indicate that ESAM-produced Alloy 625 parts exhibit tensile properties on par with cast counterparts, supporting the method’s scalability to components exceeding one metric ton, and possibly making ESAM a viable future manufacturing approach for competitive production of large-scale components currently manufactured by casting and forging.
{"title":"Electroslag additive manufacturing: A pathway for high throughput near net shape production","authors":"Adam G. Stevens , Vanshika Singh , Rangasayee Kannan , David Hebble , Sarah Graham , Paritosh Mhatre , Kevin Zinn , Christopher Masuo , William Carter , Jesse Heineman , Andres Marquez Rossy , Alexandra B. Shanafield , Charles Savage , Alex Roschli , Brian Hicks , Peeyush Nandwana , S.S. Babu , Brian K. Post","doi":"10.1016/j.addlet.2025.100343","DOIUrl":"10.1016/j.addlet.2025.100343","url":null,"abstract":"<div><div>Electroslag Additive Manufacturing (ESAM), a new high-throughput additive manufacturing (AM) method that combines Electroslag Strip Cladding (ESC) and wire arc AM (WAAM) is introduced. This combination enables the high deposition rate of ESC (more than 20 kg/h with a 60 mm strip electrode) to benefit from the precise geometric control of WAAM. As a precursor to ESAM, the ESC process is investigated in an AM context independently by evaluating both direct and staggered bead-stacking strategies and analyzing the microstructural and mechanical properties of each. This is followed by an ESAM demonstration producing an annular geometry by pairing ESC with gas tungsten arc welding (GTAW), wherein GTAW is utilized to construct annular walls that are subsequently infilled via ESC. The microstructure and mechanical properties of ESC-only AM are compared with that of the ESAM method and it is shown that printed integral retaining walls do not impact the resulting mechanical properties of ESAM. Furthermore, results indicate that ESAM-produced Alloy 625 parts exhibit tensile properties on par with cast counterparts, supporting the method’s scalability to components exceeding one metric ton, and possibly making ESAM a viable future manufacturing approach for competitive production of large-scale components currently manufactured by casting and forging.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100343"},"PeriodicalIF":4.7,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898130","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.addlet.2025.100341
Fanshuo Wang , Qiyang Tan , Ting Liu , Jeffery Venezuela , Zhiming Shi , Sarah Hurley , Anh Ly , Chun Xu , Deniz U. Erbulut , Jun Yin , Yue Zhao , Mingxing Zhang
{"title":"Corrigendum to “Reassessing the Biodegradation Behavior of Pure Iron and Iron-Manganese Alloys Fabricated by Laser Powder Bed Fusion” [ADDLET, 15 (2025) 100321]\"","authors":"Fanshuo Wang , Qiyang Tan , Ting Liu , Jeffery Venezuela , Zhiming Shi , Sarah Hurley , Anh Ly , Chun Xu , Deniz U. Erbulut , Jun Yin , Yue Zhao , Mingxing Zhang","doi":"10.1016/j.addlet.2025.100341","DOIUrl":"10.1016/j.addlet.2025.100341","url":null,"abstract":"","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100341"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145736572","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.addlet.2025.100345
C. Garrote-Junco , A. Ghavimi , R. Busch , M.T. Pérez-Prado , M. Rodríguez-Sánchez
This work aims to investigate the influence of specimen size and loading direction on the mechanical response of a laser-powder-bed-fused (LPBF) Fe-based metallic glass (Kuamet 6B2). Cuboidal specimens of sizes ranging from 4 to 8 mm were fabricated and then systematically characterized by a range of complementary techniques including optical microscopy, image analysis, differential scanning calorimetry and electron backscattered diffraction (EBSD). All builds exhibited three highly oriented defect families: elongated lack-of-fusion pores perpendicular to BD, oblique internal cracks and large surface cracks normal to BD. These defects, along with limited amorphous retention, dominate the bulk compliance and strength.
The mechanical behavior was assessed by room temperature uniaxial compression, both parallel and perpendicular to the build direction (BD), as well as by nanoindentation. A clear, direction-dependent size effect emerges. Under loading parallel to BD, strength and uniform strain diminish with increasing specimen size, consistent with defect closure and the correlation between density and mechanical response. In contrast, when loading is perpendicular to BD, strength and uniform strain increase with size, due to the reduction of normalized defect length scales relative to specimen width. The ensuing drop in stress-intensity at defect tips, suppressing crack propagation. Nanoindentation on defect-free regions revealed substantially higher local stiffness than bulk values, underscoring that the macroscopic response is defect-controlled rather than matrix-controlled.
{"title":"Multi-scale mechanical characterization of an additively manufactured Fe-based glass-forming alloy","authors":"C. Garrote-Junco , A. Ghavimi , R. Busch , M.T. Pérez-Prado , M. Rodríguez-Sánchez","doi":"10.1016/j.addlet.2025.100345","DOIUrl":"10.1016/j.addlet.2025.100345","url":null,"abstract":"<div><div>This work aims to investigate the influence of specimen size and loading direction on the mechanical response of a laser-powder-bed-fused (LPBF) Fe-based metallic glass (Kuamet 6B2). Cuboidal specimens of sizes ranging from 4 to 8 mm were fabricated and then systematically characterized by a range of complementary techniques including optical microscopy, image analysis, differential scanning calorimetry and electron backscattered diffraction (EBSD). All builds exhibited three highly oriented defect families: elongated lack-of-fusion pores perpendicular to BD, oblique internal cracks and large surface cracks normal to BD. These defects, along with limited amorphous retention, dominate the bulk compliance and strength.</div><div>The mechanical behavior was assessed by room temperature uniaxial compression, both parallel and perpendicular to the build direction (BD), as well as by nanoindentation. A clear, direction-dependent size effect emerges. Under loading parallel to BD, strength and uniform strain diminish with increasing specimen size, consistent with defect closure and the correlation between density and mechanical response. In contrast, when loading is perpendicular to BD, strength and uniform strain increase with size, due to the reduction of normalized defect length scales relative to specimen width. The ensuing drop in stress-intensity at defect tips, suppressing crack propagation. Nanoindentation on defect-free regions revealed substantially higher local stiffness than bulk values, underscoring that the macroscopic response is defect-controlled rather than matrix-controlled.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100345"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145736571","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.addlet.2025.100339
Sean Gip Lim , Junghyun Lee , Nuran Khalid A. Bawarith , Suvash Chandra Paul , Jihye Jhun , Issam T. Amr , Bandar A. Fadhel , Ming Jen Tan
Construction industry, responsible for a substantial portion of global carbon emissions, faces an urgent demand to adopt sustainable practices. Traditional concrete manufacturing processes contribute significantly to these emissions, underscoring a pressing need for innovative technologies that not only reduce carbon footprint but also improve material performances. This study presents an extension of CO2-steam integrated 3D construction printing by incorporating functional self-curing agents, specifically Polyethylene Glycol (PEG-6000), to enhance both early-age carbonation reactions and mechanical strength developments of 3D printed cementitious materials. The presented method aims to suppress moisture loss that delays hydration and carbonation activities during unconfined atmospheric curing, which would otherwise hinder strength developments. The combined usage of in-situ CO2-steam printing with PEG-6000 demonstrated improvements in early-age carbon uptake up to 137 %, along with substantial developments in compressive, flexural, and interlayer bond strengths of up to 29.4 %, 51.9 %, and 36.5 %, respectively.
{"title":"The efficacy of self-curing agents on enhanced internal curing and accelerated carbonation with CO2-steam integrated 3D concrete printing","authors":"Sean Gip Lim , Junghyun Lee , Nuran Khalid A. Bawarith , Suvash Chandra Paul , Jihye Jhun , Issam T. Amr , Bandar A. Fadhel , Ming Jen Tan","doi":"10.1016/j.addlet.2025.100339","DOIUrl":"10.1016/j.addlet.2025.100339","url":null,"abstract":"<div><div>Construction industry, responsible for a substantial portion of global carbon emissions, faces an urgent demand to adopt sustainable practices. Traditional concrete manufacturing processes contribute significantly to these emissions, underscoring a pressing need for innovative technologies that not only reduce carbon footprint but also improve material performances. This study presents an extension of CO<sub>2</sub>-steam integrated 3D construction printing by incorporating functional self-curing agents, specifically Polyethylene Glycol (PEG-6000), to enhance both early-age carbonation reactions and mechanical strength developments of 3D printed cementitious materials. The presented method aims to suppress moisture loss that delays hydration and carbonation activities during unconfined atmospheric curing, which would otherwise hinder strength developments. The combined usage of in-situ CO<sub>2</sub>-steam printing with PEG-6000 demonstrated improvements in early-age carbon uptake up to 137 %, along with substantial developments in compressive, flexural, and interlayer bond strengths of up to 29.4 %, 51.9 %, and 36.5 %, respectively.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100339"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623555","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.addlet.2025.100346
Derui Jiang , Darren Fraser , Sherman Wong , Timothy C. Hughes , Robert Wilson , Anthony B. Murphy , Vu Nguyen
Lattice structures made by additive manufacturing (AM) are being widely studied in the field of biomedical applications. Their strength and dimensional accuracy are critical to their performance. This study explores how different strut shapes affect the as-built quality and mechanical performance of Grade 23 titanium (Ti64) simple cubic lattices made by electron beam melting (EBM). Three strut cross-section geometries, square, octagonal, and round, were evaluated. Micro-computed tomography (CT) was used to assess dimensional deviations. Finite-element stress analysis predicted the mechanical response. Compression tests were conducted in two orientations to validate the models. Square struts showed the highest geometric accuracy and the best compressive strength, followed by the octagonal and round struts. These geometric deviations translated into mechanical trends: the square-strut lattices showed ∼10 – 20 % higher stiffness and yielding load compared with the round-strut equivalents, with the octagonal struts performing intermediately. These results suggest that square struts are better suited for load-bearing implants. The findings provide guidance for designing more reliable and effective lattice-based medical devices.
{"title":"Influence of Strut Shape on the As-Built Quality and Mechanical Performance of Additively Manufactured Simple Cubic Lattices","authors":"Derui Jiang , Darren Fraser , Sherman Wong , Timothy C. Hughes , Robert Wilson , Anthony B. Murphy , Vu Nguyen","doi":"10.1016/j.addlet.2025.100346","DOIUrl":"10.1016/j.addlet.2025.100346","url":null,"abstract":"<div><div>Lattice structures made by additive manufacturing (AM) are being widely studied in the field of biomedical applications. Their strength and dimensional accuracy are critical to their performance. This study explores how different strut shapes affect the as-built quality and mechanical performance of Grade 23 titanium (Ti64) simple cubic lattices made by electron beam melting (EBM). Three strut cross-section geometries, square, octagonal, and round, were evaluated. Micro-computed tomography (CT) was used to assess dimensional deviations. Finite-element stress analysis predicted the mechanical response. Compression tests were conducted in two orientations to validate the models. Square struts showed the highest geometric accuracy and the best compressive strength, followed by the octagonal and round struts. These geometric deviations translated into mechanical trends: the square-strut lattices showed ∼10 – 20 % higher stiffness and yielding load compared with the round-strut equivalents, with the octagonal struts performing intermediately. These results suggest that square struts are better suited for load-bearing implants. The findings provide guidance for designing more reliable and effective lattice-based medical devices.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100346"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693143","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.addlet.2025.100342
John P. Reidy , Catherine Ott , Alexandra J. Barbosa , Fernando Reyes Tirado , Gianna M. Valentino , Ian McCue
Nb-base alloys offer excellent high-temperature properties, but many legacy compositions were sidelined due to poor machinability. Additive manufacturing (AM) provides a pathway to bypass these limitations while simultaneously producing heterogeneous microstructures that can enhance performance. In this work, the legacy alloy Cb752 was gas-atomized to produce spherical powder feedstock for laser powder bed fusion, and a modified powder variant was prepared by tumbling HfC nanoparticles with the base powder. Tensile specimens were fabricated from both powders under optimized laser parameters, alongside arc-melted Cb752 for comparison. Compared to arc-melted Cb752, AM specimens exhibited consistently higher strength across 800–1600°C due to stable subgrain dislocation networks that delay recrystallization and enhance strain hardening. The HfC additions further stabilized these networks, improving post-yield performance at intermediate temperatures, though their contribution diminished after particle coarsening at 1600°C. These findings demonstrate that custom atomization and feedstock modification can unlock new performance in Nb-base alloys and provide a generalizable strategy for advancing refractory alloy systems through tailored AM processing.
{"title":"High-temperature deformation behavior of additively manufactured niobium alloys from in-house gas-atomized feedstock","authors":"John P. Reidy , Catherine Ott , Alexandra J. Barbosa , Fernando Reyes Tirado , Gianna M. Valentino , Ian McCue","doi":"10.1016/j.addlet.2025.100342","DOIUrl":"10.1016/j.addlet.2025.100342","url":null,"abstract":"<div><div>Nb-base alloys offer excellent high-temperature properties, but many legacy compositions were sidelined due to poor machinability. Additive manufacturing (AM) provides a pathway to bypass these limitations while simultaneously producing heterogeneous microstructures that can enhance performance. In this work, the legacy alloy Cb752 was gas-atomized to produce spherical powder feedstock for laser powder bed fusion, and a modified powder variant was prepared by tumbling HfC nanoparticles with the base powder. Tensile specimens were fabricated from both powders under optimized laser parameters, alongside arc-melted Cb752 for comparison. Compared to arc-melted Cb752, AM specimens exhibited consistently higher strength across 800–1600°C due to stable subgrain dislocation networks that delay recrystallization and enhance strain hardening. The HfC additions further stabilized these networks, improving post-yield performance at intermediate temperatures, though their contribution diminished after particle coarsening at 1600°C. These findings demonstrate that custom atomization and feedstock modification can unlock new performance in Nb-base alloys and provide a generalizable strategy for advancing refractory alloy systems through tailored AM processing.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100342"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623561","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01DOI: 10.1016/j.addlet.2025.100347
Berk Baris Celik , Amir Hossein Mirzaei , Nima Razavi , Brecht Van Hooreweder
Metallic lattice structures are increasingly employed in advanced engineering applications where a high strength-to-weight ratio and enhanced dynamic response are required. Recent studies on functionally graded lattice structures show that these structures stand out for their tuneable properties. This study presents novel insights into the mechanical and dynamic properties of modal simulation-driven, density-gradient strut-based lattices fabricated from aluminum A205 powder using laser powder bed fusion (LPBF). Cubic bounding volume diamond unit cell lattice specimens with identical mass and four distinct gradient profiles were designed. One specimen without a density gradient and three with mode shape-informed density gradients were included in the study. A new printing parameter set was developed to enable density gradient samples to be printed at high material densities and in a robust manner. Modal and static finite element simulations were conducted to validate the dynamic property optimization of density gradient structures. Impulse excitation technique (IET) tests showed that the field-optimized design (FO) has an increase of 23.7% and 16.1% in natural frequency in two different modes, and an increase of 130% and 45% in damping capacity in the same modes, compared to the uniform density sample (NG). Compression tests showed that FO was slightly less stiff but had better maximum compressive stress values than NG. FO also outperformed the other three designs in terms of energy absorption. Despite being optimized for natural frequency and damping capacity, FO demonstrated acceptable fatigue performance with hysteresis analyses indicating greater energy dissipation per cycle than the uniform lattice design. The insights and results from this work therefore opens new opportunities for creating lightweight yet high-performance and multifunctional metal lattice structures.
{"title":"Mode shape-informed design of lightweight metal lattice structures produced by laser powder bed fusion for enhanced dynamic properties","authors":"Berk Baris Celik , Amir Hossein Mirzaei , Nima Razavi , Brecht Van Hooreweder","doi":"10.1016/j.addlet.2025.100347","DOIUrl":"10.1016/j.addlet.2025.100347","url":null,"abstract":"<div><div>Metallic lattice structures are increasingly employed in advanced engineering applications where a high strength-to-weight ratio and enhanced dynamic response are required. Recent studies on functionally graded lattice structures show that these structures stand out for their tuneable properties. This study presents novel insights into the mechanical and dynamic properties of modal simulation-driven, density-gradient strut-based lattices fabricated from aluminum A205 powder using laser powder bed fusion (LPBF). Cubic bounding volume diamond unit cell lattice specimens with identical mass and four distinct gradient profiles were designed. One specimen without a density gradient and three with mode shape-informed density gradients were included in the study. A new printing parameter set was developed to enable density gradient samples to be printed at high material densities and in a robust manner. Modal and static finite element simulations were conducted to validate the dynamic property optimization of density gradient structures. Impulse excitation technique (IET) tests showed that the field-optimized design (FO) has an increase of 23.7% and 16.1% in natural frequency in two different modes, and an increase of 130% and 45% in damping capacity in the same modes, compared to the uniform density sample (NG). Compression tests showed that FO was slightly less stiff but had better maximum compressive stress values than NG. FO also outperformed the other three designs in terms of energy absorption. Despite being optimized for natural frequency and damping capacity, FO demonstrated acceptable fatigue performance with hysteresis analyses indicating greater energy dissipation per cycle than the uniform lattice design. The insights and results from this work therefore opens new opportunities for creating lightweight yet high-performance and multifunctional metal lattice structures.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100347"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693142","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-25DOI: 10.1016/j.addlet.2025.100344
Henry D. Davis , James G. Harkness , David K. Hayes , Brian D. Jensen , Richard Vanfleet , Nathan B. Crane , Robert C. Davis
Interfacing is a consistent weak point in the manufacturing of microscale gas chromatography columns. Current techniques for interfacing with microfluidic systems often degrade under high temperatures and thermal cycling and suffer from dead volumes. To address these challenges, we fabricated all-metal interfaces that connect 3D-printed microchannels (500 µm diameter) to industry-standard stainless-steel (SS) capillaries. Our fabrication process uses SS binder-jet printing and bronze infiltration to fuse the capillary to the printed part and reduce dead volumes at the interface while utilizing pressure control to prevent the infiltrant from filling the channel or capillary. These interfaces withstood pressures greater than 100 PSI and showed no leakage after thermal cycling to 350 °C. Cross-sections of the interfaces show smooth connections between the channel and capillary with minimal dead volume.
{"title":"Binder-jet printing and pressure-controlled infiltration for fabrication of high-temperature, low-dead-volume microfluidic interfaces","authors":"Henry D. Davis , James G. Harkness , David K. Hayes , Brian D. Jensen , Richard Vanfleet , Nathan B. Crane , Robert C. Davis","doi":"10.1016/j.addlet.2025.100344","DOIUrl":"10.1016/j.addlet.2025.100344","url":null,"abstract":"<div><div>Interfacing is a consistent weak point in the manufacturing of microscale gas chromatography columns. Current techniques for interfacing with microfluidic systems often degrade under high temperatures and thermal cycling and suffer from dead volumes. To address these challenges, we fabricated all-metal interfaces that connect 3D-printed microchannels (500 µm diameter) to industry-standard stainless-steel (SS) capillaries. Our fabrication process uses SS binder-jet printing and bronze infiltration to fuse the capillary to the printed part and reduce dead volumes at the interface while utilizing pressure control to prevent the infiltrant from filling the channel or capillary. These interfaces withstood pressures greater than 100 PSI and showed no leakage after thermal cycling to 350 °C. Cross-sections of the interfaces show smooth connections between the channel and capillary with minimal dead volume.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"16 ","pages":"Article 100344"},"PeriodicalIF":4.7,"publicationDate":"2025-11-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145712243","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Modeling the track cross-sectional profile (CSP) in deposition processes is critical for assessing and controlling deposition quality. This article focuses on modeling time-invariant deposition (TID) processes, where deposited material does not move after impact with the evolving surface, and deposition efficiency remains constant. For a TID process, the CSP can be computed from the mass flux distribution using the Abel integral transform. The model is validated for cold spray (CS) and aerosol jet printing. Using the TID assumption enables the modeling of CS and AJP tracks from dot deposition data with height and width errors down to 11 and 22% for CS, and 7 and 21% for AJP. The error of this model when considering short and curved tracks is discussed, as well as the effects of nozzle standoff distance and tilt. Fast methods for arbitrary CSP computations and a fast CS method considering varying deposition efficiency are also discussed.
{"title":"Track cross-sectional profile model for time-invariant deposition processes — Applied to cold spray and aerosol jet printing","authors":"Alexander Martinez-Marchese , Alex-George Miclaus , Bahareh Marzbanrad , Ehsan Marzbanrad , Chen Qian , Max Wörner , Hamid Jahed , Ehsan Toyserkani , Chinedum Okwudire","doi":"10.1016/j.addlet.2025.100338","DOIUrl":"10.1016/j.addlet.2025.100338","url":null,"abstract":"<div><div>Modeling the track cross-sectional profile (CSP) in deposition processes is critical for assessing and controlling deposition quality. This article focuses on modeling time-invariant deposition (TID) processes, where deposited material does not move after impact with the evolving surface, and deposition efficiency remains constant. For a TID process, the CSP can be computed from the mass flux distribution using the Abel integral transform. The model is validated for cold spray (CS) and aerosol jet printing. Using the TID assumption enables the modeling of CS and AJP tracks from dot deposition data with height and width errors down to 11 and 22% for CS, and 7 and 21% for AJP. The error of this model when considering short and curved tracks is discussed, as well as the effects of nozzle standoff distance and tilt. Fast methods for arbitrary CSP computations and a fast CS method considering varying deposition efficiency are also discussed.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100338"},"PeriodicalIF":4.7,"publicationDate":"2025-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145528329","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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