Additive manufacturing letters最新文献_第3页

Bimetallic 17-4 PH/316 L stainless steel: Interfacial diffusion and mechanical response in multi-material MEX 双金属17-4 PH/ 316l不锈钢：多材料MEX中的界面扩散和力学响应

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-13 DOI: 10.1016/j.addlet.2025.100332

Héctor García de la Torre, Giovanni Gómez-Gras, Marco A. Pérez

Multi-material additive manufacturing enables the integration of distinct alloys with contrasting mechanical and microstructural properties, such as stainless steels 17–4 PH and AISI 316 L that are widely used in aerospace and tooling, within a single build; however, their combined performance in hybrid configurations remains underexplored. Here, we address key challenges related to densification, interfacial behavior and mechanical property control of metallic multi-material additive manufacturing structures. Near-full densification (98–99 %) was achieved with strong interfacial bonding and minimal deformation. Microstructural analysis revealed solid-state diffusion of Ni and Mo from 316 L into 17–4 PH, resulting in a chemically and structurally graded interface that affects local phase composition and fracture mechanics. Mechanical testing under tensile and flexural loading demonstrated that configurations with 17–4 PH as face material and 316 L as the core provided higher stiffness and strength while maintaining ductility, with flexural property metrics more than double to those of monolithic 316 L cores. Fractographic analysis confirmed that fractures initiated within the more brittle 17–4 PH material and often thereafter propagated along the interface, identifying it as a mechanically weaker zone serving as a crack pathway. These results highlight the potential hybrid stainless steel structures to achieve combined mechanical responses suitable for advanced engineering applications in a single manufacturing step, enabling the design of cost-efficient, multifunctional components for structural applications requiring hybrid mechanical behavior.

多材料增材制造能够在一次构建中集成具有不同机械和微观结构性能的不同合金，例如广泛用于航空航天和模具的17-4 PH不锈钢和AISI 316 L不锈钢；然而，它们在混合配置中的综合性能仍未得到充分研究。在这里，我们解决了与金属多材料增材制造结构的致密化、界面行为和力学性能控制相关的关键挑战。接近完全致密化（98 - 99%），界面结合强，变形最小。显微组织分析表明，Ni和Mo从316 L向17-4 PH的固相扩散，形成了一个化学和结构梯度界面，影响了局部相组成和断裂力学。拉伸和弯曲载荷下的力学测试表明，采用17-4 PH作为表面材料，316l作为芯材的配置在保持延展性的同时提供了更高的刚度和强度，其弯曲性能指标是单片316l芯材的两倍以上。断口学分析证实，裂缝起源于更脆的17-4 PH材料，随后经常沿着界面扩展，将其确定为机械较弱的区域，作为裂缝路径。这些结果突出了混合不锈钢结构的潜力，可以在单个制造步骤中实现适合高级工程应用的组合机械响应，从而为需要混合机械行为的结构应用设计成本效益高的多功能组件。

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引用次数: 0

Suppression of the leading-edge bulge effect in ceramic vat photopolymerization via yield stress regulation for enhanced part performance 通过屈服应力调节抑制陶瓷还原釜光聚合中前缘凸起效应以提高零件性能

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-13 DOI: 10.1016/j.addlet.2025.100333

Ning Wang , Chi Zhang , Hai Chang , Dongxu Yao , Zirong Zhai , Rui Yang

This study addresses the "leading-edge bulge effect" encountered during the ceramic slurry recoating stage in ceramic vat photopolymerization by regulating the slurry’s yield stress to suppress backflow. A three-dimensional network structure was constructed using Carbomer 940 as a thickening agent, thereby enhancing the slurry’s yield stress. A combined approach of numerical simulation and experimental validation was employed to evaluate the impact of yield stress modulation on liquid level control and part performance. When the thickener concentration reached ≥2 %, backflow was effectively suppressed, resulting in stable slurry leveling and intact surface quality of printed parts. Under these conditions, the average flexural strength reached a peak value of 928.59 MPa, comparable to that of conventionally sintered silicon nitride. However, excessive thickener content further restricted backflow but led to insufficient slurry coverage, adversely affecting the fabrication of complex geometries. These findings demonstrate that yield stress optimization is critical for achieving a balance between print quality and mechanical performance, offering theoretical guidance for process refinement in ceramic vat photopolymerization.

本研究通过调节陶瓷浆体的屈服应力来抑制回流，解决了陶瓷浆体光聚合中陶瓷浆体重涂阶段遇到的“前缘凸起效应”。以卡波姆940为增稠剂，构建了三维网络结构，从而提高了浆料的屈服应力。采用数值模拟和实验验证相结合的方法，评估了屈服应力调制对液位控制和零件性能的影响。当增稠剂浓度达到≥2%时，回流得到有效抑制，浆液流平稳定，打印件表面质量完好。在此条件下，平均抗弯强度达到峰值928.59 MPa，与常规烧结氮化硅相当。然而，过量的增稠剂含量进一步限制了回流，但导致浆体覆盖不足，对复杂几何形状的制造产生不利影响。这些发现表明，屈服应力优化对于实现打印质量和机械性能之间的平衡至关重要，为陶瓷大桶光聚合的工艺改进提供了理论指导。

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引用次数: 0

Effect of interface orientation in laser powder bed fusion of IN718/GRCop-42 bimetallic parts for Aerospace 航空航天用IN718/GRCop-42双金属件激光粉末床熔接界面取向的影响

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-12 DOI: 10.1016/j.addlet.2025.100331

Alasdair Bulloch , Amanda Cruchley , Allin Groom , Andy Harris , Fiona Schulz , Christopher J. Tuck , Richard Hague , Marco Simonelli

Additive manufacturing of bimetallic parts has gathered significant interest in recent years. Of particular relevance is the combination of Ni-based superalloys and Cu-based alloys suitable for high temperature applications, such as those found in aerospace rocket engines. To provide confidence in the production of such bimetallic parts, a detailed understanding of the process-structure relationship is required. This study investigates the effect of deposition sequence and recoating direction on the interfacial microstructure evolution in samples where material is graded through horizontal, vertical and angled interfaces. The samples in this study are produced through laser powder bed fusion of IN718 and GRCop-42, using a Schaeffler Aerosint selective powder deposition recoater. Analysis was conducted through a combination of backscatter electron imaging, x-ray diffraction, energy dispersive spectroscopy, and electron backscatter diffraction. For a horizontal interface, the deposition sequence has a significant effect on the presence of defects and phase formation at the interface. The recoating direction is shown to have an influence on the mixing behaviour for vertical and angled interfaces, with a gradual transition of the alloys produced when the interface is aligned parallel to the recoating direction. In contrast either a significant crossing of the first-deposited material across the interface occurs, or a sudden change in composition develops when deposition is perpendicular to the interface. On the basis of these findings, design rules can be developed to ensure the fabrication of suitably designed bimetallic parts for high temperature applications such as rocket engines in the aerospace sector.

近年来，双金属零件的增材制造引起了人们的极大兴趣。特别相关的是适用于高温应用的镍基高温合金和铜基合金的组合，例如在航空航天火箭发动机中发现的合金。为了对这种双金属部件的生产提供信心，需要对工艺结构关系有详细的了解。本研究考察了沉积顺序和重涂方向对水平、垂直和倾斜界面梯度试样中界面微观结构演变的影响。本研究的样品是使用舍弗勒Aerosint选择性粉末沉积重涂器，通过激光粉末床熔融IN718和GRCop-42制备的。通过背散射电子成像、x射线衍射、能量色散光谱和电子背散射衍射相结合的方法进行分析。对于水平界面，沉积顺序对界面缺陷的存在和相的形成有显著影响。重涂方向对垂直界面和倾斜界面的混合行为有影响，当界面平行于重涂方向时，合金的过渡逐渐发生。相反，要么是第一次沉积的材料在界面上发生明显的交叉，要么是当沉积垂直于界面时，成分突然发生变化。在这些发现的基础上，可以制定设计规则，以确保制造适合设计的双金属部件，用于高温应用，如航空航天领域的火箭发动机。

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引用次数: 0

Physics-informed machine learning surrogate for scalable simulation of thermal histories during wire-arc directed energy deposition 在电弧定向能沉积过程中，为可扩展的热历史模拟提供物理信息的机器学习替代品

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-08 DOI: 10.1016/j.addlet.2025.100327

Michael Ryan, Mohammad Hassan Baqershahi, Hessamoddin Moshayedi, Elyas Ghafoori

Wire-arc directed energy deposition (DED) has emerged as a promising additive manufacturing (AM) technology for large-scale applications. However, the complex thermal dynamics inherent to the process present challenges in ensuring structural integrity and mechanical properties of fabricated components. Finite element method (FEM) simulations have been conventionally employed to predict thermal history during deposition. However, their high computational demand increase significantly with scale. Given the necessity of multiple repetitive simulations for heat management and the determination of optimal printing strategy, FEM simulation quickly becomes unfit. Instead, advancements have been made in using trained neural networks as surrogate models for rapid prediction. However, traditional data-driven approaches necessitate large amounts of relevant and verifiable external data, either from simulation, experimental, or analytical solutions, during the training and validation of the neural network. Regarding large-scale wire-arc DED, none of these data sources are readily available in quantities sufficient for an accurate surrogate. The introduction of physics-informed neural networks (PINNs) has opened up an alternative simulation strategy by leveraging the existing physical knowledge of the phenomena with advanced machine learning methods. However, the practical application of PINNs for real-world large-scale wire-arc DED has been rarely explored, particularly within the context of structural engineering. This study investigates one of the necessary steps for up-scaling PINN with a focus on advanced and effective sampling of collocation points — a critical factor controlling both the training time and the performance of the model. The results affirm the potential of PINNs to outperform FEM in terms of wall-clock times, while maintaining the desired accuracy and offering resolution-agnostic evaluation. Further discussion provides an outlook on the future steps for improving the PINNs for wire-arc DED simulations.

线弧定向能沉积（DED）已成为一种有前景的大规模增材制造（AM）技术。然而，复杂的热动力学固有的过程提出了挑战，以确保结构完整性和机械性能的制造组件。传统上采用有限元法（FEM）模拟来预测沉积过程中的热历史。然而，它们的高计算需求随着规模的增加而显著增加。考虑到热管理和最佳打印策略的确定需要多次重复模拟，有限元模拟很快变得不适合。相反，在使用训练有素的神经网络作为快速预测的替代模型方面取得了进展。然而，在神经网络的训练和验证过程中，传统的数据驱动方法需要大量相关且可验证的外部数据，无论是来自仿真、实验还是分析解决方案。对于大规模的线弧DED，这些数据来源都不容易获得足够数量的准确替代。物理信息神经网络（pinn）的引入，通过利用现有的物理知识和先进的机器学习方法，开辟了一种替代的模拟策略。然而，pin在现实世界大规模线弧DED中的实际应用很少被探索，特别是在结构工程的背景下。本研究探讨了扩展PINN的必要步骤之一，重点是高级和有效的搭配点采样-这是控制训练时间和模型性能的关键因素。结果证实了pinn在壁钟时间方面优于FEM的潜力，同时保持所需的精度并提供与分辨率无关的评估。进一步的讨论展望了改进线弧DED模拟pin的未来步骤。

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引用次数: 0

Additive friction stir deposition of multi-layer aluminum-silicon carbide metal matrix composites 添加剂搅拌摩擦沉积多层铝-碳化硅金属基复合材料

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-04 DOI: 10.1016/j.addlet.2025.100330

Robert C. Pack , John W. Bohling , Joshua Kincaid , Abrian Abir , Tony Schmitz , Brett G. Compton

Aluminum metal matrix composites (MMCs) possess good strength and stiffness combined with low density, making them attractive in a variety of applications. Additive friction stir deposition (AFSD) is a relatively new, solid state metal additive manufacturing process that has high potential as a forming route for MMCs of complex shape. However, little work has been done to investigate how AFSD affects microstructure and properties of conventional MMCs. In this work, aluminum-silicon carbide (Al-SiC) MMC extruded plate was used as feedstock for AFSD to create a five-layer deposit of an Al-SiC MMC for characterization. Microstructure, particle size distribution, and hardness were evaluated in the as-deposited condition while hardness recovery was investigated with post-deposition solution and aging heat treatments. The deposited MMC revealed complex, macroscale mixing behavior, mild fragmentation of the SiC particles, and uniform particle size distribution and dispersion across MMC regions of the deposit. Solution and aging heat treatment restored the hardness of the deposited MMC to that of the as-received feedstock. This work suggests AFSD is a promising route for producing complex MMC parts with similar or better properties to those produced by traditional processes.

金属铝基复合材料（MMCs）具有良好的强度和刚度，且密度低，具有广泛的应用前景。添加剂搅拌摩擦沉积（AFSD）是一种相对较新的固态金属增材制造工艺，作为一种复杂形状的金属复合材料的成形途径具有很高的潜力。然而，很少有人研究AFSD如何影响传统mmc的微观结构和性能。在这项工作中，铝-碳化硅（Al-SiC） MMC挤压板被用作AFSD的原料，以创建一个五层沉积的Al-SiC MMC进行表征。研究了沉积状态下的显微组织、粒度分布和硬度，并研究了沉积后固溶和时效热处理的硬度恢复情况。沉积的MMC表现出复杂的宏观混合行为，SiC颗粒轻度破碎，粒度分布均匀，在MMC区域内分散。固溶和时效热处理使沉积的MMC的硬度恢复到原料的硬度。这项工作表明，AFSD是一种有前途的路线，用于生产复杂的MMC部件，具有与传统工艺生产的部件相似或更好的性能。

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引用次数: 0

In situ recrystallization of pure Cu during electron beam powder bed fusion 纯铜在电子束粉末床熔合过程中的原位再结晶

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-04 DOI: 10.1016/j.addlet.2025.100329

Alexandre Margueret , Pierre Lhuissier , Guilhem Martin

Additively manufactured parts often exhibit an anisotropic microstructure characterized by columnar grains resulting from epitaxial growth from the underlying layers in the direction of the thermal gradient, i.e. parallel to the build direction. Herein we report that the columnar grains of pure Cu produced by electron beam powder bed fusion can be transformed into equiaxed grains by reducing the hatch spacing and increasing the scanning speed. Columnar grains are observed for hatch spacings ≥ 100 µm and a scanning speed = 100 mm/s, whereas equiaxed grains are observed when the hatch spacing is ≤ 60 µm and the scanning speed ≥ 150 mm/s. The underlying mechanism is discussed and identified on the basis of EBSD analyses. It is concluded that in situ recrystallization during electron beam powder bed fusion can be locally activated by varying the processing parameters. Further insight into the underlying mechanism is gained from the characterization of layered samples produced with varying processing parameters along the build direction. We show that in situ recrystallization offers an interesting pathway to produce site-specific microstructures in electron beam powder bed fusion.

增材制造的零件通常表现出各向异性的微观结构，其特征是柱状晶粒是由下层在热梯度方向（即平行于构建方向）的外延生长引起的。本文报道了通过减小舱口间距和提高扫描速度，电子束粉末床熔合产生的纯Cu柱状晶粒可以转变为等轴晶粒。当舱口间距≥100µm，扫描速度= 100 mm/s时，观察到柱状晶粒；当舱口间距≤60µm，扫描速度≥150 mm/s时，观察到等轴晶粒。在EBSD分析的基础上，讨论并确定了其潜在机制。结果表明，改变工艺参数可以局部激活电子束粉末床熔合过程中的原位再结晶。从沿着构建方向的不同处理参数产生的分层样品的表征中获得了对潜在机制的进一步了解。我们发现原位再结晶为电子束粉末床熔合中产生特定位置的微结构提供了一个有趣的途径。

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引用次数: 0

Investigation and potentials of a novel resin-based additive manufacturing process 一种新型树脂基增材制造工艺的研究与潜力

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-10-04 DOI: 10.1016/j.addlet.2025.100328

Leo Körber , Thomas Wettemann , Margarita Etchegaray Bello , Isabell Petri , Gabriel Rojas , Daniela Schreil , Klaus Drechsler , Satoshi Enzaki , Yuichiro Tsuda , Jun Inagaki

Polymer Additive Manufacturing (AM) processes are a means of producing complex parts in small numbers. Short fibers are frequently added to enhance the parts’ mechanical properties. Alignment along the extrusion path during printing results in highly anisotropic material behavior. In this study, a novel resin-based AM process (“Core-Shell Method”, developed by Toray Engineering) is investigated consisting of a vat photopolymerization printing of a non-reinforced mold (“shell”) that is subsequently filled with a short fiber filled thermally cured resin (“core”). Thermal and chemical analyses were performed and recommendations for process adjustments derived. Mechanical, microscopic and CT analyses were performed on samples produced using the Core-Shell Method and manual variants of the process as reference. The Core-Shell samples show an only slightly anisotropic material behavior. From these findings, potentials for the printing process are derived, including further modification of the fiber alignment towards either improving isotropy or selectively introducing load-path adjusted fiber orientation and reinforcement within a homogenous material mixture.

聚合物增材制造（AM）工艺是一种小批量生产复杂零件的方法。为了提高零件的机械性能，经常添加短纤维。在印刷过程中，沿着挤压路径的排列导致材料的高度各向异性。在这项研究中，研究了一种新的基于树脂的AM工艺（“核-壳法”，由东丽工程公司开发），包括一个非增强模具（“壳”）的大桶光聚合打印，随后填充短纤维填充热固化树脂（“芯”）。进行了热分析和化学分析，并提出了工艺调整的建议。机械、显微镜和CT分析对使用核-壳法和手工工艺变体作为参考的样品进行。核壳样品表现出轻微的各向异性材料行为。根据这些发现，印刷工艺的潜力得到了推导，包括进一步修改纤维排列，以改善各向同性或选择性地引入负载路径调整的纤维取向和增强均质材料混合物。

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引用次数: 0

Scanner position accuracy, repeatability, and process anomalies correlation in PBF-LB/M PBF-LB/M中扫描仪位置精度、可重复性和过程异常相关性

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-09-30 DOI: 10.1016/j.addlet.2025.100326

Jesus Rivas , Jorge Mireles , R.B. Wicker

This study investigates position accuracy, repeatability, and reproducibility of the scanning system in a metal laser powder bed fusion (PBF-LB/M) process using a novel data collection method. Deviations between Commanded and Actual scanning positions were quantified using Euclidean distance metrics across a series of builds and geometries. Results showed a build mean accuracy of 0.014 mm, increasing to 0.029 mm at the 95th percentile, with deviations reaching >0.100 mm at complex geometric paths and corners. Layers containing high scanning path deviations, showed up to 10 times more porosity than other areas, underscoring a strong correlation between scan accuracy and anomaly formation. Reproducibility testing across multiple build plate locations showed a 95th percentile deviation of 0.042 mm, with maximum deviations up to 0.080 mm. Scanning accuracy anomalies that can alter local energy density such as missing or additional hatch sections were found as a function of the build plate location, suggesting a root cause of part variability in addition to other process conditions such as gas flow. Despite high repeatability (0.004 mm mean deviation) of the scanning path, only ∼30 % of pores appeared in consistent locations, suggesting that scanner qualification alone is insufficient to explain pore final location. The study also highlighted the influence of geometry, speed, and scanning parameters in the scanning system accuracy. These findings provide new insights into how scanning system performance affects part quality and repeatability and provide a framework for incorporating scanning data metrics into future qualification protocols.

本研究使用一种新颖的数据收集方法研究了金属激光粉末床熔合（PBF-LB/M）过程中扫描系统的位置精度、可重复性和再现性。命令和实际扫描位置之间的偏差使用欧几里得距离度量在一系列构建和几何形状中进行量化。结果表明，构建平均精度为0.014 mm，在第95百分位时增加到0.029 mm，在复杂的几何路径和拐角处偏差达到0.100 mm。具有高扫描路径偏差的层的孔隙度是其他区域的10倍，这表明扫描精度与异常地层之间存在很强的相关性。多个构建板位置的重复性测试显示，第95个百分位数偏差为0.042 mm，最大偏差可达0.080 mm。扫描精度异常可能会改变局部能量密度，如缺失或额外的舱口部分，这是构建板位置的函数，这表明除了其他工艺条件（如气体流动）外，零件可变性的根本原因。尽管扫描路径的重复性很高（平均偏差为0.004 mm），但只有~ 30%的孔隙出现在一致的位置，这表明仅靠扫描仪的资格不足以解释孔隙的最终位置。研究还强调了几何形状、速度和扫描参数对扫描系统精度的影响。这些发现为扫描系统性能如何影响零件质量和可重复性提供了新的见解，并为将扫描数据指标纳入未来的鉴定协议提供了框架。

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引用次数: 0

High-fidelity thermomechanical simulation of laser powder bed fusion process: Impact of constitutive model choice 激光粉末床熔合过程的高保真热力学模拟：本构模型选择的影响

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-09-17 DOI: 10.1016/j.addlet.2025.100324

P. Markovic , P. Scheel , R. Wróbel , S. Van Petegem , C. Leinenbach , E. Mazza , E. Hosseini

Laser Powder Bed Fusion (LPBF) is a widely adopted metal additive manufacturing technology that enables the fabrication of intricate metal components, yet it faces challenges arising from intrinsic residual stress and distortion development. High-fidelity thermomechanical simulations offer essential insights for predicting and mitigating these effects. The reliability of such simulations depends on various factors, but critically on the material input data, primarily the constitutive model which should accurately represent the material’s deformation behaviour under the complex loading conditions expected during LPBF. The present study integrates an advanced elastic-viscoplastic constitutive model into the LPBF thermomechanical simulation, capable of capturing the cyclic response of LPBF Hastelloy X across a broad range of temperatures and strain rates, and accounting for both isotropic and kinematic hardening. Simulation outcomes are validated against in-situ temperature and distortion measurements obtained during an LPBF experiment for Hastelloy X. Acknowledging the extensive effort required to develop such an advanced constitutive model, this study also calibrates three alternative models of simpler formulation to assess the impact of model selection on simulation outcomes and computational cost. The four investigated models span from rate-dependent elastic-viscoplastic to rate-independent elastic-plastic formulations, each with different capabilities for representing the alloy’s cyclic hardening response. The results provide valuable insights into trade-offs between simulation accuracy, constitutive model development effort, and computational efficiency in LPBF thermomechanical simulations.

激光粉末床融合（LPBF）是一种广泛采用的金属增材制造技术，可以制造复杂的金属部件，但它面临着固有残余应力和变形发展带来的挑战。高保真的热力学模拟为预测和减轻这些影响提供了重要的见解。这种模拟的可靠性取决于各种因素，但主要取决于材料输入数据，主要是本构模型，它应该准确地表示材料在LPBF期间预期的复杂加载条件下的变形行为。本研究将先进的弹粘塑性本构模型集成到LPBF热力学模拟中，能够捕获LPBF哈氏合金X在广泛温度和应变速率范围内的循环响应，并考虑各向同性和运动硬化。模拟结果通过在Hastelloy x的LPBF实验中获得的现场温度和变形测量结果进行验证。考虑到开发这样一个先进的本构模型需要付出大量的努力，本研究还校准了三种更简单的替代模型，以评估模型选择对模拟结果和计算成本的影响。所研究的四种模型涵盖了从速率相关的弹粘塑性到速率无关的弹塑性公式，每种模型都具有不同的能力来表示合金的循环硬化响应。结果提供了有价值的见解之间的权衡模拟精度，本构模型的发展努力，和计算效率在LPBF热力学模拟。

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引用次数: 0

Additively manufactured self-expandable stents from Zr-based bulk metallic glasses via laser powder bed fusion 以zr基大块金属玻璃为材料，采用激光粉末床熔接技术增材制造自膨胀支架

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-09-13 DOI: 10.1016/j.addlet.2025.100325

Jan Wegner , Lars Bruckhaus , Daniel Leonardo Schwöppe , Hanna Schönrath , Stefan Kleszczynski

Self-expandable stents are among the most implanted biomedical devices. We investigate the feasibility of additive manufacturing via laser powder bed fusion to fabricate Zr-based bulk metallic glasses into self-expandable stents to enable automated and customizable stent fabrication while implementing a novel class of materials with superior resilience compared to established alloys such as Nitinol. Three geometries are investigated with different cell dimensions. The additively manufactured stents are analyzed by µCT, SEM imaging and DSC. Overhanging geometry features show increasing crystalline defects in the amorphous matrix. However, with steep elevation angles, an amorphous fraction of up to 97.3 ± 1% is achieved in the struts. Three-point bending tests reveal large resilience of the structures, allowing for full compaction for diamond shaped cells with a height of 7 mm and an elevation angle of 77.5°, without fracture. Our findings offer preliminary evidence supporting the potential of additive manufacturing for Zr-based bulk metallic glass stents, while further studies are necessary to validate and optimize the process.

自膨胀支架是植入最多的生物医学设备之一。我们研究了增材制造的可行性，通过激光粉末床熔融将zr基大块金属玻璃制造成自膨胀支架，以实现自动化和可定制的支架制造，同时实现与镍钛诺等现有合金相比具有优越弹性的新型材料。研究了具有不同单元尺寸的三种几何形状。通过微CT、扫描电镜和DSC对增材制造支架进行分析。悬垂几何特征表明非晶基体中晶体缺陷增多。然而，当仰角较陡时，支板中的非晶态分数可达97.3±1%。三点弯曲试验表明，结构具有很大的弹性，允许高度为7毫米、仰角为77.5°的菱形单元完全压实，而不会断裂。我们的研究结果为支持zr基大块金属玻璃支架的增材制造潜力提供了初步证据，同时需要进一步的研究来验证和优化该工艺。

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引用次数: 0