Additive manufacturing letters最新文献_第6页

Cross-modality transfer for DED-LB/M: AI-based prediction of schlieren phenomena from coaxial imaging d - lb /M的跨模态转移：基于人工智能的同轴成像纹影现象预测

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100298

Benedikt Brandau , João Sousa , Rico Hemschik , Frank Brueckner , Alexander F.H. Kaplan

Real-time process monitoring is essential for ensuring stability and defect control in directed energy deposition - laser beam/metal (DED-LB/M). Schlieren imaging has proven to be a valuable tool for detecting refractive index variations in the process zone, providing insights into gas flow behaviour, shielding gas efficiency and process plume dynamics. However, schlieren imaging typically requires specialized optical setups, making integration into industrial systems challenging. This study explores an artificial intelligence-driven cross-modality transfer approach that enables the prediction of schlieren-induced refractive index variations from coaxial imaging data, eliminating the need for a dedicated schlieren setup. A background-oriented schlieren system was used to capture reference data, while a coaxial camera recorded the melt pool and surrounding process zone during DED-LB/M. A machine learning model was trained on the combined dataset, establishing correlations between schlieren activity and intensity variations in the coaxial images. The model successfully predicted schlieren-induced disturbances, allowing for the indirect detection of gas flow instabilities and shielding gas deficiencies. The results demonstrate that artificial intelligence-based analysis of coaxial imaging can provide schlieren-equivalent process information, making it possible to monitor refractive index variations, detect process deviations and improve defect prediction in real time. This approach enhances process monitoring capabilities in DED-LB/M, enabling cost-effective, scalable and easily integrable monitoring solutions for industrial applications.

实时过程监控是保证定向能沉积-激光束/金属（ed - lb /M）工艺稳定性和缺陷控制的关键。纹影成像已被证明是一种有价值的工具，用于检测过程区的折射率变化，提供对气体流动行为、保护气体效率和过程羽流动力学的见解。然而，纹影成像通常需要专门的光学设置，使得集成到工业系统具有挑战性。本研究探索了一种人工智能驱动的跨模态转移方法，该方法能够从同轴成像数据中预测纹影诱导的折射率变化，从而消除了对专用纹影设置的需要。采用面向背景的纹影系统捕获参考数据，同轴相机记录了d- lb /M过程中的熔池和周围工艺区域。在组合数据集上训练机器学习模型，建立纹影活动与同轴图像强度变化之间的相关性。该模型成功地预测了纹影引起的扰动，允许间接检测气体流动不稳定性和保护气体缺陷。结果表明，基于人工智能的同轴成像分析可以提供纹影等效的工艺信息，从而可以实时监测折射率变化，检测工艺偏差并改进缺陷预测。这种方法增强了ed - lb /M的过程监控功能，为工业应用提供了经济高效、可扩展且易于集成的监控解决方案。

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引用次数: 0

Chamfer distance for non-linear registration of Triply Periodic Minimal Surface lattices 三周期极小曲面格非线性配准的倒角距离

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100299

Michela Lapenna , Francesco Faglioni , Keerthana Chand , Bardia Hejazi , Rita Fioresi , Giovanni Bruno

We present a 3D image registration technique for non-linear deformation estimation in Additive Manufacturing processes. The methodology involves comparing X-ray Computed Tomography (XCT) data with Computer Aided Design (CAD) models for Triply Periodic Minimal Surface (TPMS) lattices and employs the Chamfer distance to refine mesh non-linear deformations.

提出了一种用于增材制造过程中非线性变形估计的三维图像配准技术。该方法包括将x射线计算机断层扫描（XCT）数据与三周期最小表面（TPMS）网格的计算机辅助设计（CAD）模型进行比较，并使用倒角距离来细化网格非线性变形。

引用次数: 0

Improved corrosion resistance of selective laser melted NiTi alloys via nanosecond pulsed laser annealing treatment for biomedical application 生物医学用纳秒脉冲激光退火提高选择性激光熔化NiTi合金的耐蚀性

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100306

Chao Yang , Tao Long , An Yan , Hongwei Ma , Haizhou Lu , Liang Liang , Weisi Cai

NiTi alloys, known for their excellent biocompatibility, have broad application prospects in the biomedical field, making surface quality and corrosion resistance critical for practical applications. This study employs nanosecond pulsed laser annealing to improve the surface properties of NiTi alloys fabricated by selective laser melting (SLM). The results show that laser annealing significantly reduces surface roughness, with the average roughness (Ra) decreasing from 8.76 µm to 1.42 µm. Meanwhile, potential dynamic polarization analysis conducted at 37 °C in Hank’s solution indicates that laser annealing effectively enhances corrosion resistance, with the corrosion potential shifting positively from -0.68 V to -0.23 V and the corrosion current density decreasing from 3.580 μA·cm⁻² to 0.151 μA·cm⁻². This improvement is attributed to the reduction in surface roughness, grain refinement, and the formation of a more stable oxide layer through laser annealing. This study not only validates the potential of laser annealing for surface modification of SLMed NiTi alloys but also provides valuable insights for their further optimization in biomedical applications.

NiTi合金具有良好的生物相容性，在生物医学领域具有广阔的应用前景，其表面质量和耐腐蚀性对实际应用至关重要。采用纳秒脉冲激光退火技术改善选择性激光熔化制备的NiTi合金的表面性能。结果表明：激光退火能显著降低表面粗糙度，平均粗糙度（Ra）由8.76µm降至1.42µm；同时，对Hank’s溶液在37°C下进行的电位动态极化分析表明，激光退火有效地提高了材料的耐蚀性，腐蚀电位从-0.68 V正移到-0.23 V，腐蚀电流密度从3.580 μA·cm⁻²下降到0.151 μA·cm⁻²。这种改进归因于表面粗糙度的降低，晶粒细化，以及通过激光退火形成更稳定的氧化层。该研究不仅验证了激光退火在SLMed NiTi合金表面改性中的潜力，而且为其在生物医学应用中的进一步优化提供了有价值的见解。

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引用次数: 0

Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing 采用激光粉末床熔融增材制造新型高比强度多拓扑Al-Ni-Ti-Zr-Mn合金

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100308

Amit Kumar Singh , Prithvi D. Awasthi , Ankita Roy , Priyanka Agrawal , Aishani Sharma , Anurag Gumaste , Ravi Sankar Haridas , Rajiv S. Mishra

Additive manufacturing has opened a paradigm for the efficient and quick production of lightweight lattice structures showing characteristic high specific strength (strength-to-weight ratios). The current study describes the development of methodology and utilization of high strength Al alloy for building complex lattice using additive manufacturing. Thin plate lattice <1 mm of Al-Ni-Ti-Zr-Mn alloy with wide processing window, achieving an average yield strength of 63.13±3.32 MPa in compression, with 28 % lower density than Ti-6Al-4V demonstrates a successful design of Al-Ni-Ti-Zr-Mn alloys using laser beam powder bed fusion (PBF-LB). The mitigation of cracks within thin plate parallel to the loading axis was achieved through the formation of Al-Al₃Ni eutectic channels, exploiting the rapid solidification of this short-freezing-range alloy. In addition to multi-topology structural design, the enhanced strength is attributed to hierarchical microstructure featuring L1₂ phases, bimodal grain distribution, and solid solution strengthening by Mn. This work establishes a printability-performance synergy of Al-Ni-Ti-Zr-Mn alloy for thin plate complex lattice, advancing the use of metamaterials through PBF-LB.

增材制造为高效、快速生产具有高比强度（强度重量比）特征的轻质点阵结构开辟了一个范例。本文介绍了利用增材制造技术构建复杂晶格的高强度铝合金的方法和应用。1 mm的Al-Ni-Ti-Zr-Mn薄板点阵，宽加工窗口，压缩平均屈服强度为63.13±3.32 MPa，密度比Ti-6Al-4V低28%，证明了采用激光束粉末床熔合（PBF-LB）技术成功设计了Al-Ni-Ti-Zr-Mn合金。通过形成Al-Al₃Ni共晶通道，利用这种短冻结范围合金的快速凝固，实现了平行于加载轴的薄板内裂纹的缓解。除了多拓扑结构设计外，强度的提高还归因于L1₂相的分层组织、双峰晶粒分布和Mn的固溶强化。本工作建立了Al-Ni-Ti-Zr-Mn合金用于薄板复合晶格的印刷性-性能协同效应，通过PBF-LB推进了超材料的使用。

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引用次数: 0

On the mechanical isotropy and corrosion behavior of tantalum produced via laser beam powder bed fusion 激光粉末床熔合制备钽的力学各向同性和腐蚀行为

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100317

Andrew B. Kustas , Erin Barrick , Jonathan Pegues , Hannah Sims , Mary L. Gucik , Michael Melia , Alexander E. Wilson-Heid , Joshua D. Sugar , Eric D. Hintsala , Kevin M. Schmalbach , Frank W. DelRio , Tyler LeBrun

Tantalum (Ta) is a refractory metal with excellent corrosion resistance and biocompatability, high melting temperature and density, and good electrical and thermal conductivity, with applications in capacitors, medical implants and devices, linings in the chemical industry, penetrator projectiles, and nuclear reactors. In this work, we examined the mechanical isotropy and corrosion behavior of tantalum produced through laser beam powder bed fusion (PBF-LB). Electron backscatter diffraction (EBSD), tensile tests, nanoindentation, and environmental and galvanic corrosion tests were utilized to establish structure-property relationships as a function of orientation, temperature, and pH. EBSD showed the horizontal and vertical orientations had different grain size distributions and weak texture. From tensile testing, PBF-LB Ta exhibited comparable strain-at-failure relative to wrought Ta, with significantly higher yield and ultimate strengths relative to ASTM B708. Room-temperature nanoindentation confirmed weak mechanical anisotropy via complementary EBSD images and showed small variations in reduced modulus and hardness after annealing to 800 °C due to oxide formation. The environmental corrosion tests in HCl (acid), NaCl (neutral), and KOH (basic) suggested the corrosion current density for PBF-LB Ta was lower than wrought, signifying slower corrosion for PBF-LB Ta. The passive nature of PBF-LB and wrought Ta was observed during galvanic corrosion; when coupled with titanium, aluminum, or stainless steel, most systems did not show corrosion after 24 hr. In all, the results showed that PBF-LB Ta has comparable or, in some cases, superior mechanical and corrosion properties to wrought Ta.

钽（Ta）是一种难熔金属，具有优异的耐腐蚀性和生物相容性，高熔融温度和密度，以及良好的导电性和导热性，应用于电容器，医疗植入物和设备，化学工业衬里，穿透弹丸和核反应堆。在这项工作中，我们研究了激光粉末床熔合（PBF-LB）生产的钽的力学各向同性和腐蚀行为。利用电子背散射衍射（EBSD）、拉伸试验、纳米压痕、环境腐蚀和电偶腐蚀试验建立了取向、温度和ph的结构-性能关系。EBSD表明，水平取向和垂直取向具有不同的晶粒尺寸分布和弱织构。从拉伸测试中，PBF-LB Ta相对于锻造Ta表现出相当的失效应变，相对于ASTM B708具有更高的屈服和极限强度。通过互补的EBSD图像，室温纳米压痕证实了弱的力学各向异性，并且在退火到800°C后，由于氧化物的形成，降低的模量和硬度变化很小。HCl（酸性）、NaCl（中性）和KOH（碱性）环境腐蚀试验表明，PBF-LB Ta的腐蚀电流密度低于变形电流，表明PBF-LB Ta的腐蚀速度较慢。在电偶腐蚀过程中观察到PBF-LB和变形Ta的钝化性质；当与钛，铝或不锈钢结合使用时，大多数系统在24小时后不会出现腐蚀。总之，结果表明，PBF-LB Ta具有与锻造Ta相当的机械性能和腐蚀性能，在某些情况下甚至优于锻造Ta。

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引用次数: 0

Microstructure homogenization of laser powder bed fusion support-free low angle IN718 walls through heat treatment 热处理后激光粉末床熔合无支架低角IN718壁的显微组织均匀化

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100312

Minsol Park, Mudit Kesharwani, Mohammad Attarian Shandiz, Mathieu Brochu

This study investigates the effectiveness of heat treatment (HT) to homogenize the microstructural and mechanical asymmetry between the bulk and the downskin regions of support-free IN718 walls fabricated at angles of 30°, 20°, 15°, and 10° In the as-built condition, the microhardness ranged from 340 ± 5 HV to 351 ± 4 HV for the bulk and from 315 ± 4 HV to 323 ± 10 HV for the downskin region, resulting in a maximum difference range of 35 HV. The HT eliminated this difference where microhardness values of 482 ± 3 HV in the bulk and 478 ± 4 HV in the downskin were measured. The HT induced γ″ precipitation with volume fraction and mean precipitate size in the bulk of 16.6 % and 24.7 ± 7.3 nm. These values are statistically comparable to those in the downskin: 15.8 % and 26.5 ± 7.9 nm. The similarity in the γ″ characteristics explains the recovery of the mismatch in hardness as γ″ contributes approximately 85 % of the strengthening in the HT condition.

本研究调查的有效性热处理(HT)之间的微观结构和机械不对称散装同质化,支持自由downskin地区的IN718墙壁捏造在30°角,20°,15°,和10°竣工条件,显微硬度范围从340±5高压351±4高压散装和从315±4高压323±10 downskin地区的高压,导致最大35高压范围的差异。HT消除了这种差异，测量了主体的显微硬度值为482±3hv，下皮肤的显微硬度值为478±4hv。高温诱导γ″析出，体积分数为16.6%，平均析出尺寸为24.7±7.3 nm。这些值在统计上与下皮肤的值相当：15.8%和26.5±7.9 nm。γ″特征的相似性解释了硬度不匹配的恢复，因为γ″在高温条件下贡献了大约85%的强化。

引用次数: 0

Combining fusion-based and solid-state additive manufacturing: Investigation of additive DED structures with friction surfacing interlayer 融合与固态增材制造的结合：具有摩擦表面夹层的增材DED结构研究

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-07-01 DOI: 10.1016/j.addlet.2025.100302

Zina Kallien , Eloise Eimer , Arne Roos , Victor Ortolland , Lars Rath , Stewart Williams , Benjamin Klusemann

Fusion-based additive manufacturing (AM) techniques face some challenges for aluminium due to the necessity of material melting resulting in insufficient bonding. The present work provides a novel insight into the combination of fusion-based and solid-state AM approaches to successfully generate structures from different aluminium alloys. Specifically, the friction-based solid-state AM technique of friction surfacing (FS) is used to generate an interlayer structure on AA2050 substrate material. On top of this structure, additional AA5087 is deposited via Wire and Arc Additive Manufacturing (WAAM). For the FS interlayer structure, two different alloys, AA5083 and AA7050, are explored. Additionally, the effect of inter-layer rolling is investigated for the final WAAM structure. The built structures are investigated with special focus on the interfaces, i.e., FS deposit-to-substrate and WAAM deposit-to-FS deposit interfaces. In the cross sections, no defects could be detected at the FS deposit-to-substrate interfaces and the structures did not show visible cracks at the WAAM deposit-to-FS deposit interfaces. The investigation showed that the mechanical properties of the WAAM structure improve when inter-layer rolling is applied, leading to homogeneous mechanical properties across the interfaces. The study highlights that FS as friction-based solid-state AM process is capable to build interlayer structures for material combinations, which cannot be achieved directly via a fusion-based process. The approach of combining different AM techniques can be advantageous not only to achieve a dissimilar material combinations but also to build hybrid structures with locally optimized properties.

基于融合的增材制造（AM）技术由于材料熔化的必要性而导致粘接不足，因此对铝面临一些挑战。目前的工作为融合和固态增材制造方法的结合提供了新的见解，以成功地从不同的铝合金中生成结构。具体而言，采用基于摩擦的摩擦表面固态增材制造技术（FS）在AA2050衬底材料上生成层间结构。在此结构的顶部，通过线材和电弧增材制造（WAAM）沉积额外的AA5087。对于FS层间结构，研究了两种不同的合金AA5083和AA7050。此外，还研究了层间轧制对最终WAAM结构的影响。对所建结构进行了研究，特别关注界面，即FS沉积-衬底和WAAM沉积-FS沉积界面。在横截面上，FS沉积层与基体界面处未检测到缺陷，WAAM沉积层与FS沉积层界面处结构未出现明显裂纹。研究表明，层间轧制能改善WAAM组织的力学性能，使其在界面上的力学性能趋于均匀。该研究强调，FS作为基于摩擦的固态增材制造工艺能够为材料组合构建层间结构，这是无法通过基于融合的工艺直接实现的。结合不同增材制造技术的方法不仅有利于实现不同的材料组合，而且有利于构建具有局部优化性能的混合结构。

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引用次数: 0

AdditiveLLM: Large language models predict defects in metals additive manufacturing AdditiveLLM：大型语言模型预测金属增材制造中的缺陷

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-06-11 DOI: 10.1016/j.addlet.2025.100292

Peter Pak , Amir Barati Farimani

In this work we investigate the ability of large language models to predict additive manufacturing defect regimes given a set of process parameter inputs. For this task we utilize a process parameter defect dataset to fine-tune a collection of models, titled AdditiveLLM, for the purpose of predicting potential defect regimes including Keyholing, Lack of Fusion, and Balling. We compare different methods of input formatting in order to gauge the model’s performance to correctly predict defect regimes on our sparse Baseline dataset and our natural language Prompt dataset. The model displays robust predictive capability, achieving a Baseline accuracy of 94% and Prompt accuracy of 82% when asked to provide the defect regimes associated with a set of process parameters. The incorporation of natural language input further simplifies the task of process parameters selection, enabling users to identify optimal settings specific to their build.

在这项工作中，我们研究了给定一组工艺参数输入的大型语言模型预测增材制造缺陷制度的能力。对于这个任务，我们利用一个过程参数缺陷数据集来微调一组模型，标题为AdditiveLLM，用于预测潜在的缺陷机制，包括Keyholing、Lack of Fusion和Balling。我们比较了不同的输入格式方法，以衡量模型在稀疏基线数据集和自然语言提示数据集上正确预测缺陷制度的性能。该模型显示出强大的预测能力，当要求提供与一组过程参数相关的缺陷制度时，达到94%的基线准确度和82%的提示准确度。自然语言输入的结合进一步简化了过程参数选择的任务，使用户能够确定特定于其构建的最佳设置。

引用次数: 0

Part distortion monitoring in additive manufacturing using machining 增材制造中零件变形监测

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-06-06 DOI: 10.1016/j.addlet.2025.100295

Jaydeep Karandikar , Akash Tiwari , Josh Harbin , Christopher Tyler , Scott Smith , Derril Vezina , Rob Caron

In additive manufacturing, accumulation of residual stresses can result in severe part distortion from the desired preform shape. Current methods for in-situ part distortion monitoring in additive manufacturing typically require expensive sensors, or capital equipment, and require time-consuming post-processing to understand the shape deviation. This paper presents an in-situ method, in the context of hybrid manufacturing, for part distortion detection using machining of additively manufactured parts. As a surrogate, three test artifacts were used to represent different distorted geometries. The tool axis positions from the machine tool controller and the cutting power were monitored during a facing operation. Cutting power data was used to detect the tool entry and exit in the workpiece using a novel approach with power standard deviation metric. The workpiece geometry and distorted configuration was subsequently predicted for positional and rotational deviations to within 2 mm accuracy using synchronized tool position data with cutting power. The proposed method can be used in a hybrid (additive and subtractive) machine tool to periodically check part distortion in the additive build. The method is applicable for any additive process and is low-cost and computationally inexpensive.

在增材制造中，残余应力的积累会导致零件严重变形。目前在增材制造中进行原位零件变形监测的方法通常需要昂贵的传感器或资本设备，并且需要耗时的后处理才能了解形状偏差。本文提出了一种在混合制造背景下，利用增材制造的零件加工进行零件畸变检测的原位方法。作为代理，三个测试工件被用来表示不同的扭曲几何。在加工过程中，通过机床控制器监测刀具轴的位置和切削功率。采用一种新的功率标准差度量方法，利用切削功率数据检测刀具在工件中的进出。随后，利用同步刀具位置数据和切削功率，预测了工件几何形状和变形结构的位置和旋转偏差，精度在2mm以内。该方法可应用于加减法混合机床中，对加式制造中的零件畸变进行周期性检测。该方法适用于任何增材工艺，成本低，计算成本低。

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引用次数: 0

Damage modes and mechanical properties of Ti6Al4V lattice structures under transverse impact loading Ti6Al4V晶格结构在横向冲击载荷下的损伤模式与力学性能

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters

Pub Date : 2025-05-30 DOI: 10.1016/j.addlet.2025.100294

Minghao Huang , Yixiao Luo , Tenglong Xie , Xin Yang , Shenghang Xu , Chen Chang , Chao Ding , Huiping Tang

The light-weighting of high-end equipment structural components is an eternal pursuit in structural engineering. The development of Laser Powder Bed Fusion (L-PBF) technology has enabled the easy fabrication of lattice structure materials, which exhibit exceptional mechanical properties. The present study investigates the mechanical properties and deformation processes of ten Ti6Al4V lattice structures (Primitive, Diamond, Fischer-Koch, I-WP, Gyroid; 6-Layered Plate, 4-Layered Plate, Truss Plate; Auxetic honeycomb X, and Auxetic honeycomb Y) under a transverse impact loading. Firstly, it was found that the truss plate and 4-layered plate exhibited the highest specific absorbed energy (SAE) of 38.67 J/(g∙cm^-3) and specific peak force (SPF) of 6033 N/(g∙cm^-3), respectively. The Negative Poisson's ratio structure demonstrated the best damage tolerance during the impact test procedure. Meanwhile, the TPMS structures, which exhibit similar deformation behavior and shear failure modes, have closely matched peak force values. These findings provide critical guidance for aerospace and automotive applications requiring mass-efficient energy absorption.

高端设备结构件的轻量化是结构工程永恒的追求。激光粉末床融合（L-PBF）技术的发展使晶格结构材料的制造变得容易，这些材料具有优异的力学性能。本文研究了十种Ti6Al4V晶格结构(Primitive, Diamond, Fischer-Koch, I-WP, Gyroid；6层板、4层板、桁架板；辅助蜂窝X和辅助蜂窝Y)在横向冲击载荷下。首先，发现桁架板和四层板的比吸收能（SAE）和比峰力（SPF）分别为38.67 J/(g∙cm-3)和6033 N/(g∙cm-3)。负泊松比结构在冲击试验过程中表现出最佳的损伤容限。同时，TPMS结构具有相似的变形行为和剪切破坏模式，其峰值力值非常接近。这些发现为需要高质量能量吸收的航空航天和汽车应用提供了重要指导。

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引用次数: 0