Additive manufacturing letters最新文献

As additive manufacturing (AM) production volumes grow to the industrial scale, quality systems must also scale to verify that every part satisfies requirements. Quality systems are particularly challenging for personalized medical devices, where every patient requires a unique design. This research studies the repeatability of an additively manufactured guide for knee surgery that is personalized to the size and shape of a patient and explores concepts for predicting geometric accuracy. We created 258 unique surgical guide designs with different sizes of the critical features to simulate practical conditions, and manufactured 2100 parts using multi-jet fusion AM. An automated measurement technique collected 8400 individual feature dimensions. Across four critical features, the standard deviation of feature size was 0.076 to 0.173 mm, however the accuracy was consistently different than the target dimensions by -0.308 to 0.017 mm. We show how machine learning (ML) models can predict these geometry distortions and explore the number of parts required to effectively train these models. The accuracy of these models are 0.033 to 0.075 mm, such that the part shape distortion can be accurately predicted to within one standard deviation across a wide range of part sizes.

CSAM (cold spray additive manufacturing) of Ti6Al4V is a challenging task and high-quality deposits conforming to the AM application standards have not been developed so far. In our study, two distinct feedstock Ti6Al4V powders with different morphology and microstructure, spherical and crystalline, were used and their influence on the deposits was investigated in terms of microstructure as well as tensile properties. The results indicate the mechanical strength and ductility of the as-deposited samples to be in the range of 8–30 % compared to wrought Ti6Al4V and highlight a significant anisotropy in different in-plane directions. The post-treatments of the deposits from the spherical, plasma atomized powder effectively reduced the porosity and triggered microstructural homogenization and recrystallization, leading to a significant increase in the yield and tensile strengths, reaching 892 MPa and 954 MPa, respectively, while achieving an enormous enhancement in the elongation to 21.6 % at the same time. This was in a striking contrast to the deposits from the crystalline powder: despite the yield and tensile strength increase to 853 MPa and 1058 MPa, respectively, the elongation remained virtually zero, highlighting the importance of the feedstock powder selection in cold spray additive manufacturing of Ti6Al4V.

Amongst the many sub-systems that make up laser powder bed fusion (PBF-LB) machines, the optomechanical sub-system stands out due to its potential for off-nominal performance but incommensurate level of study on performance evaluation. Nominally, the optomechanical system focuses the laser onto a planar field which is at a controlled position and orientation relative to the powder bed. Deviations from this assumed condition, sometimes referred to as defocus or focus offset, have the potential to significantly impact the manufacturing process by influencing the energy intensity at the process zone. Herein, a novel, high-throughput, low-cost, artifact-based methodology to measure focus offset is detailed. In a single continuous build process, tracks at varying offsets from the build plane were created by ablating the coating on discrete coupons located throughout the build area. By examining these track widths, the focus offset was determined at a relatively fine spatial resolution over the build space, down to 25 mm intervals along the x and y directions, thus ascertaining the discrepancy between the laser focal plane and the build plane, i.e., focal plane error. Results were found to agree with reference measurements to within 0.27 mm over the entire build space and defocus levels ranging from approximately -1.6 to 1.7 mm were discovered. Field sag and optomechanical misalignment were the major casual factors. It is concluded that similar or more severe levels of defocus may be present in the typical PBF-LB machine, which may impart considerable impacts to the overall PBF-LB process.

In this paper, a novel design strategy for l-PBFed AlMnMgScZr/TiN composites with ultrahigh strength was proposed. TiN particles can not only function as ceramic reinforcement, but also decompose and reprecipitate to form a large density of L1₂-precipitates at a high melting temperature during l-PBF. Meanwhile, the primary L1₂-Al₃X (X=Ti/Sc/Zr) phase promotes the columnar-to-equiaxed grain transition effect, creating a fine bi-modal grain structure in the as-built sample. A high volume fraction of L1₂ nanoparticles are additionally precipitated from Al matrix during post heat treatment. In this regard, effective grain refinement and precipitation hardening mechanism contribute to an excellent tensile performance with a combination of an ultimate tensile strength of 681±4 MPa, a yield strength of 677±4 MPa, and an elongation rate of 5.4 ± 1.2%. The yield strength of 677 MPa is particularly the highest among all previously reported l-PBFed Al matrix composites and Al alloys.

Fusion-based Material Extrusion (MEX) Additive Manufacturing (AM) processes have been extensively used for the fabrication of smart structures with embedded sensors, proving to have several benefits such as reduction in cost, manufacturing time, and assembly. A major issue negatively affecting 3D printed sensors is related to their poor electrical conductivity, as well as inconsistent electrical performance, which leads to electrical power losses amongst other issues. In the present paper, a set of process parameters (ironing, printing temperature, and infill overlap) has been analyzed by performing a Design of Experiment (DoE) factorial plan to minimize the electrical resistance. The best process parameters configuration involves a remarkable reduction of electrical resistance of 47.9%, as well as an improvement of mechanical properties of 31.9% (ultimate tensile strength), 25.8% (elongation at break) and 28.14% (flexural stress). The microstructure of the obtained results has also been analyzed by employing a high-resolution, X-ray Computed Tomography (X-Ray CT) system showing a reduction of intralayer voids of 19.5%. This work demonstrates a clear correlation between process parameters and the corresponding electrical properties, mechanical properties, and internal microstructure. In the present research, it has been shown that i) it is possible to significantly improve the overall 3D printed sensors performance by process parameter selection, and ii) small changes in the microstructure lead to remarkable improvements in electrical and mechanical performance.

We have assessed the structural evolution and dispersoid coarsening behaviors of the oxide dispersion-strengthened superalloy MA754 during two different melt-based additive manufacturing techniques – metal laser powder bed fusion (PBF-LB/M) and directed energy deposition (DED). The mechanically alloyed MA754 powder posed challenges for both processes due to its irregular flaky morphology and large particle size. Successful consolidation with PBF-LB/M required increasing the layer height, decreasing the scanning speed, and increasing the laser power relative to typical Ni superalloy printing parameters. The resulting materials contained residual porosity and large Y-Al-oxide slag inclusions which formed in situ. The more prolonged thermal excursion during DED resulted in even larger, mm-scale slag inclusions, which spanned several build layers. In both PBF-LB/M and DED, these inclusions grew at the expense of nanoscale dispersoids, depleting the material of this strengthening phase. These observations motivate alternative approaches for preparing dispersion-strengthened powder feedstocks besides mechanical alloying and highlight the deleterious effects of Al microalloying on dispersoid stability and structure.

Vat photopolymerization (VPP) is one of the most widely used additive manufacturing methods. The VPP process temperature and material curing reaction interplay with each other to critically determine the final product quality. Insights about the time-varying process temperature and degree of conversion (DoC) is desired for VPP process control but difficult to attain due to lacking effective operando characterization technologies. This work reports a new method to create a thermal-chemical model of the VPP process by solving an inverse heat conduction problem (IHCP) based on in-situ observable temperature measurement to estimate the chemistry reaction-induced heat source that is a function of DoC. Ex-situ photo differential scanning calorimetry (Photo-DSC) characterization is used to initialize the chemistry reaction model parameters so that DoC can be calculated. Specifically, vat substrate temperature is measured using an in-situ infrared thermal camera and used as input to solve an IHCP for estimating exothermic heat generation rate for the internal heat generation component at the curing part. Overall, the newly developed VPP modeling framework combines an IHCP that is optimized by in-situ thermal monitoring with a chemical reaction heat generation and conduction model that is educated by Photo-DSC characterization. The model predictions of temperature and DoC are experimentally validated by comparing against in-situ temperature measurement and ex-situ spectroscopy measurement of prints at different exposure times.

Laser-beam powder bed fusion (PBF-LB) technique was used to produce an Al–2.5 %Fe–2 %Cu ternary alloy, featuring a two-phase eutectic composition of α-Al/Al₂₃CuFe₄ in non-equilibrium solidification, as determined by thermodynamic calculations. The specimen manufactured by PBF-LB exhibited a high tensile strength exceeding 350 MPa and a low thermal conductivity of approximately 140 W m⁻¹ K⁻¹. Subsequent annealing at 300 °C improved the thermal conductivity to 175 W m⁻¹ K⁻¹ without compromising the strength. This improvement was attributable to forming numerous Al₂₃CuFe₄ nanoprecipitates, which consumed solute elements. By appropriately managing the factors contributing to strengthening, a superior strength–conductivity balance can be achieved by implementing post-heat treatments.

Additive manufacturing build parameters are used to engineer structural metamaterials lattices with controllable mechanical performance, achieved through microstructural grading of 17-4PH steel without compositional or geometric modification. The high solidification rates of laser powder-bed fusion suppress the thermal martensitic transformation and lead to elevated levels of retained austenite. Diamond cubic lattices built at low energy density (low thermal strain) retain a low martensite phase fraction (3 wt%) and exhibit a bend-dominated compression response. Lattices built at high energy density experience increased thermal strain during the build, causing in-situ deformation-driven transformation, yielding 44 wt% martensite; these exhibit a stretch-dominated compression response. Metamaterial lattices, with high and low energy density parameters in different configurations, exhibit mixed compression responses. Controllable mechanical response was achieved through control of microstructure, using build parameters to adjust thermal strain and selectively suppress or trigger the martensitic phase transformation in-situ.

A wide range of additive manufacturing (AM) processing conditions can be rapidly realized within a single specimen via high-speed direct energy deposition laser based (DED-LB), due to a variety of cooling conditions and in-situ powder mixing. Since existing approaches are inefficient in exploring the vast material and process design space in AM, high-speed DED-LB can be employed as a novel technology for high-throughput alloy design tool. However, an evaluation of the process transferability of the high-speed DED-LB process with respect to the currently dominating metal AM technologies, namely laser powder bed fusion (PBF LB/M) and conventional DED-LB, is required. In this study, high-speed DED-LB is applied for the high-throughput sample production, using the nickel alloy IN718 as reference material as well as the AM processes PBF LB/M and DED-LB as reference processes. The resulting microstructures are characterized and compared using optical microscopy and large-area scanning electron microscopy (SEM) analysis combined with energy-dispersive X-ray spectroscopy (EDS). Furthermore, a model for calculation of the volumetric energy density is developed to compare the applied AM processes. The significant influence of the processing conditions on the solidification behavior of the investigated material allows for efficient exploration of the microstructure and phase composition. Specific high-speed DED-LB-process conditions achieved the average solidification cell size and laves phase content as observed in the PBF LB/M- and DED-LB -produced counterparts. The applicability of the high-speed DED-LB process for rapid alloy and process development, i.e., process transferability, is critically evaluated. The results show that high-speed DED-LB can be used to emulate cooling conditions of PBF-LB/M and DED-LB and, therefore, be used as tool for rapid alloy development.