Article
Nanoscience & Nanotechnology
X. P. Ren, H. Q. Li, H. Guo, F. L. Shen, C. X. Qin, E. T. Zhao, X. Y. Fang
Summary: The study provides a comprehensive benchmark comparison on the microstructure, mechanical properties, and underlying mechanisms of Ti-6Al-4V alloys processed through selective laser melting (SLM), electron beam melting (EBM), and millannealing. Different processing methods result in distinct microstructures and material properties, with potential for improving ductility in SLMed samples and enhancing strength in EBMed samples through post-annealing and process optimization.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Automation & Control Systems
Giuseppe Del Guercio, Manuela Galati, Abdollah Saboori
Summary: The study analyzed the impact of heat treatments on the microstructure and mechanical behavior of Ti-6Al-4V lattice structures manufactured by electron beam melting, finding that heat treatments had positive effects on increasing ductility and energy absorption.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Natalia Pushilina, Ekaterina Stepanova, Andrey Stepanov, Maxim Syrtanov
Summary: The study investigated the surface modification of Ti-6Al-4V samples manufactured by electron beam melting using a pulsed carbon ion beam, revealing the formation of gradient microstructure and improvements in micro- and nanohardness through pulsed ion beam exposure.
Article
Materials Science, Multidisciplinary
William J. Davids, Hansheng Chen, Keita Nomoto, Hao Wang, Sudarsanam Babu, Sophie Primig, Xiaozhou Liao, Andrew Breen, Simon P. Ringer
Summary: The study reveals significant variations in beta phase fraction within a given build and categorizes high-temperature beta phase into two types based on their formation temperature, providing new insights into the phase transformation pathway during additive manufacturing.
Article
Chemistry, Physical
Selim Demirci, Tuncay Dikici, Mehmet Masum Tuncay, Ramazan Dalmis, Nusret Kaya, Kursat Kanbur, Fatih Sargin, Arif Nihat Gulluoglu
Summary: Various surface modifications have been explored to enhance the apatite formation ability of EBM Ti-6Al-4V alloy. Among the methods tested, micro-arc oxidations in 1 M H2SO4 solution (SM) showed the best results in terms of apatite formation ability, which could be attributed to its high roughness, low contact angle, presence of Ti-OH groups, and anatase and rutile phases.
SURFACES AND INTERFACES
(2022)
Article
Engineering, Mechanical
Julia Richter, Thomas Wegener, Robert Kratzsch, Malte Vollmer, Urs Peuker, Thomas Niendorf
Summary: This study investigates the importance of powder recycling in additive manufacturing and conducts experiments on the preparation and application of recycled powder. The results show that mechanically recycled powder can partially substitute virgin powder.
INTERNATIONAL JOURNAL OF FATIGUE
(2023)
Article
Nanoscience & Nanotechnology
L. Ednie, R. J. Lancaster, A. A. Antonysamy, F. Zelenka, A. Scarpellini, L. Parimi, R. Maddalena, N. C. Barnard, P. Efthymiadis
Summary: This study focuses on the effects of surface roughness on the fatigue properties of additive manufacturing (AM) built components. Results show that as-built components have lower fatigue life compared to machined and polished samples. It is also shown that a decrease in the surface roughness parameter Rp is correlated with an increase in the number of cycles to failure. The study concludes that while surface roughness is an important factor, other features such as porosity also play a significant role in influencing fatigue performance.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Engineering, Mechanical
Nan Jin, Zhenyu Yan, Yangwei Wang, Huanwu Cheng, Hongmei Zhang
Summary: The study investigates the relationship between microstructure and mechanical properties of titanium lattice materials fabricated by selective laser melting (SLM) with different heat treatments. The results show that the bending-dominated structure BCC is more sensitive to heat treatment conditions, with the optimal temperatures being 920 degrees C for BCC and 750 degrees C for FCC. A numerical simulation model was also established to depict the relationship between the mechanical properties of the base material and the lattice materials.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2021)
Article
Materials Science, Multidisciplinary
Costanzo Bellini, Rosario Borrelli, Francesco Di Caprio, Vittorio Di Cocco, Stefania Franchitti, Francesco Iacoviello, Carmine Pirozzi, Luca Sorrentino
Summary: In this article, small trusses with different diameters were produced through electron beam melting (EBM) by varying the process parameters, like the orientation and the position in the build chamber. The diameter of the trusses was evaluated and compared with the nominal one. The study found that the orientation in the chamber had a significant influence on the geometrical error and the nominal diameter, while the position in the building chamber had no influence. Furthermore, the highest deviation was observed for the specimens oriented at 0 degrees and those with a diameter of 1 mm, and a similar result was found for the ovalisation of the truss section.
Article
Engineering, Mechanical
A. K. Syed, D. Parfitt, D. Wimpenny, E. Muzangaza, B. Chen
Summary: The cyclic deformation and damage mechanisms in electron-beam-melted Ti-6Al-4V have been investigated. The as-built samples exhibit a graded microstructure, with larger alpha-laths and higher plastic strain in the top samples. After hot isostatic pressing (HIPing), the alpha-lath width increases and grain misorientation decreases, resulting in reduced microstructural and property gradients. In both conditions, the observed cyclic softening is caused by a reduction in friction stress and an increase in grain misorientation, indicating the fragmentation of the lath structure into smaller grains. As-built samples typically show lower fatigue life due to crack initiation from gas pores and lack-of-fusion defects.
INTERNATIONAL JOURNAL OF FATIGUE
(2022)
Review
Metallurgy & Metallurgical Engineering
Mohammad Karimzadeh Kolamroudi, Mohammed Asmael, Mustafa Ilkan, Naser Kordani
Summary: Electron beam melting (EBM) is a high technology increasingly used in various industries such as bioengineering, aerospace, and marine engineering due to its efficiency in part production process and time and cost-efficient accurate production results.
TRANSACTIONS OF THE INDIAN INSTITUTE OF METALS
(2021)
Article
Materials Science, Multidisciplinary
Robert Fleishel, William Ferrell, Stephanie TerMaath
Summary: Electron Beam Melting (EBM) is a widely used additive manufacturing technology for metallic-part fabrication. However, the presence of microstructural defects, such as lack of fusion and smooth facets, can greatly affect the fatigue life of final products. In this study, intentional defects were induced in EBM Ti-6Al-4V to investigate their impact on stress-controlled fatigue life. It was found that fatigue damage primarily occurred at smooth facet sites or areas with un-melted powder, and increasing the focus offset parameter led to an increase in both fatigue life and void content. These results indicate that smooth flaws are likely a result of lack of fusion.
Article
Chemistry, Physical
Alessandro Carrozza, Giulio Marchese, Abdollah Saboori, Emilio Bassini, Alberta Aversa, Federica Bondioli, Daniele Ugues, Sara Biamino, Paolo Fino
Summary: This study focuses on the effect of different heat treatments on the Ti-6Al-4V alloy processed by electron beam melting (EBM). The results show that super beta-transus annealing reduces anisotropy generated by the EBM process and the aging treatment further improves the microstructure and mechanical properties of the alloy.
Article
Chemistry, Physical
Zhijun Yu, Zhuo Chen, Dongdong Qu, Shoujiang Qu, Hao Wang, Fu Zhao, Chaoqun Zhang, Aihan Feng, Daolun Chen
Summary: The study finds that 3D-printed samples manufactured via SLM and EBM exhibit poor corrosion resistance compared to samples manufactured via ISF. The superior corrosion resistance of ISF-manufactured samples is attributed to the presence of a higher amount of beta phase and lower fraction of phase interfaces in the equiaxed alpha + beta microstructure.
Article
Metallurgy & Metallurgical Engineering
Jinsen Tian, Jiang Ma, Ming Yan, Zhuo Chen, Jun Shen, Jing Wu
Summary: The study found that different grains have varying effects on the mechanical properties of Ti-6Al-4V alloy, including factors such as the size of the alpha phases, dispersion of the beta phases, and the presence of the free dislocation path. Although no direct link was discovered between the mechanical properties and the parent beta orientations, this work provided a promising method to further study the anisotropic mechanical behavior in Ti-6Al-4V alloy.
ACTA METALLURGICA SINICA-ENGLISH LETTERS
(2021)
Article
Metallurgy & Metallurgical Engineering
Seyed Kiomars Moheimani, Azadeh Keshtgar, Saeed Khademzadeh, Morteza Tayebi, Ali Rajaee, Abdollah Saboori
Summary: This study investigated the dry sliding wear properties of AZ31 magnesium alloy and B4C-reinforced AZ31 composites with bimodal sizes. The results showed that the hardness of the composites increased with the reinforcement content when the distribution of B4C particles was uniform. The composites with 5 and 10 wt.% B4C exhibited significantly higher wear resistance in all conditions, while the composite with 20 wt.% B4C had lower resistance at high sliding speeds and high loadings. The highest wear resistance was observed at high sliding speeds and low loadings, with oxidative wear as the dominant mechanism.
JOURNAL OF MAGNESIUM AND ALLOYS
(2022)
Article
Automation & Control Systems
Seyed Kiomars Moheimani, Luca Iuliano, Abdollah Saboori
Summary: In this study, AISI 316L specimens were produced using directed energy deposition (DED) technology. The effect of substrate preheating on the microstructure, hardness, surface roughness, and mechanical properties of the samples was investigated. The results showed that samples produced on a preheated substrate had lower thermal gradient and cooling rate, as well as higher inclusion content. Additionally, samples deposited on a cold substrate exhibited better mechanical performance.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
G. Del Guercio, D. G. McCartney, N. T. Aboulkhair, S. Robertson, R. Maclachlan, C. Tuck, M. Simonelli
Summary: This study provides a detailed investigation of crack formation in the AlCuMg alloy AA2024 during laser powder bed fusion (L-PBF) process. Through microstructural characterization, hot cracks and solid state cracks were differentiated and a modeling approach was proposed to predict the susceptibility of hot cracks based on solidification velocities. The observation of cracks associated with microporosity offers new insights into the complex problem of hot tearing during L-PBF.
ADDITIVE MANUFACTURING
(2022)
Article
Chemistry, Physical
Alessandro Carrozza, Giulio Marchese, Abdollah Saboori, Emilio Bassini, Alberta Aversa, Federica Bondioli, Daniele Ugues, Sara Biamino, Paolo Fino
Summary: This study focuses on the effect of different heat treatments on the Ti-6Al-4V alloy processed by electron beam melting (EBM). The results show that super beta-transus annealing reduces anisotropy generated by the EBM process and the aging treatment further improves the microstructure and mechanical properties of the alloy.
Review
Automation & Control Systems
Vittorio Viale, John Stavridis, Alessandro Salmi, Federica Bondioli, Abdollah Saboori
Summary: This review examines the impact of process parameters on the surface quality of complex parts in additive manufacturing, particularly at low angles where support structures are not required. Research highlights the challenges of part detachment and dross formation, which are influenced by both angles and materials.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Review
Chemistry, Multidisciplinary
Gabriele Piscopo, Eleonora Atzeni, Abdollah Saboori, Alessandro Salmi
Summary: Laser Powder Directed Energy Deposition (LP-DED) is a powerful additive manufacturing process, but its application is limited by the lack of understanding of the process mechanisms. This paper reviews the mechanisms of LP-DED and their relationship with input process parameters, focusing on their effects on deposition effectiveness and interrelation among the mechanisms. The results highlight the complexity of LP-DED mechanisms and provide guidance for engineers in exploring new materials and optimizing the deposition process.
APPLIED SCIENCES-BASEL
(2023)
Article
Materials Science, Multidisciplinary
Amir Behjat, Morteza Shamanian, Aboozar Taherizadeh, Erika Lannunziata, Sara Bagherifard, Elzbieta Gadalinska, Abdollah Saboori, Luca Iuliano
Summary: Laser polishing and water jet assisted recirculating shot peening can improve the surface quality, microstructure, and electrochemical properties of AISI316L stainless steel components. Laser polished samples had a smooth surface with high tensile residual stress, while shot peened samples exhibited higher surface hardness and compressive residual stress, and had a wider passive range in cyclic potentiodynamic polarization measurements, higher polarization resistance in electrochemical impedance spectroscopy measurements, and less defective passive film in Mott-Schottky analysis.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Optics
Giuseppe Del Guercio, Marco Simonelli
Summary: Aluminium alloys from the 2xxx series are important structural materials due to their optimal combination of strength and corrosion resistance. However, their production using laser powder bed fusion (PBF-LB/M) is hindered by defects such as pores and hot cracks. This study utilizes modelling and experimental work to predict the consolidation behavior of AA2024 alloy and proposes a new approach that can increase productivity in industrial settings without machine adaptations.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Manuela Galati, Paolo Antonioni, Flaviana Calignano, Eleonora Atzeni
Summary: Additive manufacturing technologies for metallic materials enable the production of high-performance components with optimized weight, geometry, and mechanical properties. However, post-processing operations are necessary, including part removal from the build platform, which must be performed quickly, accurately, and with a smooth surface finish. This study investigates the wire electric discharge machining (W-EDM) process for Ti6Al4V specimens produced by AM technologies and analyzes the influence of cutting parameters compared to those of conventional technology. Models of cutting speed and surface roughness are derived from collected data, highlighting the significance of the manufacturing process in defining surface roughness and the key parameters affecting machining performance.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Engineering, Manufacturing
Giovanni Rizza, Manuela Galati, Paolo Antonioni, Luca Iuliano
Summary: A distinctive characteristic of the powder bed fusion with electron beam (PBF-EB) process is the sintering of the powder particles, which is crucial for the success of the subsequent melting and the overall process. This study systematically investigated the effects of different particle diameters, particle diameter ratios, and the impact of the rigid body motion of the particles in the sintering process. The results demonstrated that the sintering outcomes significantly depended on the EB-PBF process conditions.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Review
Materials Science, Multidisciplinary
Mohammad Hossein Mosallanejad, Ata Abdi, Farshid Karpasand, Navid Nassiri, Luca Iuliano, Abdollah Saboori
Summary: Additive manufacturing (AM) is considered a reliable technology for replacing traditional methods in the manufacturing of Ti alloy components. This article reviews the progress made in this field in the past years, aiming to facilitate the selection of the best-fit AM procedure for the desired alloy. It also presents practical applications and potential industrial uses of Ti components produced using metal AM methods.
ADVANCED ENGINEERING MATERIALS
(2023)
Article
Materials Science, Multidisciplinary
Reza Ghanavati, Erika Lannunziata, Ehsan Norouzi, Sara Bagherifard, Luca Iuliano, Abdollah Saboori
Summary: This study investigated the capability of the standard laser powder bed fusion process to produce SS316L-IN718 functionally graded materials with different designs. The analysis and discussion revealed the gradual evolution of the solidification structure, smooth distribution of constituent elements, and orientation and grain growth in the build direction. The gradient design with a 50 wt% mixed intermediate zone and optimum processing condition showed the best mechanical properties.
Article
Chemistry, Physical
Farideh Davoodi, Mohammad Taghian, Giuseppe Carbone, Abdollah Saboori, Luca Iuliano
Summary: Fast progress in near-net-shape production has led to increased interest in internal surface finishing. This literature review focuses on the development of non-traditional finishing methods and compares their working principles, capabilities, and limitations. A thorough assessment is conducted based on seven key features, with two selected methods determining the value for a hybrid machine.
Article
Materials Science, Ceramics
Mehran Dadkhah, Jean-Marc Tulliani, Abdollah Saboori, Luca Iuliano
Summary: This review provides an overview of the challenges in additive manufacturing of ceramics compared to polymers and metals, and discusses the recent progress and current challenges in producing complex shaped ceramic components via AM technologies. The state of the art in 3D printing processes for ceramic fabrication is discussed, including their advantages, disadvantages, and potential applications. The potential and challenges of AM in producing complex shape ceramic components are also explored.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2023)
Article
Materials Science, Multidisciplinary
Iman Ansarian, Reza Taghiabadi, Saeid Amini, Abdollah Saboori
Summary: Surface modification of metal Additive Manufacturing components, specifically using Ultrasonic Peening (UP), has been shown to significantly improve corrosion properties by forging surface porosities, refining microstructure, and enhancing corrosion resistance.