Article
Materials Science, Multidisciplinary
Suraj Dinkar Jadhav, Pushkar Prakash Dhekne, Etienne Brodu, Brecht Van Hooreweder, Sasan Dadbakhsh, Jean-Pierre Kruth, Jan Van Humbeeck, Kim Vanmeensel
Summary: This article explores the use of optically absorptive surface-modified copper powders for fabricating fully dense and highly conductive copper alloy parts via laser-based additive manufacturing (L-AM). It discusses the densification mechanism of parts and the distinct processing behaviors of different surface-modified powders. The advantage of a firmly bonded modified layer present on the surface of carburized CuCr1 powder over a loosely attached carbon nanoparticle layer in carbon-mixed CuCr1 powder is clearly outlined, with customized final properties achievable through tailored post-heat treatments.
MATERIALS & DESIGN
(2021)
Article
Engineering, Manufacturing
Suraj Dinkar Jadhav, Louca Raphael Goossens, Yannis Kinds, Brecht Van Hooreweder, Kim Vanmeensel
Summary: This article evaluates the laser-based powder bed fusion (L-PBF) processing behavior of pure copper powder using a conventional infrared fiber laser, and identifies the key factors for producing solid copper parts with near full density.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
P. Navarrete-Segado, C. Frances, M. Tourbin, C. Tenailleau, B. Duployer, D. Grossin
Summary: This paper focuses on the tailoring of calcium phosphate powders for their use in powder bed selective laser process feedstock. Through the addition of graphite as a laser absorptance additive, the processing window of the powder blends containing different amounts of graphite was increased, making the powder without additive non-processable. The study also showed the phase transition of hydroxyapatite while chlorapatite remained thermally stable during the whole process. Another study evaluated the production of solid and complex parts using a powder blend of hydroxyapatite and graphite. The microstructure and mechanical properties of the samples were analyzed, and the bioactivity of the bioceramic scaffolds was improved through a post-treatment process. These findings are expected to contribute to bone tissue engineering using powder bed selective laser processing of calcium phosphate powders.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Manufacturing
Martin Maly, Daniel Koutny, Libor Pantelejev, Laurent Pambaguian, David Palousek
Summary: The study investigated the impact of using a high-power laser source and high-temperature base plate preheating as a heat source on the relative density of pure copper thin-walled and thick-walled samples, as well as the effects of various process parameters on the quality of the parts. The results showed that to achieve a relative density of over 99%, the proper combination of process parameters must be set.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Ottman A. Tertuliano, Philip J. DePond, David Doan, Manyalibo J. Matthews, X. Wendy Gu, Wei Cai, Adrian J. Lew
Summary: Laser powder bed fusion (LPBF) of pure copper for thermal and electrical applications is limited by low near-infrared absorptivity and high thermal diffusivity. This study investigates the effect of nanoparticle additives on absorptivity and melting behavior during LPBF. Using an in situ calorimetry system, decorated copper substrates with three nanoparticle systems (CuS, TiB2, multilayer graphene flakes) demonstrated enhanced absorptivity compared to pure copper. Graphene nanoflakes resulted in the highest improved absorption due to their stability at high laser scanning powers. The work also showed an improvement in relative density of the copper-graphene powder prints compared to as-purchased copper powder prints.
ADDITIVE MANUFACTURING
(2022)
Article
Materials Science, Multidisciplinary
Tian Yang, Zhijian Feng, Yating Qiu, Wei Han, Lingbao Kong
Summary: This paper explores the benefits and possibilities of using irregular shaped powder in selective laser melting (SLM) of glass. Through a series of experiments, it is demonstrated that irregularly-shaped glass powder can be successfully used in the SLM process and that process parameter changes can yield builds with comparable porosity levels to builds using typical spherical powder.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Manufacturing
Yongjia Wu, Kan Sun, Shifeng Yu, Lei Zuo
Summary: This study utilized selective laser melting to manufacture flexible and functionally graded thermoelectric materials, establishing a physical model to understand and study the thermal and fluid phenomena during the melting process. The effects of process parameters on temperature distribution, powder bed shrinkage, pool size, and particle aggregation were investigated, providing crucial insights for thermoelectric device fabrication using SLM.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Zijun Yuan, Xiangdong Chen
Summary: Fabricating overhanging structures in Selective laser melting is challenging. Temporary supports are currently required, but they generate additional waste. This study proposes a new method by using a defocused laser to print a new structure layer directly on the powder bed, eliminating the need for traditional supports. Experimental results demonstrate that this approach can greatly reduce waste caused by conventional supports.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Review
Engineering, Manufacturing
Guilherme Maziero Volpato, Ulrich Tetzlaff, Marcio Celso Fredel
Summary: This review examines the past 14 years of research on Inconel superalloys, summarizing the most significant findings, current challenges, and research goals. The effects of processing parameters, heat treatment, and machining on the materials and their composites are evaluated, and the performance of materials in terms of mechanical, corrosion, and tribological behavior is compared. The research trends in the literature are mapped according to the focus of publications.
ADDITIVE MANUFACTURING
(2022)
Article
Chemistry, Physical
Ivan A. Pelevin, Maxim A. Burmistrov, Dmitriy Yu. Ozherelkov, Alexander S. Shinkaryov, Stanislav V. Chernyshikhin, Alexander A. Gromov, Anton Yu. Nalivaiko
Summary: By utilizing recycled powder in the laser powder bed fusion process, despite the formation of extra spherical pores, a relative density of 99.2% was achieved through optimization of LPBF parameters. The solidified microstructure exhibited a small volume of defects, consisting of an oversaturated dendritic Cu matrix and nano-sized Cr precipitations to provide strengthening mechanisms, resulting in satisfactory mechanical properties such as sigma(0.2) = 136.8 MPa, UTS = 187.4 MPa, and 15.5% elongation.
Article
Automation & Control Systems
Sergey Grigoriev, Riana Ableyeva, Andrey Korotkov, Roman Khmyrov, Tatiana Tarasova, Andrey Gusarov
Summary: Recent studies have highlighted the significance of powder transport by gas-phase flows in the laser-interaction zone in laser powder bed additive manufacturing. This phenomenon has important implications for the development and optimization of laser-assisted processes in additive manufacturing.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Optics
Robin Kromer, Cyril Gorny, Elise Gruhier, Emilie Le Guen, Corinne Arvieu, Eric Lacoste
Summary: The effective absorptivity of IR laser light for different powder beds was studied. Reflectivity of aluminum, titanium, stainless steel, and copper alloys was measured, showing that the absorptivity of the powder bed was significantly higher than that of a uniform surface due to multiple scattering. The substrate also had an impact on the powder bed absorption. The inhomogeneity of the powder bed strongly modified the laser absorption for a small spot size, and the absorption fluctuated during the transition from the powder state to the molten pool state.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Yusuke Sugiura, Ryo Koike
Summary: This study developed a high-gravitational powder bed fusion system that improves the surface quality, density, and hardness of fabricated parts by applying high gravitational acceleration. Experimental evaluations demonstrate that a high gravitational field enhances the quality of the parts produced.
ADDITIVE MANUFACTURING
(2021)
Article
Materials Science, Multidisciplinary
Timothee Delacroix, Fernando Lomello, Frederic Schuster, Hicham Maskrot, Vincent Jacquier, Pierre Lapouge, Frederic Coste, Jean-Paul Garandet
Summary: The quality of laser powder bed fusion (L-PBF) and its cost efficiency depend heavily on the ability to produce high-quality parts using recycled powders. To control material quality, it is important to assess particle oxidation, which increases with powder recycling and indicates powder degradation. In this study, a new methodology was developed to measure the oxygen content of powders using in-line scanning of powder bed layers. By analyzing the coloration of stainless steel particles, the oxygen concentration was determined based on Red, Green, and Blue channel values. The results demonstrate a new opportunity for in-situ monitoring and evaluation of powder degradation in powder bed layers through image analysis.
MATERIALS & DESIGN
(2023)
Article
Chemistry, Physical
Philipp Mair, Valerie Sue Goettgens, Tobias Rainer, Nikolaus Weinberger, Ilse Letofsky-Papst, Stefan Mitsche, Gerhard Leichtfried
Summary: The addition of 2 wt% CaB6 nanoparticles in 2024 aluminum alloy results in a columnar-to-equiaxed transition, improving processability and producing high-density, crack-free specimens. The nanoparticles act as heterogeneous nuclei, reducing grain coarsening and enhancing strength and elongation properties.
JOURNAL OF ALLOYS AND COMPOUNDS
(2021)
Article
Engineering, Industrial
S. D. Jadhav, S. Dadbakhsh, L. Goossens, J-P Kruth, J. Van Humbeeck, K. Vanmeensel
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2019)
Article
Materials Science, Multidisciplinary
Suraj Dinkar Jadhav, Sasan Dadbakhsh, Rong Chen, Rajashekhara Shabadi, Jean-Pierre Kruth, Jan Van Humbeeck, Kim Vanmeensel
ADVANCED ENGINEERING MATERIALS
(2020)
Article
Materials Science, Multidisciplinary
Etienne Brodu, Suraj Dinkar Jadhav, Kim Vanmeensel, Marc Seefeldt
MATERIALS CHARACTERIZATION
(2020)
Article
Engineering, Manufacturing
M. A. Balbaa, A. Ghasemi, E. Fereiduni, M. A. Elbestawi, S. D. Jadhav, J-P Kruth
Summary: This study aims to investigate the processability of fine AlSi10Mg powder in the L-PBF process and compare it with commonly used coarse powder. The results indicate that using fine powders in L-PBF processing is challenging, highlighting the differences in processability between fine and coarse powders.
ADDITIVE MANUFACTURING
(2021)
Article
Materials Science, Multidisciplinary
Guichuan Li, Suraj Dinkar Jadhav, Arturo Martin, Maria L. Montero-Sistiaga, Jeroen Soete, Maria San Sebastian, Carmen M. Cepeda-Jimenez, Kim Vanmeensel
Summary: The study developed a Si-modified Al7075 alloy to reduce solidification cracking during L-PBF, resulting in crack-free samples with improved microstructure and grain size. The addition of Si, Mg2Si, and Al2Cu phases in the modified alloy contributed to the enhanced mechanical properties and age hardening resistance.
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
(2021)
Article
Materials Science, Multidisciplinary
Suraj Dinkar Jadhav, Pushkar Prakash Dhekne, Etienne Brodu, Brecht Van Hooreweder, Sasan Dadbakhsh, Jean-Pierre Kruth, Jan Van Humbeeck, Kim Vanmeensel
Summary: This article explores the use of optically absorptive surface-modified copper powders for fabricating fully dense and highly conductive copper alloy parts via laser-based additive manufacturing (L-AM). It discusses the densification mechanism of parts and the distinct processing behaviors of different surface-modified powders. The advantage of a firmly bonded modified layer present on the surface of carburized CuCr1 powder over a loosely attached carbon nanoparticle layer in carbon-mixed CuCr1 powder is clearly outlined, with customized final properties achievable through tailored post-heat treatments.
MATERIALS & DESIGN
(2021)
Article
Engineering, Manufacturing
Suraj Dinkar Jadhav, Dongmei Fu, Maxim Deprez, Kristof Ramharter, Denise Willems, Brecht Van Hooreweder, Kim Vanmeensel
ADDITIVE MANUFACTURING
(2020)
Article
Chemistry, Physical
Mirko Sinico, Suraj Dinkar Jadhav, Ann Witvrouw, Kim Vanmeensel, Wim Dewulf
Summary: This study compares dense specimens produced from virgin and surface-modified CuCr1 powder, as well as characterizes a third sample with abnormal porosity content. High-resolution micro-CT scans reveal that the virgin CuCr1 sample has keyhole pores and pit cavities, while the surface-modified sample mainly contains small and spherical equi-distributed metallurgical defects. The presence of W contamination in the third specimen leads to lack-of-fusion pores in subsequent LPBF layers. The different porosity types are connected to the LPBF melting mode, material properties, and potential contaminants.
Article
Materials Science, Multidisciplinary
Eskandar Fereiduni, Ali Ghasemi, Mohamed Elbestawi, Suraj Dinkar Jadhav, Kim Vanmeensel
Summary: Understanding the laser-powder interaction during LPBF of composite systems is crucial for producing robust parts. The presence of a reinforcing agent on the metallic powder surface hinders full melting and deteriorates powder flowability, despite improving optical absorption.
Article
Engineering, Manufacturing
Suraj Dinkar Jadhav, Louca Raphael Goossens, Yannis Kinds, Brecht Van Hooreweder, Kim Vanmeensel
Summary: This article evaluates the laser-based powder bed fusion (L-PBF) processing behavior of pure copper powder using a conventional infrared fiber laser, and identifies the key factors for producing solid copper parts with near full density.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Ali Ghasemi, Eskandar Fereiduni, Mohamed Balbaa, Suraj Dinkar Jadhav, Mohamed Elbestawi, Saeid Habibi
Summary: This study investigates the influence of alloying elements and process parameters on the laser powder bed fusion processability of aluminum, showing that the removal of oxide compounds during processing outweighs in-situ oxidation. The research suggests that the laser absorptivity of alloys and the oxidation tendency of pure aluminum do not negatively affect their processability.
ADDITIVE MANUFACTURING
(2021)
Article
Nanoscience & Nanotechnology
Pushkar Prakash Dhekne, Tijmen Vermeij, Vivek Devulapalli, Suraj Dinkar Jadhav, Johan P. M. Hoefnagels, Kim Vanmeensel
Summary: The plastic deformation mechanisms of heat-treated L-PBF processed Ti-6Al-4V components were studied by in-situ uniaxial tensile loading, revealing the accommodation of higher strain in the transformed beta phase, strain accumulation in primary alpha at interface regions with lower Al content, and strain localization pathways created by needle-shaped secondary alpha precipitates.
SCRIPTA MATERIALIA
(2023)
Article
Engineering, Manufacturing
Przemyslaw Golebiewski, Pawel Wienclaw, Jaroslaw Cimek, Pawel Socha, Dariusz Pysz, Adam Filipkowski, Grzegorz Stepniewski, Olga Czerwinska, Ireneusz Kujawa, Ryszard Stepien, Rafal Kasztelanic, Andrzej Burgs, Ryszard Buczynski
Summary: We report the development of a 3D printing process for producing soft glass optical fibers. The process involves direct printing using a miniaturized crucible and depositing straight horizontally-oriented lines to replace traditional assembly techniques. Experimental results demonstrate good performance of the printed photonic crystal fiber preform.
ADDITIVE MANUFACTURING
(2024)
