Article
Engineering, Manufacturing
Chaochao Wu, Muhammad Qasim Zafar, Haiyan Zhao, You Wang, Christoph Schoeler, Christian Heinigk, Markus Niessen, Wolfgang Schulz
Summary: The research analyzes the formation process of side surfaces in electron beam PBF through 3-D mesoscale multi-physics simulation, providing insights into side roughness mechanisms from the perspective of heat and mass transfer. The study reveals that cases with lower heat input result in greater fluctuations in melted traces, leading to higher side roughness. The investigation also identifies melt pool flow driven by surface tension as the main cause of track shape fluctuation.
ADDITIVE MANUFACTURING
(2021)
Article
Automation & Control Systems
Yuk Lun Chan, Olaf Diegel, Xun Xu
Summary: A time-efficient machined substrate hybrid AM strategy was developed to reduce manufacturing time for injection mould inserts, with four inserts fabricated in a metal powder bed fusion system. Compared to the standard AM practice, a considerable saving in processing time was achieved, albeit with a slight compromise in tensile strength.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Industrial
Ying Zhang, Yaoyao Fiona Zhao
Summary: This paper presents a novel solution for predicting the manufacturability of the LPBF process by using a sparse matrix to store design data and combining it with a neural network model to train process data, achieving high-resolution analysis.
JOURNAL OF MANUFACTURING SYSTEMS
(2022)
Article
Engineering, Manufacturing
O. Dolev, S. Osovski, A. Shirizly
Summary: The tensile behavior and fracture toughness of a hybrid Ti-6Al-4V alloy were examined, showing good properties without a preference for crack growth. The hybrid manufacturing approach studied here expands the current limitations of large-scale critical components and allows for higher throughput.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
A. Plotkowski, J. Ferguson, B. Stump, W. Halsey, V Paquit, C. Joslin, S. S. Babu, A. Marquez Rossy, M. M. Kirka, R. R. Dehoff
Summary: By developing a new geometry agnostic scan path algorithm, the ability to control grain structure and crystallographic texture during metal additive manufacturing has been demonstrated, with profound implications for the design and optimization of next-generation products.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Francis Ogoke, Amir Barati Farimani
Summary: Powder-based additive manufacturing techniques offer a powerful tool for building intricate structures, but defects in Laser Powder Bed Fusion pose challenges. A Deep Reinforcement Learning framework is proposed to generate a versatile control policy that adjusts laser velocity or power to ensure melt pool consistency and prevent overheating in the final product.
ADDITIVE MANUFACTURING
(2021)
Review
Engineering, Mechanical
Mahyar Khorasani, Ian Gibson, Amir Hossein Ghasemi, Elahe Hadavi, Bernard Rolfe
Summary: The purpose of this study is to compare laser-based additive manufacturing and subtractive methods. The principles, performance, and capabilities of laser-based subtractive manufacturing and laser-based powder bed fusion are discussed and evaluated. The study finds that both methods have advantages and disadvantages, such as low energy efficiency and production rate, but can be applied to a wide range of materials. The study also suggests the possibility of hybrid manufacturing options for producing complex components.
RAPID PROTOTYPING JOURNAL
(2023)
Article
Materials Science, Multidisciplinary
Peng Chen, Jin Su, Haoze Wang, Lei Yang, Maoyuan Li, Zhaoqing Li, Jie Liu, Shifeng Wen, Yan Zhou, Chunze Yan, Yusheng Shi
Summary: This study investigates the aging mechanism of polyetheretherketone powder under infrared radiation, revealing that infrared radiation promotes particle spheroidization and crystalline structure organization but reduces crystallinity in the powder.
MATERIALS & DESIGN
(2022)
Article
Engineering, Chemical
Zhaowei Xiang, Mingde Zhang, Ran Yan, Qin Yin, Kaifei Zhang
Summary: The study examines the powder-spreading dynamics under different substrate surface roughness and finds that a rough substrate surface helps retain particles and enhances their kinetic intensity. The research also reveals that a high spreading speed with an appropriately large layer thickness can resolve the conflict between spreading efficiency and packing quality.
Article
Automation & Control Systems
Vincenza Mercurio, Flaviana Calignano, Luca Iuliano
Summary: Laser powder bed fusion (L-PBF) is an additive manufacturing technology that produces complex and lightweight parts without specific tooling. However, its use in mass production is limited by problems such as low productivity, high material consumption, and quality issues. This study presents good practices to reduce resource consumption and increase production rate using L-PBF. By analyzing process parameters and observing samples with non-destructive testing, the study provides insights into improving density and mechanical properties while maintaining surface roughness.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Du-Rim Eo, Seong Gyu Chung, Jin Myoung Jeon, Jung-Wook Cho
Summary: This study investigated the mechanism of melt pool oxidation and reduction during powder bed fusion by analyzing the impact of process parameters on the oxygen, nitrogen, and carbon content in the printed material. It was found that in 316L stainless steel, melt pool oxidation and reduction occur simultaneously, with higher energy density and shield gas flow speed leading to a decrease in porosity. The presence of nitrogen and CO gas as vapor constituents was observed in materials with high oxygen and nitrogen content, impacting solidification texture and melt pool stability.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Hao Gu, Fayez AlFayez, Lanti Yang, Toseef Ahmed, Zahir Bashir
Summary: This study demonstrates the successful use of a dry mix of aluminum and PET powders for freeforming with PBF. However, the Al-PET powder has a narrower processing window and lower tensile strength and impact resistance compared to PET powder. The decrease in strength and resistance in Al-PET articles made by PBF is due to the inherent and interfacial voids caused by the PBF process. Nevertheless, PBF offers the advantage of easier crystallization of the PET phase, making it suitable for thermally conductive articles.
ADDITIVE MANUFACTURING
(2022)
Article
Nanoscience & Nanotechnology
Paria Karimi, Esmaeil Sadeghi, Joakim Algardh, Jonas Olsson, Magnus Hornqvist Colliander, Peter Harlin, Ehsan Toyserkani, Joel Andersson
Summary: This study introduces a unique melting strategy in electron beam-powder bed fusion to tailor the grain morphology of Alloy 718 from columnar to equiaxed. By controlling the local solidification conditions and motions within the melt pools, the transition in grain morphology was achieved. Four different microstructures were identified, with the typical texture being <001>, and shrinkage defects and cracks were reduced with a decrease in areal energy input. Hardness was increased due to the growth of gamma precipitates and high grain boundary density in the fully-equiaxed grain morphology.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Engineering, Manufacturing
Ehsan Malekipour, Hazim El-Mounayri, Mallikharjun Marrey, Eric J. Faierson, Mohammad Al Hasan
Summary: The thermal evolution of printed parts in PBF processes is crucial for component quality, but simulating temperature distribution in layers with complex geometry remains a challenge due to high computational costs.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Amir Hadadzadeh, Babak Shalchi Amirkhiz, Brian Langelier, Jian Li, Mohsen Mohammadi
Summary: The study investigates the microstructural consistency in a laser powder bed fusion (L-PBF) AlSi10Mg material, finding that repeated thermal cycles affect the characteristics of precipitates and the chemistry of the matrix, while not significantly impacting the grain and cell structures.
ADDITIVE MANUFACTURING
(2021)