Article
Materials Science, Multidisciplinary
B. Rozegari Ghashghay, H. R. Abedi, S. G. Shabestari
Summary: This study investigates the grain refinement in the microstructure of selective laser-melted AlSi10Mg alloy. Randomly oriented grains without preferred micro-texture are observed in the printed microstructure. Columnar grains aligned with the building direction have been formed in the molten pool. Refined equiaxed grains with a size of fewer than 10 mm are formed during solidification or dynamic recrystallization.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
H. Zhang, Y. Wang, J. J. Wang, D. R. Ni, D. Wang, B. L. Xiao, Z. Y. Ma
Summary: This study investigates the issue of inferior mechanical properties along the building direction in additive manufactured aluminum alloys and develops an optimized heat treatment method. The results show that direct aging treatment can retain the fine grain microstructure and promote Si phase precipitation, but it also leads to pore growth. By balancing the refinement of cell structure and pore growth, aging at 130 degrees C is determined to be the optimal treatment, resulting in improved tensile strength and elongation of the samples.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Jino Joshy, Allan George, Basil Kuriachen, Jose Mathew
Summary: This study compares the machinability characteristics of cast and SLM produced AlSi10 Mg samples and their effects after heat treatment. The results show that SLM manufactured samples have increased thrust force and cutting force compared to cast samples, but heat treatment can reduce these forces.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Materials Science, Multidisciplinary
Abhishek Tiwari, Gaurav Singh, Rengaswamy Jayaganthan
Summary: The corrosion behavior of AlSi10Mg alloy produced by selective laser melting (SLM) in different atmospheres, argon and nitrogen, was compared to that of cast AlSi10Mg alloy. The electrochemical behavior of SLMed AlSi10Mg alloy in 0.1 M NaCl solution was investigated using potentiodynamic polarization and electrochemical impedance spectroscopy (EIS), and the degradation features were analyzed through SEM. The corrosion resistance of AlSi10Mg produced by selective laser melting was found to be 2-3 times higher than that of cast AlSi10Mg, which can be attributed to the faster cooling rate during solidification.
Article
Materials Science, Multidisciplinary
Hui Liu, Gaoshen Cai, Yanxi Xin
Summary: The effects of different processing parameters on the forming quality of overhanging round hole parts were investigated using numerical simulation and experiment. A response surface model was established to predict the optimization of processing parameters. The experimental results validated the accuracy of the response surface analysis.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Materials Science, Multidisciplinary
Murat Akturk, Mehmet Boy, Munish Kumar Gupta, Saad Waqar, Grzegorz M. Krolczyk, Mehmet Erdi Korkmaz
Summary: This study focuses on the material constitutive parameters of the widely used aluminum alloy AlSi10Mg, using SLM technology to manufacture tensile samples and conducting quasi-static and high temperature tensile tests to determine the Johnson-Cook material model. The comparison between numerically simulated tensile results and experimental results shows a maximum error of around 7.5%, demonstrating the accuracy of the established material model.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Materials Science, Multidisciplinary
F. Bathaee, A. Zarei-Hanzaki, A. Moshiri, H. R. Abedi
Summary: This study investigates the cyclic deformation behavior of AlSi10Mg alloy fabricated through selective laser melting. The directly aged microstructure exhibited the best fatigue performance with an outstanding balance between fatigue life and strength level. The low aspect ratio of the melt pools intensified the Marangoni effect, leading to crack initiation and the formation of balling defects.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Chemistry, Physical
C. G. Wang, J. X. Zhu, G. W. Wang, Y. Qin, M. Y. Sun, J. L. Yang, X. F. Shen, S. K. Huang
Summary: This paper investigated the effects of building orientation and heat treatment temperature on the anisotropy of SLM-formed AlSi10Mg specimens. Various characterization techniques were used to analyze the microstructure and properties of the specimens, revealing that orientation and heat treatment can impact grain size, distribution, and low-angle grain boundaries, which in turn affect the alloy's plasticity.
JOURNAL OF ALLOYS AND COMPOUNDS
(2022)
Article
Chemistry, Physical
Jiantao Zhou, Xu Han, Hui Li, Sheng Liu, Shengnan Shen, Xin Zhou, Dongqi Zhang
Summary: The study investigates the impact of laser polishing on the surface quality of AlSi10Mg material, showing significant reduction in surface roughness and improvement in microhardness. Better surface quality can be achieved by adjusting the parameters of laser polishing.
Article
Automation & Control Systems
Alessandra Pirinu, Teresa Primo, Antonio Del Prete, Francesco Willem Panella, Fabio De Pascalis
Summary: Additive Manufacturing (AM), specifically Selective Laser Melting (SLM), allows for the production of complex metal lattice structures with desired properties and reduced weight. This study investigates how cell topology, size, and beam diameter affect deformation and failure behavior of SLM-manufactured AlSi10Mg alloy structures under static compressive loading. Design of experiment (DOE) analysis is used to define the geometrical features and dimensions of the lattice structures. The experiment includes sixteen topological combinations and forty-eight lattice specimens, each with three replicas, to minimize manufacturing variations.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
N. Tabatabaei, A. Zarei-Hanzaki, A. Moshiri, H. R. Abedi
Summary: This study provides a new interpretation of the effect of different heat treatments on the microstructural evolution and deformation behavior of selectively laser-melted AlSi10Mg alloy. It is found that the flow responses of the treated microstructures have not improved as expected, mainly due to the dissolution of the cellular structure and its impact on trapped gas defects. In addition, the melt pool boundaries are prone to crack nucleation and growth, which is attributed to the high connectivity of Si-network and strain localization.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Manufacturing
Zhiheng Hu, Yang Qi, Balasubramanian Nagarajan, Xiaojia Nie, Hu Zhang, Haihong Zhu, Xiaoyan Zeng
Summary: Selective laser melting (SLM) is a powder bed based additive manufacturing technology expected to fabricate complex parts. This study systematically investigated the evolution of top surface roughness during SLM of an Al-Cu alloy, revealing that fluid flow intensity and molten pool overlapping affect surface roughness, with increases in layer number contributing to spreading of the molten pool but also harming top surface quality with increased powder thickness.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Nanoscience & Nanotechnology
Soung Yeoul Ahn, Jongun Moon, Yeon Taek Choi, Eun Seong Kim, Sang Guk Jeong, Jeong Min Park, Mungu Kang, Hyomoon Joo, Hyoung Seop Kim
Summary: The microstructure and mechanical properties of AlSi10Mg alloy fabricated by selective laser melting were investigated in this study. Substantial hardening was achieved by aging heat treatment. The alloy shows excellent combination of strength and ductility, attributed to its fine cellular structure and nanoscale needle-like precipitates.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Automation & Control Systems
Alberto Boschetto, Luana Bottini, Daniela Pilone
Summary: SLM technology allows for the production of dense and complex metallic parts, but with high surface roughness. This research aims to reduce surface roughness through skin laser remelting, although it affects subsurface defect formation.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Nanoscience & Nanotechnology
Shi Dai, Zi Chen Deng, Ya Jun Yu, Kai Yang Zhu
Summary: The study investigates the flow behavior and microstructure evolution of AlSi10Mg through hot deformation during additive manufacturing. It is found that at different temperatures, the microstructure changes significantly, with cellular structure and melt pool boundary disappearing as temperature increases. Additionally, at 400℃, a homogenization process leads to precipitation forming a dispersed phase, resulting in weak hardening of the material. The constitutive model shows good agreement with experimental results at high temperature.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Chemistry, Multidisciplinary
Alberto Boschetto, Luana Bottini, Luciano Macera, Francesco Veniali
APPLIED SCIENCES-BASEL
(2020)
Article
Chemistry, Multidisciplinary
Filippo Nalli, Luana Bottini, Alberto Boschetto, Luca Cortese, Francesco Veniali
APPLIED SCIENCES-BASEL
(2020)
Article
Engineering, Chemical
Fabrizio Quadrini, Denise Bellisario, Loredana Santo, Luana Bottini, Alberto Boschetto
POLYMER ENGINEERING AND SCIENCE
(2020)
Article
Engineering, Electrical & Electronic
L. Lamagna, A. Paiella, S. Masi, L. Bottini, A. Boschetto, F. Veniali
Summary: In this study, we evaluated the performance of additive manufactured horn antennas for the W-band, specifically focusing on the impact of two kinds of surface post-processing methods. We found that sand-blasting post-processing showed higher reliability and uniformity compared to manual grinding, encouraging further exploration of similar techniques for aluminum devices at these frequencies.
JOURNAL OF INFRARED MILLIMETER AND TERAHERTZ WAVES
(2021)
Article
Automation & Control Systems
Alberto Boschetto, Luana Bottini, Daniela Pilone
Summary: SLM technology allows for the production of dense and complex metallic parts, but with high surface roughness. This research aims to reduce surface roughness through skin laser remelting, although it affects subsurface defect formation.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Alberto Boschetto, Luana Bottini, Valerio Cardini, Marco Eugeni, Paolo Gaudenzi, Francesco Veniali
Summary: This paper provides a case study on substituting traditional manufacturing with selective laser melting for part fabrication. The study emphasizes the importance of reconfiguring the manufacturing framework to retain the advantages of additive manufacturing and offers recommendations for implementing AM for part substitutions.
RAPID PROTOTYPING JOURNAL
(2021)
Article
Engineering, Manufacturing
A. Boschetto, L. Bottini, S. Vatanparast, F. Veniali
Summary: This study proposes a method for synchronized analysis of powder bed anomalies and consequent part defects through digital image processing, aiming to address the challenges of quality control and mechanical characterization in additive manufacturing.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2022)
Article
Engineering, Aerospace
M. Eugeni, T. Quercia, M. Bernabei, A. Boschetto, F. Costantino, L. Lampani, A. Marchetti Spaccamela, A. Lombardo, M. Mecella, L. Querzoni, R. Usinger, M. Aliprandi, A. Stancu, M. M. Ivagnes, G. Morabito, A. Simoni, A. Brandao, P. Gaudenzi
Summary: In recent years, the emergence of the New Space Economy has brought in new commercial players introducing innovative business models based on large satellite constellations. This has resulted in the need for improved manufacturing approaches suitable for serial production, with Industry 4.0 methodologies being adopted to optimize the whole Manufacturing Assembly Integration and Testing (MAIL) cycle within the space industry. Through the application of Industry 4.0 concepts, intelligent factories are being created where manufacturing technologies are upgraded with the use of Cyber-Physical Systems (CPSs), Internet of Things (IoT), Cloud Computing, and Big Data Analytics for predictive monitoring features.
Article
Engineering, Manufacturing
Alberto Boschetto, Luana Bottini, Fabio Miani, Francesco Veniali
Summary: Metal Fused Filament Fabrication is a low-cost 3D printing technology that has attracted significant interest. However, there is still a lack of knowledge about roughness control and prediction. This study aims to fulfill this gap by analyzing the effect of processing parameters on surface roughness in different stages and establishing regression models for optimization.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Chemistry, Multidisciplinary
Alberto Boschetto, Luana Bottini, Luciano Macera, Somayeh Vatanparast
Summary: The research introduced in this work aids engineers in developing new designs for lightweight, stronger, and more efficient satellite platform structures that can be built using additive manufacturing. The study provides practical knowledge about 3D printing production and its impact on dimensional correctness and repeatability of the structure, which requires the utilization of different designs. The findings reveal design strategies for lattice structures, including local optimization, to meet stringent satellite requirements.
APPLIED SCIENCES-BASEL
(2023)
Article
Materials Science, Multidisciplinary
Luciano Macera, Daniele Pullini, Alberto Boschetto, Luana Bottini, Claudio Mingazzini, Gian Luca Falleti
Summary: Metal additive manufacturing is a rapidly growing field that offers numerous benefits, including the ability to produce complex shapes and optimize part performance. However, the high surface roughness of metal parts produced by selective laser melting poses challenges for their direct implementation. This paper explores the potential of sol-gel silica coatings to effectively protect aluminum alloy surfaces produced by selective laser melting, offering excellent chemical stability and corrosion resistance. Nanostructured silica sol-gel coatings have shown promising results in replacing toxic galvanic treatments and integrating aluminum parts into circular economy cycles.
Article
Engineering, Manufacturing
Alberto Boschetto, Luana Bottini, Nahal Ghanadi
Summary: This study characterizes the surfaces of selective laser melting using areal analysis, revealing substantial variability and anisotropy that cannot be evaluated through traditional measurement. Analysis of building orientation and secondary finishing operations demonstrates that barrel finishing can effectively reduce anisotropy and enhance surface quality.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2022)
