Article
Engineering, Manufacturing
Ahmed Moussa, David Melancon, Asma El Elmi, Damiano Pasini
Summary: This study introduces a methodology to integrate geometric defects in topology optimization of lattice materials built via additive manufacturing, and demonstrates the significance of accounting for process-induced defects in optimizing the mechanical properties of these materials.
ADDITIVE MANUFACTURING
(2021)
Review
Automation & Control Systems
Hossein Mohammadtaheri, Ramin Sedaghati, Marjan Molavi-Zarandi
Summary: In recent years, metal additive manufacturing, specifically the laser powder bed fusion process, has gained popularity in industrial applications due to its ability to produce components with complex geometry. However, residual stress and deformation caused by the heating and cooling cycle in the process are significant technical barriers. Developing a simulation model to predict residual stress is essential for minimizing distortion in parts and avoiding costly experimental procedures.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Optics
Zhi-Dong Zhang, Shahriar Imani Shahabad, Osezua Ibhadode, Chinedu Francis Dibia, Ali Bonakdar, Ehsan Toyserkani
Summary: This article introduces an innovative 3D heat-transfer finite element parallel-computing model with adaptive mesh capability called LPBFSim, which is used for high precision prediction and process simulation in Laser Powder Bed Fusion (LPBF) additive manufacturing. The model is parallelized to overcome the high computational cost of scaling up from single-track to multi-track or part-level models, while maintaining accuracy. Single-track, multi-track, and single-layer part-level models have been implemented to demonstrate the efficiency and accuracy of the proposed model.
OPTICS AND LASER TECHNOLOGY
(2023)
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)
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, Mechanical
Sumair Sunny, Ritin Mathews, Haoliang Yu, Arif Malik
Summary: This study investigates the effects of a hybrid metal-additive manufacturing process on residual stress. The results show that both the microstructure and the residual stress from the laser powder bed fusion process have significant influences on the induced residual stress during interlayer burnishing.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
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
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)
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
Engineering, Manufacturing
Onome Scott-Emuakpor, Joseph Beck, Brian Runyon, Tommy George
Summary: The practicality of inherent damping with Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM) process is enhanced by identifying a threshold value for unfused powder volume, which enables designing parts with inherent damping that can suppress vibration by 88-95% compared to fully-fused counterparts with only 1-4% unfused powder volume.
ADDITIVE MANUFACTURING
(2021)
Review
Engineering, Manufacturing
Balaji Soundararajan, Daniele Sofia, Diego Barletta, Massimo Poletto
Summary: This paper reviews the state of the art in numerical simulation of powder bed fusion process, highlighting the importance of physically accurate modeling in component and material qualification. It discusses various mesh-based and mesh-free methods, as well as their combined approaches, and provides a case study comparing different models for a similar problem, along with a brief discussion on experimental validation techniques.
ADDITIVE MANUFACTURING
(2021)
Article
Nanoscience & Nanotechnology
Yuan Tian, Kanwal Chadha, Sang Hoon Kim, Clodualdo Aranas
Summary: The Heatvar alloy was specifically designed for the Laser Powder Bed Fusion (LPBF) process and can withstand prolonged exposure to heat in the tool and die industries. Microstructural evolution, mechanical properties, and texture development were studied after heat treatment. Different heat treatment temperatures were used to increase hardness, tensile strength, and yield strength through dissolution and precipitation of Fe2Mo.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Engineering, Manufacturing
S. Lapointe, G. Guss, Z. Reese, M. Strantza, M. J. Matthews, C. L. Druzgalski
Summary: This paper presents a data-driven approach using experimental diagnostics to optimize laser process parameters for improved part quality in laser powder bed fusion additive manufacturing. By establishing both a forward model and an inverse model, and employing supervised learning techniques, laser parameters can be predicted based on geometry features and photodiode signals, resulting in enhanced part quality.
ADDITIVE MANUFACTURING
(2022)
Article
Materials Science, Multidisciplinary
Nthateng Nkhasi, Willie du Preez, Hertzog Bissett
Summary: Metal powders used in powder bed additive manufacturing should have specific characteristics, and plasma spheroidisation can improve the morphology of metal powders, making them suitable for additive manufacturing.
Article
Engineering, Manufacturing
Can Bayraktar, Eralp Demir
Summary: This study develops a thermomechanical model to predict the dimensions of the melt-pool and residual stresses in the laser powder bed fusion process. By using the inherent strain method, residual stresses can be accurately predicted at a faster rate compared to the thermomechanical model, and avoids the complexities of the mechanical solution.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Multidisciplinary
Zhang WeiHong, Zhang ZhiDong, Zhu JiHong, Gao Tong
SCIENCE CHINA-TECHNOLOGICAL SCIENCES
(2014)
Article
Optics
Zhidong Zhang, Yuze Huang, Adhitan Rani Kasinathan, Shahriar Imani Shahabad, Usman Ali, Yahya Mahmoodkhani, Ehsan Toyserkani
OPTICS AND LASER TECHNOLOGY
(2019)
Article
Automation & Control Systems
Shahriar Imani Shahabad, Zhidong Zhang, Ali Keshavarzkermani, Usman Ali, Yahya Mahmoodkhani, Reza Esmaeilizadeh, Ali Bonakdar, Ehsan Toyserkani
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2020)
Article
Computer Science, Interdisciplinary Applications
Osezua Ibhadode, Zhidong Zhang, Pouyan Rahnama, Ali Bonakdar, Ehsan Toyserkani
STRUCTURAL AND MULTIDISCIPLINARY OPTIMIZATION
(2020)
Article
Computer Science, Interdisciplinary Applications
Zhi-Dong Zhang, Osezua Ibhadode, Ali Bonakdar, Ehsan Toyserkani
Summary: In this work, a novel two-dimensional and three-dimensional integrated topology optimization parallel-computing framework, TopADD, was developed to handle optimization problems with arbitrary design domains. The framework demonstrated superior efficiency in computational time and memory usage compared to other frameworks in literature, and showed compatibility with additive manufacturing.
STRUCTURAL AND MULTIDISCIPLINARY OPTIMIZATION
(2021)
Article
Automation & Control Systems
Osezua Ibhadode, Zhidong Zhang, Ali Bonakdar, Ehsan Toyserkani
Summary: While structural design complexities may not be an issue for many additive manufacturing technologies, manufacturing constraints like unsupported or overhanging features need to be addressed to avoid impacting part quality and increasing production time and cost. A post-topology optimization strategy is proposed to eliminate these features by introducing additional support-free struts. This can improve the structure's stability and reduce the volume fraction for final topology optimization.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)