Article
Engineering, Manufacturing
Shuhan Li, Xinqiang Lan, Zemin Wang, Shuwen Mei
Summary: The study demonstrates that appropriate post-heat treatments can improve the mechanical properties of Ti-6.5Al-2Zr-Mo-V alloy processed by LPBF, especially ductility. By comparing samples obtained under different heat treatment conditions, the study investigated the effects of microstructure on mechanical properties.
ADDITIVE MANUFACTURING
(2021)
Article
Optics
Mahyar Khorasani, AmirHossein Ghasemi, Martin Leary, Elmira Sharabian, Laura Cordova, Ian Gibson, David Downing, Stuart Bateman, Milan Brandt, Bernard Rolfe
Summary: The research aims to develop a model to estimate laser absorption in materials and investigate the impact of absorption ratio on melt pool morphology. The developed model significantly enhances the accuracy of estimating melt pool features.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Thomas Maulet, Jerome Gimenez, Florian Deme, Pierre Alcouffe, Ruben Vera, Claire Barres, Rene Fulchiron
Summary: This study investigated the crystallization kinetics of thermoplastic polymers in laser powder bed fusion (LPBF) technique and analyzed the microstructure of parts using various microscopy and diffraction experiments. The significant nucleating effect of sub-surface layers solidification during the LPBF process was found to be important in understanding the crystallization of polymers. The presence of nuclei was confirmed through microscopic and wide-angle X-ray diffraction (WAXD) techniques.
ADDITIVE MANUFACTURING
(2022)
Review
Materials Science, Multidisciplinary
Flavio Bartolomeu, Michael Gasik, Filipe Samuel Silva, Georgina Miranda
Summary: This review focuses on the mechanical properties of selective laser-melted Ti6Al4V parts and discusses the main processing and microstructural parameters that affect the final properties. It provides a fundamental understanding of the relationship between microstructural features and mechanical properties, including tensile strength, fatigue resistance, and wear performance. The review also compares Laser Powder Bed Fusion with conventional processing routes and discusses the presence of defects in as-built Ti6Al4V parts and their impact on mechanical performance.
Article
Materials Science, Multidisciplinary
C. J. Todaro, M. Rashidi, R. L. Liu, S. Gao, T. P. Le, J. E. Fronda, J. Setyadji, Y. T. Tang, M. Seita
Summary: The development of additive manufacturing technologies has revolutionized the design and manufacturing of products, particularly high-performance metal alloys for harsh environments. This article presents the first additive manufacturing of Inconel alloy 725, a widely used nickel-based superalloy, and explores its printability and microstructure. The heat-treated Inconel alloy 725 exhibits promising properties and is suitable for applications in harsh environments.
MATERIALS CHARACTERIZATION
(2022)
Article
Optics
X. X. Yao, Z. Zhang
Summary: The use of powder in laser powder bed fusion additive manufacturing is essential in determining the accurate prediction of melt pool and temperature distribution. The absorption and distribution of laser energy by powder particles play a crucial role in the process. By analyzing the electromagnetic energy density and statistical distribution of particles, a new volumetric heat source model was developed and applied in heat transfer simulations.
OPTICS AND LASER TECHNOLOGY
(2022)
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
Chemistry, Physical
Amal Shaji Karapuzha, Darren Fraser, Daniel Schliephake, Stefan Dietrich, Yuman Zhu, Xinhua Wu, Aijun Huang
Summary: This study aimed to understand the microstructural variations and mechanical properties of Hastelloy X (HX) manufactured by electron beam powder bed fusion (PBF-EB) and laser-based powder bed fusion (PBF-LB) processes. It was found that the different processing techniques resulted in significant differences in the mechanical behavior of the HX specimens.
JOURNAL OF ALLOYS AND COMPOUNDS
(2021)
Article
Nanoscience & Nanotechnology
Feipeng Yang, Jianying Wang, Tao Wen, Lei Zhang, Xixi Dong, Dong Qiu, Hailin Yang, Shouxun Ji
Summary: The AM aluminium alloy Al5Mg3Zn2Si developed in this work exhibits high strength, ductility, and excellent mechanical properties without the addition of costly alloying elements. With an optimized relative density and refined microstructure, it has great potential for automotive and aerospace applications.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
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
Kang-Hyun Lee, Gun Jin Yun
Summary: This study proposes an optimization methodology for designing a thermally conductive lattice support structure considering the layerwise heating and cooling in the PBF process. A numerical model with homogenized properties of lattice material is constructed using the temperature-thread multiscale modeling approach, and the equivalent static loads method is employed for sensitivity analysis. A novel concept of the normalized liquid lifetime contour is introduced to analyze the inhomogeneous cooling in PBF process. The proposed framework is validated through thermo-mechanical process analysis and experiment for a benchmark case.
ADDITIVE MANUFACTURING
(2022)
Article
Nanoscience & Nanotechnology
A. Kempf, K. Hilgenberg
Summary: This study investigated the effects of post process heat treatments on the mechanical properties of AlSi10Mg specimens manufactured with Laser Powder Bed Fusion. The study found that while strength properties could be homogenized through heat treatments, ductility properties were still affected by material defects. Even slight differences in porosity could significantly impact ductility properties.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Automation & Control Systems
Mahyar Khorasani, AmirHossein Ghasemi, Martin Leary, Laura Cordova, Elmira Sharabian, Ehsan Farabi, Ian Gibson, Milan Brandt, Bernard Rolfe
Summary: This research discusses the factors that affect the meltpool depth in laser-based powder bed fusion and proposes a methodology to estimate it using simulation and validation. The developed predictive analytical model accurately estimates the meltpool depth, saving time and cost in manufacturing tasks.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Karl Sofinowski, Mallory Wittwer, Matteo Seita
Summary: This research utilizes additive manufacturing to encode data into metal parts by controlling local solidification conditions and using different crystallographic texture blocks as data bits. The encoded data can be retrieved by measuring the scattering of optical light. This technology has significant potential applications in fields such as law enforcement, biomedicine, and transportation.
ADDITIVE MANUFACTURING
(2022)
Review
Materials Science, Multidisciplinary
A. Raja, Srinivasa Rakesh Cheethirala, Pallavi Gupta, Nilesh J. Vasa, R. Jayaganthan
Summary: This article reviews the interrelationship between LPBF process parameters, microstructure, crack initiation, and crack growth mechanisms under fatigue loading conditions. It highlights the importance of standardizing mechanical testing techniques, specimen design guidelines, and post-manufacturing treatments for improving the fatigue resistance of AlSi10Mg alloy. The influence of microstructural features and post-processing conditions on fatigue properties is discussed, along with the crack growth mechanism observed in LPBF processed material.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Automation & Control Systems
Marcus Watson, Martin Leary, Milan Brandt
Summary: Generative design automates component design, reducing lead times and improving efficiency. Topology optimization and shape optimization are suitable for automatic design phases, but challenges in parameterization hinder tool integration. A novel parameterization method is proposed to address this challenge, achieving automated design processes.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Review
Materials Science, Multidisciplinary
Joe Elambasseril, Jason Rogers, Chris Wallbrink, David Munk, Martin Leary, M. Qian
Summary: The design freedom offered by additive manufacturing (AM) enables the fabrication of components with internal surfaces that are challenging to access post-manufacture. This is of concern, as the surface condition can markedly deteriorate fatigue performance. It is therefore desirable to consider deploying AM parts with no or minimal surface processing for targeted applications.
CRITICAL REVIEWS IN SOLID STATE AND MATERIALS SCIENCES
(2023)
Article
Engineering, Manufacturing
Ilknur Ilhan, Roland ten Klooster, Ian Gibson
Summary: This study investigates the influence of talc compounds and different process parameters on sealant films. The results show that talc incorporation improves seal strength, high MFI fills the gaps at the seal interphase, and high film tension and contamination have negative effects on seal integrity.
PACKAGING TECHNOLOGY AND SCIENCE
(2023)
Article
Metallurgy & Metallurgical Engineering
Laura Cordova, Cindy Sithole, Eric Macia Rodriguez, Ian Gibson, Monica Campos
Summary: This study analyzed the characteristics of highly sensitive Ti6Al4V ELI powder commonly used in medical and aerospace applications, including morphology, particle size distribution, chemical composition, and flowability, before and after multiple build cycles. The results showed that the properties of the powder and builds remained consistent throughout the experiment, demonstrating the repeatability of industrial production of metal parts.
Article
Engineering, Civil
J. Noronha, M. Qian, M. Leary, E. Kyriakou, A. Almalki, S. Brudler, M. Brandt
Summary: This study establishes a robust LPBF additive manufacturability range for Ti-6Al-4V hollow struts by examining different parameters. Three laser scan strategies were explored and compared to achieve successful fabrication. The manufacturability of horizontal struts was evaluated by comparing them with solid struts and vertical hollow struts.
THIN-WALLED STRUCTURES
(2022)
Article
Automation & Control Systems
David Downing, Jason Rogers, Rance Tino, Joe Elambasseril, Chris Wallbrink, Ma Qian, Milan Brandt, Martin Leary
Summary: Surface roughness of complex additive manufactured lattice structures is difficult to evaluate with traditional methods. Computed tomography (CT) provides qualitative insight but does not directly yield roughness profile data. This research proposes a hybrid approach that uses mathematical reconstruction and interpretation of CT data to quantify roughness profile data for lattice structures. The method is verified and found to be minimally influenced by CT reconstruction thresholding, providing certainty for its industrial application. This method accurately characterizes the surface roughness and supports subsequent certification analysis.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Ilknur Ilhan, Martin van Drongelen, Roland ten Klooster, Ian Gibson
Summary: In this study, the effect of different ratios of talc on the rheological behavior of PP/PE-LD-based compound films was examined. The results showed that increased levels of talc are associated with elevated complex viscosities, storage and loss modulus, as well as increased seal strength. The minimum required dwell time for quality sealing can be predicted by considering the reptation time and heat conduction time during the sealing process.
PACKAGING TECHNOLOGY AND SCIENCE
(2023)
Article
Automation & Control Systems
Abduladheem Almalki, David Downing, Jordan Noronha, Jason Dash, Bill Lozanovski, Rance Tino, Ahmad Alghamdi, Mahyar Khorasani, Ma Qian, Milan Brandt, Martin Leary
Summary: This research proposes a method to characterize the impact of common LB-PBF powders and geometric design parameters on section properties of as-manufactured strut elements. Micro-computed tomography has been applied to algorithmically characterize the variation and identify a scale threshold below which additional geometric resolution does not influence the section properties. This methodology provides a robust and algorithmic design tool for additive manufacturing to characterize the effects of manufacturing and design parameters on the functional response of AM strut elements.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Mohammad Moallemi, Sung-Joon Kim, Abbas Zarei-Hanzaki, Ehsan Farabi
Summary: The present research focuses on the work hardening analysis of two types of high strength-high plasticity metastable duplex stainless steel (DSS) with different compositions (4Mn & 8Mn). The strain hardening rate (SHR) was observed in three stages (I, II, III) in both alloys, and the underlying mechanisms were investigated using TEM and EBSD analysis. The microstructural observations showed that the formation of e-martensite affected the slope of stage I in the 8Mn alloy, while the lower stacking fault energy (SFE) in the 4Mn alloy resulted in faster kinetics of e-martensite formation. The appearance of sustained stacking fault bands played a crucial role in enhancing work hardening and the mechanical properties of the 8Mn steel.
MATERIALS CHARACTERIZATION
(2023)
Article
Food Science & Technology
Ilknur Ilhan, Roland ten Klooster, Ian Gibson
Summary: Folding geometry and flexible package design lead to pressure differences during heat sealing, causing microchannels, leak formation, and difficulty in hermetic packaging. Pressure optimization based on package design improves seal integrity and prevents seal defects. Changing pressure at different sealing regions affects seal characteristics, and the optimum temperature and pressure levels differ for each critical seal region in multilayer packaging. Higher temperatures and pressures lead to seal damages and squeeze-out problems, while pressure increase positively influences seal integrity at mentioned critical regions. Visual observation confirms that changing pressure distribution along layer jumps causes wrinkles and increases squeeze-out problems. This research highlights the importance of pressure optimization in improving seal integrity and preventing food quality and safety issues.
FOOD PACKAGING AND SHELF LIFE
(2023)
Article
Engineering, Manufacturing
Ehsan Farabi, Thomas Klein, Martin Schnall, Sophie Primig
Summary: Cold metal transfer (CMT)-based wire-arc directed energy deposition (waDED) is a high-speed deposition process for manufacturing Ti-alloys with tailored properties. A new CMT high deposition rate strategy was found to improve microstructure and mechanical strength, reducing anisotropy.
ADDITIVE MANUFACTURING
(2023)
Article
Nanoscience & Nanotechnology
Ahmad Mirzaei, Peter D. Hodgson, Xiang Ma, Vanessa K. Peterson, Ehsan Farabi, Gregory S. Rohrer, Hossein Beladi
Summary: This study investigated the influence of parent austenite grain refinement on the intervariant boundary network in a lath martensitic steel. It found that refining the parent austenite grain led to a decrease in the fraction of certain boundaries in the martensite and an increase in the connectivity of low energy boundaries, ultimately improving the impact toughness.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2024)
Article
Optics
Mahyar Khorasani, AmirHossein Ghasemi, Martin Leary, David Downing, Ian Gibson, Elmira G. Sharabian, Jithin Kozhuthala Veetil, Milan Brandt, Stuart Bateman, Bernard Rolfe
Summary: This study proposes novel benchmarks to detect conduction and keyhole modes in Laser-Based Powder Bed Fusion (LB-PBF) of Inconel 718. These benchmarks help establish a process window for desirable part quality and improved mechanical properties. By controlling the transition from conduction to keyhole mode, the bonding quality can be enhanced.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Engineering, Biomedical
Tom Williamson, Stewart Ryan, Ulrich Buehner, Zac Sweeney, Dave Hill, Bill Lozanovski, Endri Kastrati, Arman Namvar, Thierry Beths, Darpan Shidid, Romane Blanchard, Kate Fox, Martin Leary, Peter Choong, Milan Brandt
Summary: This study assessed the combination of surgical robotics and patient-specific additively manufactured implants, demonstrating the ability for precise removal of complex bone volumes and accurate placement of implants.
INTERNATIONAL JOURNAL OF COMPUTER ASSISTED RADIOLOGY AND SURGERY
(2023)
Article
Engineering, Biomedical
Dave Hill, Tom Williamson, Chow Yin Lai, Martin Leary, Milan Brandt, Peter Choong
Summary: This study describes an automated approach for generating conformal bone tumor resection plans. The method optimizes the resection geometry, defined by the convex hull of the tumor, to minimize the volume of healthy bone collaterally resected with the tumor. The results show significant improvements compared to manual methods in reducing the collateral resection of healthy bone.
INTERNATIONAL JOURNAL OF COMPUTER ASSISTED RADIOLOGY AND SURGERY
(2023)