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Fundamental Scaling Relationships in Additive Manufacturing and their Implications for Future Manufacturing and Bio-Manufacturing Systems Addit. Manuf. (IF 11.0) Pub Date : 2024-03-12 David M. Wirth, Chi Chung Li, Jonathan K. Pokorski, Hayden K. Taylor, Maxim Shusteff
The field of additive manufacturing (AM) has advanced considerably over recent decades through the development of novel methods, materials, and systems. However, as the field approaches a level of maturity, it is relevant to investigate emerging trends which may shed light on the fundamental scaling limits of AM systems to pattern matter from digital data. A simplified mathematical model which describes
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Effect of nitrogen atmosphere on the printability, microstructure, precipitation, and mechanical properties of laser powder bed fused Fe-xCr alloys Addit. Manuf. (IF 11.0) Pub Date : 2024-03-12 Siyuan Wei, Delvin Wuu, Verner Soh, Kwang Boon Lau, Fengxia Wei, Konstantinos A. Liogas, Baicheng Zhang, Qiang Zhu, Chee Koon Ng, Alexander M. Korsunsky, Pei Wang, Upadrasta Ramamurty
The role of the nitrogen atmosphere on the microstructure and tensile properties of laser powder bed fused (PBF-LB/M) Fe-Cr (=0, 5, 10, 15, 24wt.%, mixed using elemental Fe and pre-alloyed Fe-46 wt.% Cr powders) binary alloys was investigated and compared with those fabricated under an inert (argon) atmosphere. Microstructural characterization reveals the variations of grain morphology with the chemical
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Additive manufacturing for 3D microchannel structure using La(FexSi1-x)13 magnetic refrigerant via laser powder bed fusion Addit. Manuf. (IF 11.0) Pub Date : 2024-03-12 Kaoru Imaizumi, Asaya Fujita, Asuka Suzuki, Makoto Kobashi, Masaki Kato
The fabrication of a three-dimensional (3D) channel/pillar structure with a submillimeter scale using La(FeSi) magnetocaloric material was attempted via a laser powder bed fusion (LPBF) process to realize a regenerative bed for a room temperature magnetic refrigerator. The LPBF condition was found to govern not only the shaping conditions but also the metallographic structure in the as-fused state
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Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field simulations and computational thermal-fluid dynamics Addit. Manuf. (IF 11.0) Pub Date : 2024-03-11 Masayuki Okugawa, Kenji Saito, Haruki Yoshima, Katsuhiko Sawaizumi, Sukeharu Nomoto, Makoto Watanabe, Takayoshi Nakano, Yuichiro Koizumi
Solute segregation significantly affects material properties and is a critical issue in the laser powder-bed fusion (LPBF) additive manufacturing (AM) of Ni-based superalloys. To the best of our knowledge, this is the first study to demonstrate a computational thermal-fluid dynamics (CtFD) simulation coupled multi-phase-field (MPF) simulation with a multicomponent-composition model of Ni-based superalloy
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Ultrasonic Impact Treatment (UIT) Combined with Powder Bed Fusion (PBF) Process for Precipitation Hardened Martensitic Steels Addit. Manuf. (IF 11.0) Pub Date : 2024-03-11 R. Mazruee Sebdani, H.K. Bilan, J.D. Gale, J. Wanni, G. Madireddy, M.P. Sealy, A. Achuthan
High-strength martensitic stainless steels such as 17-4 PH (SS 17-4 PH) generally exhibit poor ductility and strain-hardening rates. In this study, an Ultrasonic Impact Treatment (UIT) is combined with a powder bed fusion (PBF) manufacturing process with the objective of enhancing the mechanical properties of SS 17-4 PH. UIT is introduced as a surface peening step at regular intervals during the PBF
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A review of multi-axis additive manufacturing: Potential, opportunity and challenge Addit. Manuf. (IF 11.0) Pub Date : 2024-03-11 Pengfei Tang, Xianfeng Zhao, Hongyan Shi, Bo Hu, Jinghu Ding, Buquan Yang, Wei Xu
The manufacturing of complex parts can be easily achieved by additive manufacturing (AM), which has attracted a significant attention from both academia and industry. Regardless of the shape of the model, the 3-axis AM techniques slice the model into a series of sections along the Z-axis and then use a fixed direction filling algorithm to plan the interiors of the sections. This approach greatly simplifies
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In-situ X-ray computed tomography of high-temperature tensile behavior for laser powder bed fused Invar 36 alloy Addit. Manuf. (IF 11.0) Pub Date : 2024-03-11 Qidong Yang, Kai Wei, Zhaoliang Qu, Xujing Yang, Daining Fang
The laser powder bed fusion (PBF-LB) process provides great potential for additive manufacturing of Invar 36 alloy, which possesses a unique low coefficient of thermal expansion. However, the high-temperature tensile behavior of PBF-LB processed Invar 36 alloy has not been explored, severely restricting its applications. Hence, herein, in-situ X-ray computed tomography (XCT) tensile tests were conducted
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Improving the processability and grain structures of additively manufactured Al-Fe-Cu-xZr alloy: experiment and high-fidelity simulation Addit. Manuf. (IF 11.0) Pub Date : 2024-03-08 Jing-Yu Xu, Wei-Hao Yuan, Cheng Zhang, Jie Pan, Shuo Yin, Hui Chen, Lin Liu
Additive manufacturing (AM) offers significant advantages over conventional manufacturing techniques in processing Al alloys, however, high-strength Al alloys produced by AM commonly encounter a few challenges including poor processability and undesirable microstructures with coarse columnar grains and even micro-cracks, leading to poor mechanical properties of the resultant Al alloys. Here, we demonstrate
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Vat photopolymerization 3D printing of yttria-stabilized ZrO2 ceramics: effects of a sintering additive (Na2O ̶ 2SiO2), biocompatibility, and osteointegration Addit. Manuf. (IF 11.0) Pub Date : 2024-03-08 S.V. Smirnov, P.V. Protsenko, M.A. Goldberg, T.O. Obolkina, O.S. Antonova, K.V. Malyutin, G.P. Kochanov, A.A. Konovalov, Iu.M. Nevolin, A.V. Volkov, S.A. Akhmedova, V.A. Kirsanova, I.K. Sviridova, N.S. Sergeeva, S.M. Barinov, V.M. Ievlev, V.S. Komlev
Effects of a liquid-phase sodium disilicate additive on the properties of ZrO ceramics containing 3mol.% of YO and 2wt.% of AlO are presented, including phase composition, microstructure, shrinkage, porosity, and bending strength. The distribution of elements along grain boundaries and the composition in a selected area of a lamella were investigated by transmission electron microscopy in pure and
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Plasma Evolution in Laser Powder Bed Fusion using a Double Pulse Format: Time-resolved Measurements and Physics-based Modeling Addit. Manuf. (IF 11.0) Pub Date : 2024-03-08 Mengchen Wu, Weidong Liu, Zahid Hussain Shah, Benxin Wu, Hanyu Song
A novel laser powder bed fusion (LPBF) process utilizing a special double-pulse format was previously proposed. In this process, typically two different types of laser pulses are fired alternatively in time: the low-intensity “sintering laser pulses” intended to melt and coalesce particles, followed by the high-intensity “pressing laser pulse(s)” intended to induce plasma to generate high pressure
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On the mechanism of binder migration in furan binder jetting of sand molds and cores Addit. Manuf. (IF 11.0) Pub Date : 2024-03-08 Christoph Hartmann, Jonas Silberhorn, Patricia Erhard, Daniel Günther
Binder Jetting is a layer-based additive manufacturing process in which a printhead deposits droplets onto a pre-prepared layer of particles. Upon droplet impact, the binder begins to migrate and infiltrate adjacent areas away from its originally intended location. The purpose of this study is to investigate the mechanism of furan binder migration. Observing in-situ binder spreading is challenging
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Novel Bulk Triaxial Residual Stress Mapping in an Additive Manufactured Bridge Sample by Coupling Energy Dispersive X-ray Diffraction and Contour Method Measurements Addit. Manuf. (IF 11.0) Pub Date : 2024-03-07 Nicholas A. Bachus, Maria Strantza, Bjørn Clausen, Christopher R. D’Elia, Michael R. Hill, J.Y. Peter Ko, Darren C. Pagan, Donald W. Brown
A novel approach for determining triaxial residual stress states by coupling energy dispersive X-ray diffraction and contour method measurements is provided and validated in a Ti-5Al-5V-5Mo-3Cr additive manufactured (AM) bridge sample. Synchrotron X-ray diffraction can provide relatively fine spatial resolution (on the order of 10 to 100µm) for mapping 3D elastic strain fields within a sample. However
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Corrigendum to “SmartScan: An intelligent scanning approach for uniform thermal distribution, reduced residual stresses and deformations in PBF additive manufacturing” [Addit. Manuf. 52 (2022) 102643] Addit. Manuf. (IF 11.0) Pub Date : 2024-03-07 Keval S. Ramani, Chuan He, Yueh-Lin Tsai, Chinedum E. Okwudire, Ehsan Malekipour
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Crystallographic texture and multiscale boundaries mediated creep anisotropy in additively manufactured Ni-based Hastelloy C276 superalloy Addit. Manuf. (IF 11.0) Pub Date : 2024-03-07 Zhijun Qiu, Hanliang Zhu, Zhiyang Wang, Ondrej Muránsky, Tao Wei, Elizabeth Budzakoska-Testone, Joel Davis, Andrew Studer, Qinfen Gu, Ulf Garbe, David Wexler, Huijun Li
The microstructure and high-temperature creep mechanisms of Ni-based Hastelloy C276 superalloy fabricated using wire and arc-based directed energy deposition were investigated systematically and innovatively. The microstructural investigation revealed that the as-fabricated samples comprise γ-Ni matrix and topologically close-packed (TCP) P phase precipitates. The γ matrix subgrains and grains are
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A novel magnetic field assisted powder arc additive manufacturing for Ti60 titanium alloy: Method, microstructure and mechanical properties Addit. Manuf. (IF 11.0) Pub Date : 2024-03-03 Kexin Kang, Yibo Liu, Huisheng Ren, Qinghua Zhang, Shiqing Wang, Yina Kong, Wenyuan Li, Jianrong Liu, Qingjie Sun
Due to the rapid heating-cooling process and unstable keyhole, pore defects are easily formed during the high energy beam-powder additive manufacturing (AM) process, posing great challenges to the high-performance manufacturing of aerospace components. Using an arc with lower energy density as a heat source can effectively avoid these defects, but its matching raw materials are limited to wire. In
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In-situ thermal control-assisted laser directed energy deposition of curved-surface thin-walled parts Addit. Manuf. (IF 11.0) Pub Date : 2024-02-29 Youyu Su, Gang Xu, Xiang Xu, Kaiyu Luo, Jinzhong Lu
Due to the single track-multilayered deposition structure and complex curvature, the curved-surface thin-walled components fabricated by laser directed energy deposition (LDED) would suffer from serious thermal accumulation effect problem. The slower cooling rate of melt pool leads to the collapse of components, which further affect the forming quality and overall performance. Therefore, an in-situ
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3D printed pyrography: Using wood filament and dynamic control of nozzle temperature for embedding shades of color in objects Addit. Manuf. (IF 11.0) Pub Date : 2024-02-29 Kongpyung (Justin) Moon, Jaeseong Yi, Valkyrie Savage, Andrea Bianchi
Colors enhance the esthetic and functional aspects of three-dimensional (3D) printed objects via material extrusion (MEX). However, existing 3D printing techniques require additional materials and hardware that are either challenging to calibrate or too costly for average 3D printing users. This paper presents a fabrication technique we call 3D printed pyrography, which enables printing multiple shades
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3D-printed thermoplastic polyurethane/polyvinylidene fluoride gradient stiffness and hierarchical cellular structures with tailored energy absorption behavior Addit. Manuf. (IF 11.0) Pub Date : 2024-02-28 Shuai Zhang, Yu Zhang, Xinyue Zhang, Chuan Yu, Kexin Xu, Jianbin Qin, Guangcheng Zhang, Xuetao Shi
Currently, designing materials and structures is the main means of improving their energy-absorption properties; however, optimization methods based on structural design can only be applied to specific structures. In this study, two optimization methods of energy-absorbing structures (EASs) are proposed from the material system and manufacturing method for fabricating gradient stiffness and hierarchical
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Inference of highly time-resolved melt pool visual characteristics and spatially-dependent lack-of-fusion defects in laser powder bed fusion using acoustic and thermal emission data Addit. Manuf. (IF 11.0) Pub Date : 2024-02-28 Haolin Liu, Christian Gobert, Kevin Ferguson, Brandon Abranovic, Hongrui Chen, Jack L. Beuth, Anthony D. Rollett, Levent Burak Kara
With a growing demand for high-quality fabrication, the interest in real-time process and defect monitoring of laser powder bed fusion (LPBF) has increased, leading manufacturers to incorporate a variety of online sensing methods including acoustic sensing, photodiode sensing, and high-speed imaging. However, real-time acquisition of high-resolution melt pool images in particular remains computationally
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Polypropylene for material extrusion: Evidence that flow-enhanced crystallization restricts welding Addit. Manuf. (IF 11.0) Pub Date : 2024-02-28 Zakarya Baouch, Riccardo Vezzoli, Jessy Koster, Andrea Costanzo, Andrea Lanfranchi, Dario Cavallo, Claire McIlroy
We present a comprehensive investigation into the effect that both the crystallization kinetics and the molecular weight of polypropylene feedstock have on the welding properties in material extrusion 3D-printing (MatEx). As sufficient welding at the interfaces between printed layers may be restricted by the onset of crystallization, there is a delicate balance between polymer interdiffusion and the
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Piezoelectric-pneumatic material jetting printing for non-contact conformal fabrication of high-temperature thick-film sensors Addit. Manuf. (IF 11.0) Pub Date : 2024-02-27 Xiong Zhou, Lida Xu, Lantian Tang, Xiaolong Lin, Xianwei Qian, Muhan Wu, Lingyun Wang, Chao Wu
Conformal printing of high-temperature thick-film sensors (TFSs) on intricate surfaces is crucial for precise integration and enhanced functionality. However, traditional contact printing faces challenges in terms of the complex motion control of 3D surfaces. With the core concept of non-contact printing, this study employs piezoelectric-pneumatic material jetting (PPMJ) to achieve rapid and uniform
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Numerical-assisted prediction model of layer height for Co-Cr-Ni-alloy direct energy deposition Addit. Manuf. (IF 11.0) Pub Date : 2024-02-27 Xu Li, Kanghong Zhu, Huabin Chen
During the L-DED multilayer stacking process, the molten pool dynamic behavior and liquid metal flow phenomenon still need to be clarified, hindering the optimization of cladding formation quality. Here, the molten pool overflow (MPO) phenomenon is defined from a theoretical analysis model and described through multi-source information sensing. We conduct a three-dimensional numerical model to reveal
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Phenolic carbon fiber composite inks for the additive manufacturing of carbon/carbon (C/C) Addit. Manuf. (IF 11.0) Pub Date : 2024-02-24 Caitlyn M. Clarkson, Connor Wyckoff, William Costakis, Andrew Abbott, Andrew Schlup, James W. Kemp, Lisa M. Rueschhoff, Matthew B. Dickerson, Hilmar Koerner
Additive manufacturing (AM) is a crucial development area for high temperature, inorganic and ceramic materials which, using conventional methods, are difficult to process into complex shapes. In particular, carbon/carbon (C/C) composites produced using AM techniques are underexplored compared to other ceramics and ceramic matrix composites. This work investigated and optimized the development of phenolic
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Four-Dimensional Printing of Polymer-Derived Ceramics with High-resolution, Reconfigurability, and Shape Memory Effects Addit. Manuf. (IF 11.0) Pub Date : 2024-02-23 Dekun Kong, Anfu Guo, Hailong Wu, Xunjin Li, Jingwen Wu, Yingbin Hu, Peng Qu, Shaoqing Wang, Shuai Guo
Owing to their high thermal stability, oxidation resistance, and corrosion resistance, polymer-derived ceramics (PDCs) have attracted extensive attentions to fabricate complex-shaped ceramic parts that can be used in high-tech industries. While flexible PDCs offer structural reconfiguration, methods for inducing shape changes primarily rely on mechanical loads, such as manual loading, motors, or pneumatic
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Predicting mechanical properties of 3D printed nanocomposites using multi-scale modeling Addit. Manuf. (IF 11.0) Pub Date : 2024-02-23 Roham Rafiee, Hadis Zehtabzadeh, Mohammad Reza Amini
The main objective of this research is to predict the Young’s modulus of 3D-printed specimens made of nanocomposites. Printable nanocomposites filaments reinforced with various portions of carbon nanotubes (CNTs) are produced at the first stage. At the second stage, extruded nanocomposite filaments are fed into a 3D desktop printer and tensile specimens are printed with two different infill patterns
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Layer thickness and path width setting in 3D printing of pre-impregnated continuous carbon, glass fibers and their hybrid composites Addit. Manuf. (IF 11.0) Pub Date : 2024-02-22 Shouling Ding, Bin Zou, Pin Zhang, Qingyang Liu, Yuexi Zhuang, Zhiwei Feng, Fengchen Wang, Xinfeng Wang
3D printing has been successfully applied in the manufacturing of variety continuous fiber and hybrid fiber reinforced composites. The process parameters have a significant impact on the overall performance of the printed parts. This paper investigates the effects of layer thickness and path width on the bending strength and surface roughness of printed pre-impregnated continuous carbon fiber, glass
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Micro-fabrication of Glassy Carbon with Low Shrinkage and High Char Yield using High-performance Photocurable Phthalonitrile (PN) Resins Addit. Manuf. (IF 11.0) Pub Date : 2024-02-20 Yong Lu, Jingdan Hu, Kok Wei Joseph Ng, Xiao Hu
Glassy carbons (GCs) are a significant class of materials that have attracted considerable attention in many scientific and technical fields due to their great thermal and chemical stability, excellent biocompatibility, and remarkable thermal and electrical conductivity. However, the thermal resistance and brittle nature of GCs pose limitations on their processing using conventional techniques such
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Corrigendum to “Thermal conductivity of three-dimensional multi-material core-shell filament structures obtained by material extrusion” [Addit. Manuf. (2024) 104018] Addit. Manuf. (IF 11.0) Pub Date : 2024-02-19 L. Moreno-Sanabria, C. Ramírez, M.I. Osendi, M. Belmonte, P. Miranzo
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Anisotropy of microstructure, mechanical properties and thermal expansion in Invar 36 alloy fabricated via laser powder bed fusion Addit. Manuf. (IF 11.0) Pub Date : 2024-02-17 Guoliang Huang, Gongming He, Ying Liu, Ke Huang
Invar 36 is a renowned iron-nickel alloy with an ultra-low coefficient of thermal expansion (CTE), which is widely used in aerospace and precision instruments. Laser powder bed fusion (LPBF) as a prevalent metal additive manufacturing technique could break through the limitations of traditional processes, such as low material utilization and difficulties in forming complex structures. In this work
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UV-assisted Robotic Arm Freeforming of SiOC Ceramics from a Preceramic Polymer Addit. Manuf. (IF 11.0) Pub Date : 2024-02-17 Kai Huang, Anna De Marzi, Giorgia Franchin, Paolo Colombo
Material extrusion is a very common and facile additive manufacturing technique for ceramic materials, allowing for rapid design and fabrication of 3D structures without expensive tools. However, fabricating sophisticated structures with large spanning parts and overhanging features using this technology is still a challenge. Here, UV-assisted additive manufacturing is enabled by performing material
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Adamantane-based low-dielectric-constant photocurable resin for 3D printing electronics Addit. Manuf. (IF 11.0) Pub Date : 2024-02-17 Jhu-Lin You, I.-Tseng Liu, Yu-Ho Chen, Ramachandran Balaji, Shih-Huang Tung, Ying-Chih Liao
In this work, a novel formulation is developed to prepare photocurable polyurethane acrylate (PUA) resin with a low dielectric constant for 3D printing applications. To amend the deficient electronic properties of regular 3D printed PUA materials, a symmetric polymer structure 1,3-adamantanediol (ADO) is introduced into the PUA polymer matrix to effectively decrease the dielectric constant. A low dielectric
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Exceptional mechanical performance by spatial printing with continuous fiber: Curved slicing, toolpath generation and physical verification Addit. Manuf. (IF 11.0) Pub Date : 2024-02-16 Guoxin Fang, Tianyu Zhang, Yuming Huang, Zhizhou Zhang, Kunal Masania, Charlie C.L. Wang
This work explores a spatial printing method to fabricate continuous fiber-reinforced thermoplastic composites (CFRTPCs), which can achieve exceptional mechanical performance. For models giving complex 3D stress distribution under loads, typical planar-layer based fiber placement usually fails to provide sufficient reinforcement due to their orientations being constrained to planes. The effectiveness
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Drop and hump behaviors in robotic arc-directed energy deposition with vertical position Addit. Manuf. (IF 11.0) Pub Date : 2024-02-16 Hongbo Liu, Siyang Wang, Hui Chen, Jun Xiong
Arc-directed energy deposition (Arc-DED) with the vertical position offers significant potential for in-situ fabrication of overhang structures. However, the vertical position application is seriously hindered by drop and hump defects since Arc-DED possesses serious heat accumulation resulting from multi-layer depositions. The novelty of this study is to reveal the formation mechanisms of drop and
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New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing Addit. Manuf. (IF 11.0) Pub Date : 2024-02-16 Abhinav Priyadarshi, Shazamin Bin Shahrani, Tomasz Choma, Lukasz Zrodowski, Ling Qin, Chu Lun Alex Leung, Samuel J. Clark, Kamel Fezzaa, Jiawei Mi, Peter D. Lee, Dmitry Eskin, Iakovos Tzanakis
Ultrasonic atomization is one of the promising technologies for producing metal powders for additive manufacturing, where precise control of particle size and morphology is essential. In this study, we coupled an ultrasonic transducer with a carbon fibre plate and atomized liquid droplets and films under different vibration amplitudes. Water, glycerol, and pure aluminium melt were used to study the
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Additive manufacturing of thermoplastic elastomer structures using dual material core-shell filaments Addit. Manuf. (IF 11.0) Pub Date : 2024-02-15 Nikhil A. Patil, Kartik Joshi, Juhyeong Lee, Kenneth E. Strawhecker, Ryan Dunn, Timothy Lawton, Eric D. Wetzel, Jay Hoon Park
Filament-based flexible material extrusion additive manufacturing is highly desirable yet faces critical challenges such as limited print resolution and repeatability. To enhance printability of a thermoplastic elastomer (TPE), a series of core-shell filaments comprising a TPE shell (Shore hardness 75 A) and a rigid ABS core are fabricated, with the ABS volume fraction varying from 11% to 78%. The
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3D-printed bioinspired cage lattices with defect-tolerant mechanical properties Addit. Manuf. (IF 11.0) Pub Date : 2024-02-15 Haoming Yang, Xiaofei Cao, Yao Zhang, Ying Li
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Analytical modelling of scanning strategy effect on temperature field and melt track dimensions in laser powder bed fusion Addit. Manuf. (IF 11.0) Pub Date : 2024-02-14 Pramod R. Zagade, B.P. Gautham, Amitava De, Tarasankar DebRoy
The manufacture of defect-free and dimensionally accurate parts in laser powder bed fusion (LPBF) is influenced by temperature field, deposited track geometry, and process-induced thermomechanical stress. The selection of an appropriate scanning strategy is key to achieving this goal. Well-tested numerical models of heat transfer and thermal stress are possible routes to design for the LPBF process
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In-situ qualification and physics-based process design for aerosol jet printing via spatially correlated light scattering measurements Addit. Manuf. (IF 11.0) Pub Date : 2024-02-13 Jeremy D. Rurup, Ethan B. Secor
Aerosol jet printing is a contactless, digital, and additive technique broadly used for manufacturing flexible, hybrid, and conformal electronics. However, both intra-batch and batch-to-batch variability have hindered widespread industry adoption and scaling to production volumes. Recently, light scattering measurements have emerged as a tool to measure aerosol volume fraction – a key parameter determining
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Integration of a Needle Valve Mechanism with Cura Slicing Software for Improved Retraction in Pellet-Based Material Extrusion Addit. Manuf. (IF 11.0) Pub Date : 2024-02-13 Luka Morita, Asad Asad, Xiaoruo Sun, Mehnab Ali, Dan Sameoto
Fused granular fabrication (FGF) is a cost-effective and increasingly popular additive technology that enables the production of parts using a wide range of exotic materials that are not typically available with material extrusion additive manufacturing. This paper presents a novel needle valve approach for flow control in a FGF system that uses flexibly connected screw extruders. The addition of a
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In situ synthesis of titanium alloy powders reinforced with nanoparticles for powder bed fusion: A step towards safer and more sustainable manufacturing Addit. Manuf. (IF 11.0) Pub Date : 2024-02-13 Luis Portolés, José-Ramón Blasco, José-Manuel Martín, Nerea Burgos, Marco Borghetto, Alexander Zoz, Norbert Ludwig, Tomaso Maccio, M.D. Marcos, J.A. García-Manrique, Lorenzo Solano
Additive manufacturing technologies for metallic materials based on powder bed fusion, either with electron (PBF-EB/M) or laser beam (PBF-LB/M) have enormous industrial potential. It is known that the reinforcement of nanoparticles in the metallic matrix improves the mechanical properties. This study presents a novel method for manufacturing reinforced powder particles for PBF technology. The method
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Detection of defects during laser-powder interaction by acoustic emission sensors and signal characteristics Addit. Manuf. (IF 11.0) Pub Date : 2024-02-13 Jun Young Song, Adrita Dass, Atieh Moridi, Gregory C. McLaskey
Acoustic Emission (AE) is an in-situ real-time nondestructive monitoring method proposed for Additive Manufacturing (AM) to detect defects such as cracks. Previous AE research in AM mainly focused on developing algorithms to automatically detect the defects from AE signals without understanding the physical mechanisms or the signal characteristics that could be used as identifiers. We study AE signals
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Additive manufacturing of carbon steel with site-specific compositions and properties using binder jetting and spark plasma sintering Addit. Manuf. (IF 11.0) Pub Date : 2024-02-10 Po-Ju Chiang, Li Sun, Li Ping Tan, Jonathan Singham, Yida Zhao, Huanlong Hu, Khor Khiam Aik, R.V. Ramanujan, John Samuel Dilip Jangam, Chang Quan Lai
The rational variation of properties with location in a unitized component can confer highly desirable traits such as site-specific mechanical properties. To achieve voxel level control throughout the 3D printed part, we employed binder jet 3D printing to deposit carbon in selected regions of each layer of the steel powder bed. The printed green part was then de-binded and densified using Spark Plasma
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Precision flow rate control during micro-scale material extrusion by iterative learning of pressure-flow rate relationships Addit. Manuf. (IF 11.0) Pub Date : 2024-02-09 Kevin T. Estelle, B. Arda Gozen
Despite its low-cost and broad material capability, material extrusion-based additive manufacturing suffers from low process resolution and dimensional accuracy, due to challenges with precisely controlling the ink flow rate during the printing process, particularly while using small nozzles and complex inks. In this paper, we present a novel approach to control the ink flow rate by utilizing (1) a
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Super elastic-plastic behavior of the surface grooves resulting in tensile anisotropy of 3D-printed elastomers Addit. Manuf. (IF 11.0) Pub Date : 2024-02-09 Xiang Lin, Shuang Wu, Dongrui Wang, Min Gong, Liang Zhang, Yao Liu, Liqun Zhang, Yonglai Lu, Runguo Wang
It is popularly acknowledged that additively manufactured polymer parts normally demonstrate mechanical anisotropy owing to their layer-wise characteristics with insufficient interface bonding. For 3D-printed rigid thermoplastic objects, such anisotropy has been largely reduced or even eliminated by accurately measuring the actual load-bearing area using microscopy technology. However, this method
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Influencing mechanisms of melt behavior on metal vapor characteristic and columnar grain formation in wire-arc directed energy deposition of titanium alloy Addit. Manuf. (IF 11.0) Pub Date : 2024-02-08 Xiao Xiao, Dongsheng Wu, Hisaya Komen, Lingran Meng, Wang Zhang, Pengkang Zhao, Shinichi Tashiro, Anthony B. Murphy, Manabu Tanaka
The metal vapor characteristic and columnar grain formation, influenced by the melt behavior in wire-arc directed energy deposition (WA-DED) of titanium alloy, have great effects on the tungsten electrode contamination and component performance. In this study, a spectroscopic system was adopted to measure the arc temperature and metal vapor distributions, and a multi-physical wire-melt pool model was
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Electromagnetic assistance enables 3D printing of silicone-based thin-walled bioinspired soft robots Addit. Manuf. (IF 11.0) Pub Date : 2024-02-08 G. Stano, A. Pricci, A. Pavone, G. Percoco
Material Extrusion (MEX) is emerging as the leading manufacturing method for fabricating complex silicone structures and is demanded in different fields such as soft robotics, space exploration, and biomedicine. At the state-of-the-art level, the fabrication of small-scale silicone structures (low value of layer height parameter) remains challenging owing to the high printing forces involved. In this
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Tomographic eigenstrain reconstruction for full-field residual stress analysis in large scale additive manufacturing parts Addit. Manuf. (IF 11.0) Pub Date : 2024-02-07 Fatih Uzun, Hector Basoalto, Konstantinos Liogas, Mohamed Fares Slim, Tung Lik Lee, Cyril Besnard, Zifan Ivan Wang, Jingwei Chen, Igor P. Dolbnya, Alexander M. Korsunsky
Current experimental and numerical quantification methods are limited in their ability to full-field mapping of the unpredictable distribution of all residual stress and permanent plastic strain components in additive manufacturing parts with discontinuous processing properties. To address this limitation, a tomographic eigenstrain (inherent strain) reconstruction method, that merges eigenstrain reconstruction
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Comprehensive numerical investigation of laser powder bed fusion process conditions for bulk metallic glasses Addit. Manuf. (IF 11.0) Pub Date : 2024-02-06 Zerong Yang, Matthias Markl, Carolin Körner
The successful application of laser powder bed fusion (PBF-LB/M) for fabricating bulk metallic glass (BMG) parts heavily relies on the development of effective process strategies. An optimal process strategy for BMGs is required to go beyond manufacturing defect-free parts and address the critical aspect of minimizing crystallization. However, traditional trial-and-error experimental methods for process
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On the thermal emissive behavior of four common alloys processed via powder bed fusion additive manufacturing Addit. Manuf. (IF 11.0) Pub Date : 2024-02-05 César A. Terrazas-Nájera, Alfonso Fernández, Ralph Felice, Ryan Wicker
Current thermal monitoring methods used in metal powder bed fusion (PBF) additive manufacturing (AM) rely on knowledge of the emissivity, which is usually assumed temperature, wavelength, and time invariant. Given the true dynamic nature of emissivity for a given material, these assumptions result in the calculation of inaccurate process temperatures, or in the reporting of radiant intensity or radiance
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Dissolution of the Laves phase and δ-precipitate formation mechanism in additively manufactured Inconel 718 during post printing heat treatments Addit. Manuf. (IF 11.0) Pub Date : 2024-02-05 Vivek Kumar Singh, Debaraj Sahoo, Murugaiyan Amirthalingam, Shyamprasad Karagadde, Sushil K. Mishra
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Limits of dispersoid size and number density in oxide dispersion strengthened alloys fabricated with powder bed fusion-laser beam Addit. Manuf. (IF 11.0) Pub Date : 2024-02-04 Nathan A. Wassermann, Yongchang Li, Alexander J. Myers, Christopher A. Kantzos, Timothy M. Smith, Jack L. Beuth, Jonathan A. Malen, Lin Shao, Alan J.H. McGaughey, Sneha P. Narra
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Isotropic cellular structure design strategies based on triply periodic minimal surfaces Addit. Manuf. (IF 11.0) Pub Date : 2024-01-30 Stephen Daynes
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Grain structure and texture selection regimes in metal powder bed fusion Addit. Manuf. (IF 11.0) Pub Date : 2024-02-03 Matt Rolchigo, John Coleman, Gerry L. Knapp, Alex Plotkowski
Additive manufacturing (AM) offers opportunities to produce complex part geometries not possible with conventional processing and in some cases even improve part performance. However, adoption has been slowed by difficulties assessing microstructure variability, and there is no straightforward approach to relate processing to grain structure characteristics. In this study, datasets from AdditiveFOAM
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Extended finite element multiscale modelling for crack propagation in 3D-printed fibre-reinforced concrete Addit. Manuf. (IF 11.0) Pub Date : 2024-02-03 Vuong Nguyen-Van, Phuong Tran, Junli Liu, Mien Van Tran, Yi Min Xie
Fracture toughness provides a quantifiable means of evaluating the ability of brittle materials, such as concrete, to withstand crack propagation. This is particularly relevant in the emerging field of 3D concrete printing. In this study, the influence of various pitch angles ranging from 0 to 90 and the number of layers (10 and 15 layers) on the fracture behaviour of the Bouligand beams is numerically
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Thermal conductivity of three-dimensional multi-material core-shell filament structures obtained by material extrusion Addit. Manuf. (IF 11.0) Pub Date : 2024-02-03 L. Moreno-Sanabria, C. Ramírez, M.I. Osendi, M. Belmonte, P. Miranzo
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Directed energy deposition of Al-Mg-Si alloys with fully-equiaxed microstructure and isotropic high strength/ductility Addit. Manuf. (IF 11.0) Pub Date : 2024-02-03 Wenzhe Li, Shiwei Pan, Yichao Zhu, Feng Qian, Yaojian Liang, Shun Xu, Xingwang Cheng
Al-Mg-Si alloys fabricated by additive manufacturing (AM) are known to suffer from the coarse columnar microstructure, which usually causes severe hot cracking and anisotropy in mechanical properties. Introducing potent nucleants to promote columnar to equiaxed transition (CET) is an efficient method to solve this problem. However, nanoscale nucleant particles are prone to agglomerate and form clusters
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FloatArch: A cable-supported, unreinforced, and re-assemblable 3D-printed concrete structure designed using multi-material topology optimization Addit. Manuf. (IF 11.0) Pub Date : 2024-02-02 Yu Li, Hao Wu, Xinjie Xie, Liming Zhang, Philip F. Yuan, Yi Min Xie
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An experimental and modeling study on warping in additively manufactured overhang structures Addit. Manuf. (IF 11.0) Pub Date : 2024-02-02 Xuesong Gao, Fernando Okigami, Nicholas Avedissian, Wei Zhang
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Design, testing, and application of an open-source powder material extrusion 3D printer Addit. Manuf. (IF 11.0) Pub Date : 2024-02-02 Xinyu Miao, Kyle C.H. Chin, Andrew J. Boydston
Powder material extrusion (PME) additive manufacturing (AM) is a convenient and practical method to study novel materials by circumventing the need for filamentation or compounding of materials. Avoiding additional processing steps can be an enabler for research with exploratory materials or those that otherwise display thermal instabilities. In this work, we present the design, development, and testing
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Strong yet ductile refractory high entropy alloy fabricated via additive manufacturing Addit. Manuf. (IF 11.0) Pub Date : 2024-02-02 Yongyun Zhang, Bailiang Qin, Di Ouyang, Lin Liu, Chuangshi Feng, Yuqiang Yan, Shulong Ye, Haibo Ke, K.C. Chan, Weihua Wang
Refractory high-entropy alloys (RHEA), particularly those with a body-centered cubic lattice structure, are garnering increased interest due to their potential industrial applications. However, their strength-ductility trade-off at room temperature presents a challenge that requires resolution. In this study, we fabricated a ductile TiHfNbV RHEA for additive manufacturing using a directed energy deposition