This paper describes an innovative 3D-printed beam-based lightweight structure that is used to increase the adhesion strength of metal-composite joints without damaging the composite fibers. It is conceived as the interface between the two parts to be joined: by filling the voids of this structure with resin, a mechanical interlocking effect can be generated to enhance the mechanical properties of

The development of Additive Manufacturing (AM) of polymer bonded Nd-Fe-B magnets has focused on increasing remanence (BR) and maximum energy-product ((BH)max) values. One possible approach is to increase the volumetric fraction of magnetic particles on the as-printed components. The present contribution strives to shed light on how the combination of feedstock characteristics and process parameters

Finite element analysis (FEA) has been widely adopted to identify potential defects in additive manufacturing (AM) processes. For personalized product realization, it is necessary to validate a number of heterogeneous product and process designs before or during manufacturing by using FEA. Multi-fidelity FEA simulations can be readily implemented with different capabilities in terms of simulation accuracy

A series of experiments were performed using a 500 W continuous wave fibre laser on a single powder bed layer using different processing variables. The aim was to investigate the effect of different shielding conditions on melting behaviour and bead profile in laser powder bed fusion (PBF). Through high-speed imaging, it was found that under an argon atmosphere a strong plasma plume is generated from

Additive manufacturing (AM) methods are being integrated in ceramics fabrication either as the main manufacturing tool or for auxiliary purposes. By using polymers, powders and preceramic formulated materials, AM techniques are pushing towards higher resolution, lower shrinkage and shorter building time. Herein, we present the fabrication of ceramic microstructures (<200 × 200 × 200 μm3) with sub-micrometer

Cyber-physical systems have been widely adopted in a number of industries, including healthcare, critical infrastructure, and manufacturing. The connectivity of machines, which characterizes cyber-physical systems and provides many of their benefits, leaves them vulnerable to cyber-attacks. Within manufacturing, cyber-attacks can compromise end-use parts, resulting in catastrophic part failure. Researchers

Three-dimensional (3D) printed highly conductive graphene-based nanocomposites have led to a paradigm shift in the development of flexible electronics as well as customized therapeutic devices. This article addresses the deployment and characterization of a piezoelectric-pneumatic material-jetting (PPMJ) additive manufacturing process to print graphene-based nanocomposites with 3D structures. Here

Titanium matrix composites (TMC) have potential applications in the aerospace industry because of their excellent performance. The comprehensive performance of TMC mainly depends on the matrix, reinforcement and interface characteristics. Hence, this study discussed the knowledge of microstructure-property relationships in detail. Crack-free high-mass-proportion TiCp/Ti6Al4Vcomposites were successfully

316 L stainless steel samples were built vertically (VB) and horizontally (HB) by selective pulsed laser melting. The microstructure of the as-fabricated samples was investigated using a range of characterisation techniques and the properties evaluated by tensile testing. It was found that at a relatively low laser power (200 W) pores evolved from lack-of-fusion pores to keyhole pores with increased

Currently, the laser powder bed fusion (L-PBF) process cannot offer a reproducible and predefined quality of the processed parts. Recent research on process monitoring focuses strongly on integrated optical measurement technology. Besides optical sensors, acoustic sensors also seem promising. Previous studies have shown the potential of analyzing structure-borne and air-borne acoustic emissions in

Spatter particles ejected from the melt pool after melting of 316 L stainless steel by laser powder bed fusion additive manufacturing (LPBF), were found to contain morphologies not observed in as-atomized 316 L powder. This spatter consisted of large, spherical particles, highly dendritic surfaces, particles with caps of accreted liquid, and agglomerations of multiple individual particles fixed together

The production of magnesium alloy WE43 was achieved by selective laser melting (SLM). The alloy was investigated after SLM, hot isostatic pressing (HIP), and solutionising heat treatment. The microstructure and corrosion behaviour of the specimens were carefully characterised, whilst assessed and contrast relative to the conventionally cast alloy counterpart. The SLM prepared specimens possess a unique

Ball-milled Ti/TiC composite particles (TiC nanoparticles assembled on Ti microparticles) were designed, prepared, and mixed with Al-Si-Mg powder to fabricate an Al-Si-Mg-Ti alloy with TiC nanoparticles (Al-Si-Mg-Ti/TiC) by selective laser melting (SLM). Microstructure features, solidification behavior, and mechanical properties were investigated, and the relationship among them was established. The

The origins of nano-scale oxide inclusions in 316 L austenitic stainless steel (SS) manufactured by laser powder bed fusion (L-PBF) was investigated by quantifying the possible intrusion pathways of oxygen contained in the precursor powder, extraneous oxygen from the process environment during laser processing, and moisture contamination during powder handling and storage. When processing the fresh

Titanium aluminide (TiAl) alloys are promising high-temperature structural materials in the aerospace field. Additive manufacturing is a desirable process for fabricating TiAl alloys. In the process of wire arc additive manufacturing of TiAl alloys, Al-based and Ti-based wires were used as the feedstocks. However, it is hard to ensure the two different wires melt synchronously under the heat of one

Advances in multi-material additive manufacturing have enabled advancements in the manufacture of composite materials. In this work, a family of thermite-based reactive materials is created and evaluated for the suitability as composite energetic structures. The burn rate with respect to binder ratio is observed to be highly predictable and exponential (coefficients of determination of rTi2=0.984 and

In this study, the heterogeneous anisotropic microstructure and mechanical properties of additively manufactured (CoCrFeMnNi)99C1 high-entropy alloy (HEA) are comprehensively investigated using experimental and theoretical analyses. For the present alloys, the selective laser melting (SLM) process produced orthogonally anisotropic microstructure with not only strong macroscopic morphological but also

Creation of pores and defects during laser powder bed fusion (LPBF) can lead to poor mechanical properties and thus must be minimized. Post-build inspection is required to ensure the printed parts contain acceptably low defect concentrations. These inspections are time consuming and costly, especially for large or complex parts. As a potential solution, in situ process monitoring can be used to detect

Droplet jetting behavior largely determines the final drop deposition quality in the inkjet printing process. Forming such behavior is governed by the fluid flow pattern. Therefore, a measurement of the flow pattern is of great importance for improving the printing quality of the inkjet printing process. Most of the current works use static images for the study of the drop evolution process. The problem

A finite element model of Laser Powder Bed Fusion (LPBF) process applied to metallic alloys at a mesoscopic scale is presented. This Level-Set model allows to follow melt pool evolution and track development during building. A volume heat source model is used for laser/powder interaction considering the material absorption coefficients, while a surface heat source is used to consider the high laser

In recent years, there have been rapid advances in our understanding of ceramic stereolithography (CSL) as a precise and high-resolution additive manufacturing (AM) technique to fabricate complex ceramic parts. This review highlights the theoretical background and engineering capabilities of CSL with an emphasis on photopolymerization of ceramic resins. We present certain constraints and characteristics

Rib-web structures are used for lightweight design in various applications. The most prominent cases are found in aerospace engineering, where intricate structures are produced by forging and subsequent machining or by machining from solid blocks of material. Due to the large scrap rate involved in conventional manufacturing, rib-web structures are suitable applications for additive manufacturing (AM)

Due to the layer-based nature of the powder bed fusion (PBF) process, part surfaces oriented in space at varying angles with respect to the build direction are differently affected by a wide array of manufacturing-induced phenomena (staircase effects, spatter, particles, etc.), which can significantly influence the functional behaviour of such surfaces, and choices for post-processing where needed

Material based actuation with metallic fibers, for example shape memory alloys (SMA) is gaining popularity to replace the conventional bulky actuators used for shape morphing in aerospace sectors. However, Joule heating arising from electrical actuation of SMA affects the interfacial bonding between the SMA and the composite matrix and thus reduces the life span of the structure. Insulating the SMA

This paper studies additive manufacturing oriented structural topology optimization with SIMP approach and aims at 3D high-resolution printable structural topology design with overhang and horizontal minimum length control for minimum compliance. To start with, we construct a hyperplane in ℝ4 by fitting a local element density distribution in the 18 Elements Scheme, use its gradient to estimate the

Cold spray (CS) residual stress was measured by the X-ray diffraction (XRD) and contour methods. The residual stress components SX and SY, perpendicular to the thickness, have similar distributions and approximately equal magnitudes. Both are compressive on the deposited surface and become tensile inside the structure. An advanced simulation model based on the arbitrary Lagrangian–Eulerian (ALE) method

Strategies for fabricating iron-based materials with high strength and ductility are rare despite intense research efforts within the last decades. This main challenge, which must be overcome in synthesizing such materials, is described by the strength-ductility trade-off dilemma. This study provides a novel approach to achieve the synthesis of highly strong and ductile iron-based composites reinforced

With the ever-increasing resolution of metal additive manufacturing processes, the ability to design and fabricate cellular or lattice structures is readily improving. While there are few limits to the variety of unit cell topologies that can feasibly be manufactured, there is little known about the effect that the underlying unit cell topology has on lattice structure mechanical performance. Increased

Dry Aerosol Deposition (DAD) is a ceramic coating process with the ability to build films and low profile 3D structures layer by layer and is therefore a promising additive manufacturing technique. DAD is unique because it uses kinetic energy rather than thermal energy for densification, and the result is a nearly theoretically dense, nano-crystalline ceramic. The main objectives of this work were

Fabry-Pérot ultrasonic metamaterials have been additively manufactured using laser powder bed fusion to contain subwavelength holes with a high aspect-ratio of width to depth. Such metamaterials require the acoustic impedance mismatch between the structure and the immersion medium to be large. It is shown for the first time that metallic structures fulfil this criterion for applications in water over

Additive manufacturing (AM) enables highly complex-shaped and functionally optimized parts. To leverage this potential the creation of part designs is necessary. However, as today’s computer-aided design (CAD) tools are still based on low-level, geometric primitives, the modeling of complex geometries requires many repetitive, manual steps. As a consequence, the need for an automated design approach

We present the results of 3D modeling of the laser and electron beam powder bed fusion process at the mesoscale with an in-house developed advanced multiphysical numerical tool. The hydrodynamics and thermal conductivity core of the tool is based on the lattice Boltzmann method. The numerical tool takes into account the random distributions of powder particles by size in a layer and the propagation

Laser powder bed fusion (LPBF) is an attractive technology of manufacturing highstrength aluminium alloy parts for the aircraft and automobile industries, limited by poor processability of these alloys. This work was aimed at finding the process window for the LPBF manufacturing of defect-free components of AA7075 alloy. Optimization of the parameters was performed at each stage of the multi-stage

This work aims to investigate the influence of the orientation and microtexture of columnar grains on the fatigue crack growth of a Ti-6.5Al-2Zr-Mo-V titanium alloy fabricated by directed energy deposition. In this paper, the fatigue crack growth rate test in three sampling directions in a directed energy deposited Ti-6.5Al-2Zr-Mo-V titanium alloy using compact specimens was carried out. The crack

Laser cladding induces high tensile residual stress (RS), which can compromise the quality of a specimen. Therefore, it is critical to accurately predict the RS distribution in cladding and understand its formation mechanism. In this study, functionally graded material (FGM) layers were successfully deposited on the surface of a titanium alloy Ti6Al4V sheet by laser cladding technology. A corresponding

This work refines surface registration methods for metrological datasets to improve the multi-method qualification accuracy of additively manufactured (AM) lattices. Datasets acquired from X-ray computed tomography and a coordinate measurement machine of an AM lattice were aligned using derived geometry datum features based on a theoretical supplemental surface definition, which has been established

The use of feedstocks from metal injection molding (MIM) for the additive manufacturing (AM) of green parts, which are then debound and sintered in a process called shaping, debinding, and sintering (SDS), is promising in terms of production costs of metallic parts. However, in order to use the cost-efficient AM technique fused filament fabrication (FFF) for SDS, powder-binder mixtures known for MIM

Extrusion-based printing frequently requires a hollowing step to remove material from inside of artifacts and subsequently reduce the amount of material, printing time, product weight, energy consumption, and ultimately, the cost. Here, we introduce a novel support-free hollowing method that uses an arrangement of vertically-aligned prolate spheroids. In addition to reducing stress concentration through

This paper explores the use of additive manufacturing as a low-cost method to integrate coaxial SubMiniature version A (SMA) connectors with waveguides operating at X-band. The integration of coaxial connectors into the filter and waveguide designs via 3D printing eliminates the need for two additional bulky external SMA-to-waveguide transitions, and allows for customizable integrated SMA-to-waveguide

The present paper aims to generate a deeper understanding of the influence of powder properties on the final parts manufactured by metal LPBF processes at constant parameter settings, except the hatch scanning speed. This issue was considered using four different AlSi10Mg powders. In addition to particle properties, such as particle size distribution and morphology, typical properties of the powder

A quasi-2D model of Micro-selective laser melting (μ-SLM) process using molecular dynamics is developed to investigate the localized melting and solidification of a randomly-distributed Aluminum nano-powder bed. One of the biggest challenges in modeling the μ-SLM process is the computational treatment of the formation and growth of crystal nuclei in the meltpool. The present work overcomes this challenge