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Direct observation of pore formation mechanisms during LPBF additive manufacturing process and high energy density laser welding
摘要： Laser powder bed fusion (LPBF) is a 3D printing technology that can print parts with complex geometries that are unachievable by conventional manufacturing technologies. However, pores formed during the printing process impair the mechanical performance of the printed parts, severely hindering their widespread application. Here, we report six pore formation mechanisms that were observed during the LPBF process. Our results reconfirm three pore formation mechanisms - keyhole induced pores, pore formation from feedstock powder and pore formation along the melting boundary during laser melting from vaporization of a volatile substance or an expansion of a tiny trapped gas. We also observe three new pore formation mechanisms: (1) pore trapped by surface fluctuation, (2) pore formation due to depression zone fluctuation when the depression zone is shallow and (3) pore formation from a crack. The results presented here provide direct evidence and insight into pore formation mechanisms during the LPBF process, which may guide the development of pore elimination/mitigation approaches. Since certain laser processing conditions studied here are similar to the situations in high energy density laser welding, the results presented here also have implications for laser welding.
关键词： Pore formation,Laser powder bed fusion,X-ray imaging,Laser welding,Additive manufacturing
更新于2025-09-23 15:21:01
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A method for energy modeling and simulation implementation of machine tools of selective laser melting
摘要： Additive manufacturing (AM) technologies are providing promising solutions to production of unique parts at reduced material and energy consumptions. However, recent studies show that the sustainable advantage of AM is not always achieved. For ensuring the sustainability of the AM processes, quantification and assessment of the levels of resource consumptions should be carried out at the design phase. To enable the energy prediction and evaluation of AM, this work proposes a method for energy modeling and simulation implementation of AM machines and applies the method to a machine tool of selective laser melting (SLM). Furthermore, the developed simulation approach is validated using an experimental comparison and has been applied in a use case to realize an energy efficiency-oriented AM process design.
关键词： bond graph,energy simulation,selective laser melting,additive manufacturing,power flow modeling
更新于2025-09-23 15:21:01
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Analytical Modeling of Residual Stress in Laser Powder Bed Fusion Considering Parta??s Boundary Condition
摘要： Rapid and accurate prediction of residual stress in metal additive manufacturing processes is of great importance to guarantee the quality of the fabricated part to be used in a mission-critical application in the aerospace, automotive, and medical industries. Experimentations and numerical modeling of residual stress however are valuable but expensive and time-consuming. Thus, a fully coupled thermomechanical analytical model is proposed to predict residual stress of the additively manufactured parts rapidly and accurately. A moving point heat source approach is used to predict the temperature ?eld by considering the e?ects of scan strategies, heat loss at part’s boundaries, and energy needed for solid-state phase transformation. Due to the high-temperature gradient in this process, the part experiences a high amount of thermal stress which may exceed the yield strength of the material. The thermal stress is obtained using Green’s function of stresses due to the point body load. The Johnson–Cook ?ow stress model is used to predict the yield surface of the part under repeated heating and cooling. As a result of the cyclic heating and cooling and the fact that the material is yielded, the residual stress build-up is precited using incremental plasticity and kinematic hardening behavior of the metal according to the property of volume invariance in plastic deformation in coupling with the equilibrium and compatibility conditions. Experimental measurement of residual stress was conducted using X-ray di?raction on the fabricated IN718 built via laser powder bed fusion to validate the proposed model.
关键词： residual stress prediction,IN718,additive manufacturing,experimental measurement of residual stress
更新于2025-09-23 15:21:01
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A New 4 ?? 4 Rectangular Waveguide Short-Slot Coupler in 3D Printed Technology at Ku-Band
摘要： This paper presents a novel design of an eight-port directional coupler with a very compact structure and simple manufacturing, working in the Ku frequency band. One of the main goals of the design was to ease the manufacturing with a simple structure: the coupler consisted of four rectangular waveguide input ports, four rectangular waveguide output ports, and a central coupling region with only H-plane variation. A prototype was fabricated using additive manufacturing, with a combination of 3D printing and silver coating metallization. The obtained performance showed a theoretical bandwidth of 6.6% with 20 dB return loss for the input/output ports. Good agreement between simulations and measurements was obtained, validating the proposed coupler as a good trade-off for low cost 3D printing, compactness, and high performance for systems requiring a high number of ports as in phase arrays or Butler matrices.
关键词： rectangular waveguide,Riblet-type coupler,directional couplers,additive manufacturing
更新于2025-09-23 15:21:01
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[ASME ASME 2018 Conference on Smart Materials, Adaptive Structures and Intelligent Systems - San Antonio, Texas, USA (Monday 10 September 2018)] Volume 2: Mechanics and Behavior of Active Materials; Structural Health Monitoring; Bioinspired Smart Materials and Systems; Energy Harvesting; Emerging Technologies - Manufacture of Lenses and Diffraction Gratings Using DLP As an Additive Manufacturing Technology
摘要： This document condenses the results obtained when 3D printing lenses and their potential use as diffraction gratings using Digital Light Processing (DLP), as an additive manufacturing technique. This project investigated the feasibility of using DLP additive manufacturing for producing custom designed lenses and gratings. DLP was identified as the preferred manufacturing technology for gratings fabrication. Diffraction gratings take advantage of the anisotropy, in additive manufacturing processes, to produce a collated pattern of multiple fringes on a substrate with completely smooth surfaces. The gratings are transmissive and were manufactured with slit separations of 10, 25 and 50 μm. More than 50 samples were printed at various build angles and mechanically treated for maximum optical transparency. The variables of the irradiance equation were obtained from photographs taken with an optical microscope. These values were used to estimate theoretical irradiance patterns of a diffraction grating and compared against the experimental 3-D printed grating. The resulting patterns were found to be remarkably similar in amplitude and distance between peaks when compared to theoretical values.
关键词： 3D printing,lenses,Digital Light Processing (DLP),additive manufacturing,diffraction gratings
更新于2025-09-23 15:21:01
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Drug-releasing Biopolymeric Structures Manufactured via Stereolithography
摘要： Additive manufacturing (AM) techniques, such as stereolithography (SLA), enable the preparation of designed complex structures. AM has gained interest especially in the tissue engineering field due to the possibility to manufacture patient specific implants. However, AM could be useful also in controlled drug release applications, since the size and shape of the device, pore architecture and surface to volume ratio can be accurately designed. In this study, SLA was used to prepare polycaprolactone scaffold structures containing the model drug lidocaine. The release of lidocaine was studied and the influence of porosity and surface to volume ratio of structures to the drug release was analyzed. Porous samples released lidocaine faster compared to solid ones, whereas the degree of porosity and surface to volume ratio did not have a clear effect on the drug release profile.
关键词： drug delivery,stereolithography,additive manufacturing,drug release,lidocaine,scaffold,controlled release,polycaprolactone
更新于2025-09-23 15:21:01
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Application of Atom Probe Tomography to Complex Microstructures of Laser Additively Manufactured Samples
摘要： Additive Manufacturing (AM) technologies have gained increasing interest across multiple industrial sectors ranging from biomedical to aerospace. AM is not only used for prototyping, but also for tooling as well as for final part production. The computer-controlled, layer-by-layer building up process allows for increased design freedom enabling to produce almost any shape. Additional benefits are potential resource efficiency, increased product customization and lightweight design. Two prominent metal-based laser AM (LAM) techniques are laser powder bed fusion (LPBF) and laser metal deposition (LMD). In LPBF, a focused laser beam is scanned over a bed filled with metal powder to locally melt and fuse the powder to produce fully dense metal parts. The next layer of powder is then distributed and the laser scans again. LMD is a nozzle-based AM process in which a focused laser beam creates a melt pool in the build’s surface. Metallic powder is then injected into the melt pool through a nozzle. The 3D part is built by moving the nozzle/laser assembly forward track by track and layer by layer. Material produced by LAM exhibits a unique thermal history: initially, the material is cooled rapidly from the liquid state in the meltpool. Subsequently, the material experiences a cyclic reheating, the so-called intrinsic heat treatment (IHT), as neighboring tracks and further layers are deposited during the LAM process. Consequences of this thermal history are very complex, sometimes hierarchical microstructures with inhomogeneities at scales ranging from nanometers up millimeters. Fully understanding and characterizing these microstructures is challenging and requires the combination of methods spanning a similar range: from light optical microscopy (LOM) to electron microscopy to atom probe tomography (APT). Here we present examples how APT can deliver valuable information on complex microstructures to better understand the IHT, rapid solidification as well as phase separation in different metallic alloys. Here I will discuss examples in steel, Al- and Ni-based superalloys, and high entropy alloys (HEA).
关键词： Laser Additive Manufacturing,Additive Manufacturing,Phase Separation,Microstructures,Atom Probe Tomography,Rapid Solidification,Intrinsic Heat Treatment
更新于2025-09-23 15:19:57
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Laser Enhanced Direct Print Additive Manufacturing of Embedded Circular Cross-Section Optical Fiber Interconnects for Board Level Computing Devices
摘要： Integrated photonics have many compelling advantages for computing and communication applications, including in high-speed and extremely wide bandwidth operations. Current systems are typically hybrid assemblies of packaged photonic devices where printed circuit boards often serve to route electrical signals and power, and in some cases, have runs of optical fibers. We present a flexible, low cost assembly method of optical interconnects for photonic systems that could enable higher transmission rates, lower power requirements, improved signal integrity and timing, less heat generation, and improved security of communication signals. The new process is based on laser enhanced direct print additive manufacturing (LE-DPAM) that combines fused deposition modeling (FDM) of plastic, micro-dispensing of rubber-like materials, and picosecond laser subtraction. The process is demonstrated by fabricating few-mode and multi-mode optical fibers in a controlled manner such that compact, 3-dimensional optical interconnects can be printed along non-lineal paths. We have produced working optical interconnects with fiber core diameters from 70-μm to as small as 12-μm. Our results demonstrate surface roughness of less than 100 nm, and optical transmitted power of 63% that of a commercial fiber, for proof of concept devices. We anticipate these devices to be a starting point in the development of more sophisticated electro-optical computing devices using this new LE-DPAM technique. The LE-DPAM approach could lead to large scale integrated photonic computing devices that would replace our current generation of servers, computers, and phones.
关键词： 3D printing,Optical fiber interconnects,Additive manufacturing,Laser enhanced direct print additive manufacturing
更新于2025-09-23 15:19:57
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Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion; Herstellung von Produktionswerkzeugen mittels additiver Fertigung durch laserbasiertes Pulverbettschmelzen;
摘要： This paper deals with the design and production of stamping tools and dies for sheet metal components and injection molds for plastic components. Laser-based Powder Bed Fusion (LPBF) is the additive manufacturing method used in this investigation. Solid and topology optimized stamping tools and dies 3D-printed in DIN 1.2709 (maraging steel) by LPBF are approved/certified for stamping of up to 2-mm thick hot-dip galvanized DP600 (dual-phase steel sheet). The punch in a working station in a progressive die used for stamping of 1-mm thick hot-dip galvanized DP600 is 3D-printed in DIN 1.2709, both with a honeycomb inner structure and after topology optimization, with successful results. 3D printing results in a significant lead time reduction and improved tool material efficiency. The cost of 3D-printed stamping tools and dies is higher than the cost of those made conventionally. The core (inserts) of an injection mold is 3D-printed in DIN 1.2709, conformal cooling optimized and 3D-printed in Uddeholm AM Corrax, and compared with the same core made conventionally. The cooling and cycle time can be improved, if the injection molding core (inserts) is optimized and 3D-printed in Uddeholm AM Corrax. This paper accounts for the results obtained in the above-mentioned investigations.
关键词： Design,Injection molding,Tools,Stamping,Powder bed fusion,Optimization,Topology,Metal,Additive manufacturing,Cooling
更新于2025-09-23 15:19:57
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Multi-physics modelling of molten pool development and track formation in multi-track, multi-layer and multi-material selective laser melting
摘要： Selective laser melting (SLM) is a promising powder-based additive manufacturing technology due to its capability to fabricate metallic components with complex geometries. While most previous investigations focus on printing with a single material, recent industry-orientated studies indicate the need for multi-material SLM in several high-value manufacturing sectors including medical devices, aerospace and automotive industries. However, understanding the underlying physics in multi-material SLM remains challenging due to the di?culties of experimental observation. In this paper, an integrated modelling framework for multi-track, multi-layer and multi-material SLM is developed to advance the in-depth understanding of this process. The main novelty is in modelling the molten pool evolvement and track morphology of multiple materials deposited on the same and across different layers. Discrete element method (DEM) is employed to reproduce the powder deposition process of multiple materials in different deposition patterns, with particle size distribution imported from a particle size analyser. Various phenomena including balling effect, keyhole depression, and lack of fusion between layers are investigated with different laser energy inputs. As a result of the different thermal properties, several process parameters including energy density and hatch spacing are optimised for different powder materials to obtain a continuous track pro?le and improved scanning e?ciency. The interface between two layers of different materials is visualised by simulation; it was found that the phase migration at the interface is related to the convection ?ow inside the molten pool, which contributes to the mixing of the two materials and elemental diffusion. This study signi?cantly contributes to the challenging area of multi-material additive manufacturing by providing a greater in-depth understanding of the SLM process from multi-material powder deposition to laser interaction with powders across multiple scanning tracks and different building layers than can be achieved by experimentation alone.
关键词： Additive manufacturing,Discrete element method (DEM),Computational ?uid dynamics (CFD),Heat transfer,Multi-material,Selective laser melting (SLM)
更新于2025-09-23 15:19:57