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Article
Engineering, Electrical & Electronic
Tim Pasang et al.
Summary: This paper provides an overview of the current state of additive manufacturing of Titanium alloys, particularly in the aerospace and biomedical industries. It discusses the two most common methods of additive manufacturing (AM), powder and wire, and evaluates their maturity as production processes. The paper also highlights the need for a rapid qualification method for AM produced components and describes the potential benefits of AM, such as part count reduction and weight reduction through design synthesis. It concludes that there are promising opportunities for the incorporation of AM components once certain challenges are addressed.
MICROELECTRONIC ENGINEERING
(2023)
Review
Computer Science, Artificial Intelligence
T. Herzog et al.
Summary: Metal Additive Manufacturing (AM) has evolved from a rapid prototyping method to a viable manufacturing tool, attracting high-value industries for direct component production. However, the highly dynamic nature of the process often leads to defect formation and lack of control. This review explores the application of Machine Learning (ML) approaches and in-situ monitoring technologies for defect detection and discusses their potential for process control implementation. It also critically evaluates trends in data structures, ML algorithms, and sensing technologies in laser metal AM monitoring tasks, providing recommendations for further research.
JOURNAL OF INTELLIGENT MANUFACTURING
(2023)
Article
Computer Science, Artificial Intelligence
Simon Oster et al.
Summary: This study presents a novel framework for predicting porosity based on extracted features from thermogram data. The framework includes a data pre-processing workflow and a supervised deep learning classifier model. The experimental results show that the model achieves high accuracy and f1-Score in predicting keyhole porosity in small sub-volumes. Furthermore, the study finds that the pre-processing parameters and local void distribution have an influence on the model performance, and the prediction is sensitive to local porosity changes.
JOURNAL OF INTELLIGENT MANUFACTURING
(2023)
Article
Materials Science, Multidisciplinary
Xuben Lu et al.
Summary: This paper investigates the production of high-quality TC11 titanium alloy parts using the Laser powder bed fusion (L-PBF) technique. The effects of scanning strategy and forming angle on the forming quality and performance of TC11 alloy are analyzed. The results show that strip-scanned molded parts have the highest upper surface quality and the fusion channel lap and surface adhesion powder are the main factors affecting surface roughness. Additionally, the surface roughness decreases and hardness increases with increasing forming angle, with the optimal surface quality and hardness achieved at a forming angle of 90 degrees. These findings provide theoretical and technical support for L-PBF forming of TC11 titanium alloy parts.
Review
Materials Science, Multidisciplinary
Mohd Rozaimi Zahidin et al.
Summary: Metal additive manufacturing, especially the Wire Arc Additive Manufacturing (WAAM) method, has gained significant attention for its capability to produce complex metal components with better mechanical and microstructural properties. However, various issues and defects arise during the process, affecting the quality of the components. This article reviews the common defects and challenges in WAAM and discusses control strategies, including the use of artificial intelligence, to improve the quality of metal parts.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
Xinyue Chen et al.
Summary: This work presents a strategy for in-situ controlling the magnitude and distribution of residual stress in laser powder bed fusion (LPBF) process. The residual stress was manipulated by regulating layer thickness, preheating temperature, and scanning strategies. The findings provide an effective approach for reducing stress during LPBF, which is critical for the fabrication of large-scale or complicated-shape metal components.
MATERIALS CHARACTERIZATION
(2023)
Article
Materials Science, Multidisciplinary
Tobias Fritsch et al.
Summary: This research investigates cylindrical struts fabricated by L-PBF using X-ray computed tomography (XCT) to explore the dependence of different defects on the build angle. The study proposes innovative analysis methods to correlate shape and position of pores, determine angular-resolved surface roughness, and quantify the amount of re-entrant surface features.
ADVANCED ENGINEERING MATERIALS
(2022)
Article
Materials Science, Multidisciplinary
Amir Mostafaei et al.
Summary: Metal additive manufacturing is a disruptive technology that revolutionizes the manufacturing industry by directly fabricating complex metal parts. However, microstructural defects and anomalies limit its widespread adoption, potentially compromising the structural integrity and performance of the products. This review aims to explore the common defects/anomalies and their formation mechanisms in powder bed fusion processes, as well as propose practical strategies for mitigating these issues.
CURRENT OPINION IN SOLID STATE & MATERIALS SCIENCE
(2022)
Review
Engineering, Industrial
Eyob Messele Sefene
Summary: Smart manufacturing and materials are increasingly used for producing high strength-to-weight ratio parts. Selective Laser Melting (SLM) is a prominent additive manufacturing technology for fabricating near-net-shape and high-quality surface parts. However, limitations in printing multi-materials, insufficient process parameter information, and porosities on printed parts restrict its industrial application.
JOURNAL OF MANUFACTURING SYSTEMS
(2022)
Article
Materials Science, Multidisciplinary
K. M. Bertsch et al.
Summary: Effective optimization of Ti-6Al-4 V production using AM requires understanding the importance of different microstructural features to deformation and failure mechanisms. This study compared the tensile response and deformation mechanisms of EBM and SLM AM Ti-6Al-4 V materials and evaluated the influence of phase distribution, defect density, and porosity on material strength and ductility. The results suggest that phase distribution and defect density are crucial for determining material strength and maximum strain to failure, while porosity limits part ductility.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Josiah Cherian Chekotu et al.
Summary: Nitinol samples were produced using Laser Powder Bed Fusion (L-PBF) technique with systematic variations in laser power, scan speed, and hatch spacing. The control of L-PBF parameters allowed for control of the part's chemical composition and phase transformation temperatures. The laser process parameters had a significant effect on the transformation temperatures of martensite and austenite. Additionally, the volumetric energy density was directly correlated with cooling and heating enthalpies.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Juri Munk et al.
Summary: Laser Powder Bed Fusion (LPBF) of Ti-6Al-4V enables the manufacturing of complex parts for lightweight applications. The emerging microstructure in the LPBF process and mechanical properties are defined by locally variable thermal cycles. Predictions of local mechanical properties by simulation are not currently possible, so experimental qualification is necessary. In this study, different geometry-dependent microstructures were mechanically characterized through simplified sample shapes. A correlation was successfully established between various geometries and temperature-time cycles, laying the foundation for simulation-based prediction of mechanical properties for LPBF-manufactured parts.
Article
Nanoscience & Nanotechnology
Jiming Lv et al.
Summary: Arc-based cold metal transfer additive manufacturing (CMTAM) technology is an effective method for constructing large metallic components. This study investigated the effects of double-sided ultrasonic impact treatment (UIT) on CMTAMed Ti6Al4V alloy, and found that UIT reduced surface roughness, converted residual stress, stimulated grain refinement, and reduced the anisotropy of tensile properties.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Engineering, Manufacturing
Chaolin Tan et al.
Summary: Aerospace is a key driver in advancing additive manufacturing, particularly in the high-value, high-mix low-volume production of complex parts. Laser additive manufacturing of aeroengine materials has shown significant progress, but there are gaps in research and challenges that need to be addressed, focusing on the relationship between material properties and process parameters.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2021)
Article
Engineering, Industrial
Zackary Snow et al.
Summary: The research demonstrates that neural networks and convolutional neural networks are effective in detecting defects in additive manufacturing processes. CNNs showed significantly better performance and generalizability than NNs, with their accuracy also being related to flaw size and the ability to generalize to diverse data.
JOURNAL OF MANUFACTURING SYSTEMS
(2021)
Review
Engineering, Manufacturing
Anil Kumar Singla et al.
Summary: This review critically examines the important contributions related to selective laser melting (SLM) process parameters, defects, and post-processing techniques for Ti6Al4V alloy. Proper selection of process parameters and post-treatment methods are crucial in improving mechanical behavior of SLMed components. Efforts have been made to identify correlations between SLM parameters and defects, as well as analyzing the impact of post-processing approaches on mechanical behavior and biocompatibility of SLM-fabricated Ti6Al4V alloy.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Review
Engineering, Multidisciplinary
M. Grasso et al.
Summary: The use of sensor signals in metal powder bed fusion processes for part and process qualification, as well as early detection of anomalies and defects, is a growing area of interest with significant research growth in recent years. Industrial PBF systems are increasingly equipped with sensors and toolkits for data collection and analysis, with new methods proposed and defect detection capabilities demonstrated. Challenges still remain in bridging the gap between proposed methods in research literature and actual industrial implementation.
MEASUREMENT SCIENCE AND TECHNOLOGY
(2021)
Article
Automation & Control Systems
Xin Zhou et al.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2020)
Review
Materials Science, Multidisciplinary
Anton du Plessis et al.
MATERIALS & DESIGN
(2020)
Article
Engineering, Manufacturing
Jinzhong Lu et al.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2020)
Review
Chemistry, Multidisciplinary
Lu-Yu Zhou et al.
ADVANCED FUNCTIONAL MATERIALS
(2020)
Article
Engineering, Electrical & Electronic
Henrik Ehlers et al.
IEEE SENSORS JOURNAL
(2020)
Article
Materials Science, Multidisciplinary
Davoud Jafari et al.
MATERIALS & DESIGN
(2020)
Article
Materials Science, Characterization & Testing
Mohammad Reza Khosravani et al.
JOURNAL OF NONDESTRUCTIVE EVALUATION
(2020)
Article
Instruments & Instrumentation
Z. Prevorovsky et al.
Article
Multidisciplinary Sciences
C. Kenel et al.
SCIENTIFIC REPORTS
(2017)
Article
Materials Science, Multidisciplinary
Dirk Herzog et al.
Article
Engineering, Biomedical
E. Sallica-Leva et al.
JOURNAL OF THE MECHANICAL BEHAVIOR OF BIOMEDICAL MATERIALS
(2016)
Article
Nanoscience & Nanotechnology
F. Bartolomeu et al.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2016)
Article
Materials Science, Multidisciplinary
Marco Simonelli et al.
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
(2014)
