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Article
Thermodynamics
Zhi-Jian Li et al.
Summary: In this paper, a semi-analytical model is established to predict the three-dimensional transient temperature field distributions during laser additive manufacturing process. The model considers heat losses caused by conduction, convection, and radiation. The effect of process parameters and heat source model on peak temperature, temperature gradient, molten pool dimensions, and heat losses is analyzed. It is found that the volumetric heat source model results in higher average temperature and lower heat losses, and heat losses increase with increasing laser power, energy absorptivity, and effective radius of the laser beam.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2023)
Article
Materials Science, Multidisciplinary
Jiqiang Zhou et al.
Summary: Copper-Chromium-Zirconium alloys are favored in electronic materials due to their excellent electrical conductivity and mechanical strength. However, additive manufacturing of Cu-Cr-Zr alloy parts remains challenging. This study used laser powder bed fusion (LPBF) to process Cu-Cr-Zr alloy and determined optimal processing parameters by monitoring sample density. Direct aging treatment from 400°C to 620°C improved strength and electrical conductivity. Tensile strength initially increased and then decreased with aging temperature, while electrical conductivity gradually increased. Aging at 475°C for 2 hours resulted in a tensile strength of 519.3 MPa, 15.5% elongation, and 78.7% IACS electrical conductivity. Theoretical calculations indicated that precipitates of Cr-enriched phases were the main factors behind increased strength and electrical conductivity.
MATERIALS CHEMISTRY AND PHYSICS
(2023)
Article
Nanoscience & Nanotechnology
Haitao Lu et al.
Summary: A three-dimensional high-fidelity discrete heat-flow-coupled model was developed to study the surface morphology, melt evolution, and defect formation mechanisms of four types of alloys formed using laser powder bed fusion (LPBF) under different laser processes. Multiple characterizations were used to analyze the microstructure and mechanical properties of the as-built parts of the alloys. The study provides insights into melt evolution and flow behavior and is a reference for selecting and optimizing materials, laser-process parameters, and heat treatment regimes in engineering applications.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Engineering, Multidisciplinary
Napo Bonfoh et al.
Summary: A new micromechanical approach based on the strain gradient elasticity theory is developed to predict the effective properties of composite materials by dealing with the problem of Eshelby's inhomogeneity. The method uses the Green's function technique to obtain an integral equation for the heterogeneous elastic problem. By utilizing this integral equation, the exact solution for Eshelby's inhomogeneity problem with spherical inhomogeneity and isotropic elastic behavior is determined. The effective elastic properties of a two-phase composite material are then predicted using Mori Tanaka's homogenization scheme through the expression of strain localization relations. The suggested approach is tested against reference models and experimental data to assess its relevance.
APPLIED MATHEMATICAL MODELLING
(2023)
Review
Engineering, Mechanical
Yaozhong Wu et al.
Summary: Lightweight materials and structures have been extensively studied for design and manufacturing of more sustainable products with reduced materials and energy consumption, while maintaining proper mechanical and energy absorption characteristics. Additive manufacturing techniques have offered more freedom for designing novel lightweight materials and structures, but the rational design for desired mechanical properties remains challenging. This review comprehensively discusses the recent advances in additively manufactured materials and structures, focusing on their mechanical properties and energy absorption applications. It also addresses challenges, future directions, and optimization techniques in this field.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Mechanics
Yang Wu et al.
Summary: In this study, a three-step method is proposed to derive the average Eshelby tensor of an arbitrarily shaped inclusion in an elastic field. The method is user-friendly and avoids the singularity that arises from solving complicated integrals. The reliability of the method is verified through comparisons with existing data, and it is also incorporated into a micromechanical model to predict the effective elastic moduli of two-phase composites.
INTERNATIONAL JOURNAL OF SOLIDS AND STRUCTURES
(2023)
Article
Materials Science, Multidisciplinary
Hui Ruan et al.
Summary: Thermal fracture is a common and devastating defect in metal additive manufacturing. This study proposes a thermo-mechanical phase-field fracture model based on a thermodynamically consistent derivation. The model considers different coupling terms, fracture formulations, and thermomechanics information. The finite element method is used for numerical implementation, and the model is applied to simulate hot cracking in additive manufacturing considering thermal strain and solidification shrinkage. The study reveals the dominant roles of solidification shrinkage strain and temperature gradient in crack formation and provides insights into process parameter effects on crack types. The numerical predictions of crack patterns are in good agreement with experimental observations, demonstrating the capability of the model.
JOURNAL OF THE MECHANICS AND PHYSICS OF SOLIDS
(2023)
Article
Materials Science, Multidisciplinary
N. Tabatabaei et al.
Summary: This study provides a new interpretation of the effect of different heat treatments on the microstructural evolution and deformation behavior of selectively laser-melted AlSi10Mg alloy. It is found that the flow responses of the treated microstructures have not improved as expected, mainly due to the dissolution of the cellular structure and its impact on trapped gas defects. In addition, the melt pool boundaries are prone to crack nucleation and growth, which is attributed to the high connectivity of Si-network and strain localization.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Mechanical
Qinyuan Yao et al.
Summary: Acoustic softening is a physically significant phenomenon with important applications, such as in ultrasonic-assisted metal processing and the use of metal materials in acoustic field environments. However, there is a lack of theoretical models to characterize the evolution of metal material strength with an acoustic field. This study developed two models, one for the yield strength and the other for the ultimate tensile strength, based on the equivalent relationship between acoustic energy and elastic deformation/elastoplastic strain energy. The models were validated by experimental results and used to analyze the effects of different acoustic fields on material strength.
EXTREME MECHANICS LETTERS
(2023)
Article
Thermodynamics
Zhi-Jian Li et al.
Summary: A coupled thermo-mechanical model of titanium alloy parts in the powder bed fusion process is developed, taking into account the process-induced interfacial lack of fusion and pores. The equivalent temperature-dependent thermal properties of the parts with defects are calculated based on mixture theory, and the three-dimensional thermal, mechanical, and displacement fields are predicted using the differential quadrature method. The predicted results demonstrate the significant influence of process and geometry parameters on the temperature distribution, residual stress buildup, and deformation of the printed parts.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2023)
Article
Materials Science, Multidisciplinary
Qiao Zhong et al.
Summary: The study investigates the effects of rotation angles on the surface morphology, microstructure, and mechanical properties of Inconel 718 alloy produced by high-power laser powder bed fusion (HP-LPBF). Low rotation angles result in poor surface finish and lack-of-fusion defects, while high rotation angles lead to smaller surface roughness and better relative density. There are noticeable edge effects and a downward trend in maximal heights with increased rotation angle. The tensile property is slightly enhanced with increasing rotation angle.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Kunjie Dai et al.
Summary: Irregular large pores induced by LPBF are inherent defects that affect the mechanical properties of components. Laser remelting combined with different scanning strategies on Hastelloy X alloy was studied, and the chessboard strategy showed the highest density and finer microstructure, leading to superior tensile strength and elongation.
MATERIALS & DESIGN
(2023)
Review
Materials Science, Multidisciplinary
Amir Mostafaei et al.
Summary: This review provides a comprehensive discussion on fusion-based additive manufacturing (AM) of Nickel-based superalloys, focusing on the influential factors affecting microstructure, mechanical properties and defect generation. The mechanical properties of AM Nickel-based superalloys are analyzed, and commonly utilized modeling approaches in literature are highlighted.
PROGRESS IN MATERIALS SCIENCE
(2023)
Article
Engineering, Mechanical
Zhihao Ren et al.
Summary: This study improved the widely used top free surface heat source model in existing literature by introducing the scattered heat source (SHS) model and adopting calorimetric measurement method, enhancing simulation accuracy and solving the uncertainty of laser absorptivity.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
Article
Engineering, Manufacturing
Di Wang et al.
Summary: This article provides a comprehensive review of the recent achievements in multi-material structures fabricated via LPBF, including interface characteristics and strengthening methods, critical technical issues, and potential applications. The paper introduces the concept and scope of multi-material structures, presents the interface characteristics and strengthening methods, discusses the critical technical issues in LPBF, and illustrates the potential applications in various fields. Finally, an outlook is outlined for future research in this area.
VIRTUAL AND PHYSICAL PROTOTYPING
(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)
Article
Engineering, Mechanical
Hongzhuang Zhang et al.
Summary: This paper comprehensively investigated the material characteristics, mechanical properties, and deformation behaviors of LPBF 304L austenitic stainless steel subjected to HIP process with different temperatures. The experimental results showed that increasing HIP temperature led to increased grain size, inclusion size, recrystallization fraction, and dimple size, resulting in homogenized microstructure, reduced yield strength and microhardness, and significantly improved ductility. Furthermore, the study revealed the influence of porosity, inclusion, residual stress, and dislocation density on the fatigue life of HIP-treated samples after surface post-treatment.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
Article
Mechanics
Orion L. Kafka et al.
Summary: This study investigates the tensile properties of nickel-based alloy IN718, focusing on the spatial and orientation-based differences. The researchers used in-situ x-ray computed tomography to observe the internal pore populations and measured the evolution of pore shape during deformation. The results were compared to simulations using a computational crystal plasticity scheme, providing insights into the grain orientation in which the pore resides. The measurements show that pores tend to grow and elongate in the direction of loading, consistent with ductile deformation, and do not cause premature failure.
INTERNATIONAL JOURNAL OF SOLIDS AND STRUCTURES
(2022)
Article
Engineering, Mechanical
Hongzhuang Zhang et al.
Summary: This paper investigates the microstructural evolution of laser powder bed fused 304 L austenitic stainless steel after stress-relieving annealing and solution annealing. The results show the migration of dislocations and the formation of subgrain boundaries during annealing, leading to changes in strength and ductility. The study also reveals the distortion networks and misorientation ranges in the samples. Tensile deformation results in deformation twins in different oriented grains, dependent on the annealing conditions.
INTERNATIONAL JOURNAL OF PLASTICITY
(2022)
Article
Nanoscience & Nanotechnology
Benjamin Stegman et al.
Summary: The influence of a wide range of major build parameters on the microstructures and mechanical properties of 718 Ni alloys is explored. Volumetric energy density is found to be a key parameter capturing the relationship between energy input and the measured properties and microstructures of the alloys. A threshold energy density is identified, below which the properties of additively manufactured specimens degrade substantially. The correlation between the simulated quality of built specimens using Flow3D AM and the experimental results is good.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Computer Science, Interdisciplinary Applications
Kejia Zhuang et al.
Summary: This paper presents a numerical investigation on the evolution of residual stress in sequential cutting, taking into account the effects of edge radius and cutting depth. The study finds that the residual stress on the machined surfaces will decrease during sequential cutting and reach a stable value after a certain number of cuts.
SIMULATION MODELLING PRACTICE AND THEORY
(2022)
Article
Engineering, Manufacturing
Shubhra Kamal Nandi et al.
Summary: Selective laser melting (SLM) is an advanced manufacturing process that can build highly customized products. This study proposes an algorithm that combines analytical and numerical methods to estimate temperature and melt pool shape during the SLM process. The method provides a deep understanding of this dynamic process at a low computational cost and has been validated experimentally.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Nanoscience & Nanotechnology
Xing Qi et al.
Summary: This study explores the influence of varying laser energy density on the microstructure and tensile properties of Al-Fe alloys fabricated using laser powder bed fusion. The results show that at higher energy density, the alloy exhibits improved tensile ductility with only a slight decrease in tensile strength. The study also demonstrates that the laser conditions can control the local microstructural inhomogeneities, enabling the manufacturing of Al-Fe alloys with high strength and good ductility.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Mechanics
Yuxin He et al.
ENGINEERING FRACTURE MECHANICS
(2022)
Review
Materials Science, Multidisciplinary
Niloofar Sanaei et al.
Summary: Additive manufacturing is emerging as an alternative method for producing unique and complex parts, with fatigue performance being a key consideration. Defects such as Lack of Fusion, porosities, and un-melted particles can affect fatigue performance, but can be minimized through process optimization and post-processing. Analytical techniques can reduce the need for costly fullscale testing for assessing reliability in fatigue performance.
PROGRESS IN MATERIALS SCIENCE
(2021)
Article
Engineering, Multidisciplinary
Binqi Liu et al.
Summary: The study introduces a new analytical model to predict the molten pool geometry in SLM, focusing on establishing heat balance assumptions and considering the interaction between recoil pressure and melted metal flow. Experimental validations show good accuracy of the model at medium energy density, exploring correlations between predicted geometry and defect thresholds.
APPLIED MATHEMATICAL MODELLING
(2021)
Article
Engineering, Mechanical
Changping Zhou et al.
Summary: A hybrid fabrication method combining AM and UIT techniques was developed to improve the microstructure and mechanical properties of additive manufactured metal parts. Experimental and numerical methods were conducted to analyze the stress and strain fields of ultrasonic impact on additive manufactured parts. Both experimental and numerical results confirm that UIT can effectively improve the performance of additive manufactured metal parts.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2021)
Article
Materials Science, Multidisciplinary
Hui Huang et al.
Summary: Computational modeling is crucial in product design and optimization for additively manufactured structures, especially in laser powder bed fusion processes that involve complex geometries and localized heat input. This study utilized GPU-accelerated finite element analysis and approximated heat conduction analysis to predict thermo-mechanical behavior in laser selective melting. By grouping adjacent layers and tracks, the model efficiency was improved without compromising accuracy, allowing for cost-effective simulations. The developed approach allowed for faster computation of detailed residual stress and distortion in Inconel alloy 625 thin-wall builds compared to conventional methods.
JOURNAL OF PHYSICS-MATERIALS
(2021)
Article
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Jun-Ren Zhao et al.
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(2020)
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Zhongxu Xiao et al.
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(2020)
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COMPOSITE STRUCTURES
(2019)
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Aiden A. Martin et al.
NATURE COMMUNICATIONS
(2019)
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Yingli Li et al.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2018)
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T. F. Flint et al.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2018)
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Hui Chen et al.
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Weiguo Li et al.
ACTA MECHANICA SINICA
(2010)
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SS Sih et al.
PARTICULATE SCIENCE AND TECHNOLOGY
(2004)
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PARTICULATE SCIENCE AND TECHNOLOGY
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