Search Results (1,006)

In the 21st century, the desire for improved fuel efficiency of engines, lower fuel prices, and the need to reduce greenhouse gas emissions such as ${\mathrm{C}\mathrm{O}}_2$ and ${\mathrm{N}\mathrm{O}}_{\mathrm{x}}$ are leading the aviation industry to seek hybrid-electric jet engines for commercial aircraft. These aircraft will have greater maintenance challenges due to additional components requiring more reliable materials for the engine’s parts, such as turbine blades. Turbine blades must be composed of materials that have enhanced fatigue performance. Resistance to dynamic loads and high strength will be needed to ensure modern gas turbine blades are as reliable as possible. This review paper examines hybrid-electric engine turbine blades and subsequently introduces additive manufacturing (AM) and multi-principal element alloys (MPEAs) with a focus on laser powder bed fusion (LPBF), high-entropy alloys (HEAs), and medium-entropy alloys (MEAs). The tensile properties of LPBF HEAs range from 5 to 47% elongation and a UTS of 572–1640 MPa, while LPBF MEAs range from 8 to 73.9% and a UTS of 573–1382 MPa. This study focused on dynamic and fatigue properties while acknowledging gaps in high-temperature testing. The combination of mechanical properties with the ability to control internal geometry makes these AM alloys an attractive option for the next generation of gas turbine blades. Full article

Laser-based Powder Bed Fusion (LPBF) enables the fabrication of complex metal components but often results in high porosity and microdefect densities, compromising fatigue performance despite acceptable static properties. Standard fatigue characterisation methods are time-consuming and costly and yield scattered results due to defect-induced brittleness and residual stresses. This study investigates the application of thermographic techniques as a rapid alternative for evaluating the intrinsic fatigue behaviour of tensile coupons fabricated by LPBF employing AISI 316L steel. By monitoring surface temperature during stepwise static monotone and fatigue loading, thermographic methods aim to detect early hints of heat dissipation associated with microdamage initiation. Approaches based on temperature harmonic analysis have been implemented, allowing near-real-time and full-field mapping of stress distribution and damage development. Results show that harmonic metrics correlate with the material state and effectively track the thermoelastic effect-induced temperature changes. Some evidence is found regarding the onset of intrinsic heat dissipation, which needs to be confirmed by more focused and extensive experimental tests. Full article

Despite the growing adoption of Ti6Al4V-ELI made by Laser Powder Bed Fusion (LPBF) in tribologically demanding applications, the influence of hybrid nanoparticle additives on its lubrication behavior under starved contact conditions remains insufficiently explored. The tribological performance of Ti6Al4V was investigated under starved boundary-to-mixed lubrication conditions using engine oil modified with Ag-doped TiO₂ nanoparticles. Double-scan LPBF-fabricated discs were tested in a ball-on-disc configuration against AISI 52100 bearing steel using a TRB³ tribometer. Nanolubricants were prepared by dispersing TiO₂ and Ag–TiO₂ nanopowders with different Ag⁺/Ti⁴⁺ ratios (0.5%, 1.5%, and 2.5%) in SAE 10W-40 engine oil at a constant nanoparticle concentration of 0.05 wt%. Comprehensive physicochemical characterization of the nanopowders and nanolubricants was performed through structural, chemical, optical, morphological, rheological, and stability analyses. Tribological experiments were conducted following a full-factorial design combining three normal loads (5–15 N), three sliding speeds (0.10–0.20 m·s⁻¹), and four lubricant formulations. The steady-state coefficient of friction ranged between 0.281 and 0.359, while the specific wear rate varied from 2.81 × 10⁻⁴ to 4.83 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The contact temperature rise remained relatively moderate, within the interval of 1.9–9.4 °C. Among the investigated formulations, the lubricant containing 1.5% Ag–TiO₂ exhibited the lowest friction coefficient, whereas the formulation with the highest Ag content showed improved stability of tribological performance across the investigated operating domain. These results indicate that Ag-modified TiO₂ nanoparticles are consistent with the formation of protective tribofilms and contribute to the stabilization of friction, wear, and thermal behavior under starved lubrication conditions. ANOVA confirmed that sliding speed and the load–lubricant interaction are the dominant factors governing friction and wear, while normal load controls the thermal response. These findings support the use of Ag–TiO₂ nanolubricants as a viable strategy for stabilizing interfacial behavior in LPBF-fabricated titanium components operating under starved lubrication conditions. Full article

This study investigated the correlation between mechanical strengthening and electrochemical corrosion behavior in 18Ni300 maraging steel fabricated via laser powder bed fusion (LPBF). To evaluate the impact of post-processing, specimens were analyzed under four conditions: solution treated (S), solution peened (SP), solution aged (SA), and solution aged peened (SAP). The aging treatment (490 °C for 6 h) effectively enhanced the corrosion resistance by homogenizing the martensitic matrix and promoting the formation of a stable passive film, resulting in the lowest corrosion current density (<!-- MathType@Translator@5@5@MathML2 (no namespace).tdl@MathML 2.0 (no namespace)@ --> Full article

Additive manufacturing (AM) represents a quite interesting technology for manufacturing components of nuclear reactors. This work investigated the microstructural stability of 316 L steel fabricated via Laser Powder Bed Fusion (L-PBF) from room temperature to 650 °C. Despite the reduced susceptibility of the material to sensitization owing to its low carbon content, temperature variations may induce deleterious effects in nuclear safety-critical components. In as-printed condition, the microstructure is not stable and undergoes significant changes induced by thermal cycling up to 650 °C in Mechanical Spectroscopy (MS) tests: the typical melt-pool pattern disappears, a population of equiaxed grains substitutes the original ones elongated in the build direction, the average size of the cells forming a finer sub-structure inside the grains increases, texture changes, and the excess of vacancies induced by the rapid cooling is recovered. Although the current literature reports that the microstructure is stable up to 500 °C, MS results indicate that the aforesaid irreversible phenomena start at a lower temperature (~230 °C). The present results suggest that the microstructure of the printed material must be stabilized through suitable heat treatments before its application in structural components for nuclear reactors. Full article

This study proposes a novel parameterized hollow spiral lattice (HSL) structure designed for additive manufacturing (AM). The structure is composed of two right-handed and two left-handed spiral members. Its unit cell is formed by sweeping a circular ring cross-section along a cylindrical helical path, creating a porous topology that integrates continuous flow channels with structural load-bearing capability. An analytical model correlating key design parameters, including spiral radius, helix angle, and tube inner/outer diameters, with the structural relative density is established. Considering the manufacturability constraints of Laser Powder Bed Fusion (LPBF), an adaptive parametric design framework is developed to simultaneously optimize the geometry, relative density, and process feasibility. Ti6Al4V HSL samples were fabricated using LPBF. Their thermo–mechanical performance was systematically characterized through Computational Fluid Dynamics (CFD) simulations, Finite Element Analysis (FEA), and quasi-static compression experiments. Thermal analysis under internal and internal–external flow conditions reveals that the centrifugal force induced by the spiral geometry generates Dean vortices. This enhances momentum exchange between the central mainstream and near-wall fluid, significantly improving radial mixing, promoting temperature uniformity, and effectively suppressing local hot spots. Mechanically, the HSL exhibits significantly superior specific strength and stiffness compared to traditional body-centered cubic (BCC) and diamond lattices, approaching the performance of cubic topology, thus demonstrating outstanding lightweight load-bearing potential. The developed HSL structure presents a promising innovative design strategy for next-generation applications requiring integrated thermal management and structural load-bearing functions. Full article

Accurate prediction of transient melt pool thermal fields in Laser Powder Bed Fusion (LPBF) is essential for understanding melt pool geometry and defect formation mechanisms, yet conventional finite element methods (FEM) impose prohibitive computational costs for parametric process exploration. A variational physics-informed neural network (VPINN) framework is presented for 3D transient thermal modeling of a GH3536 single-track LPBF scan. The framework incorporates a continuously differentiable Goldak double-ellipsoid moving heat source, temperature-dependent thermophysical property surrogates, and an effective heat-capacity treatment of latent heat associated with solid–liquid phase change and vaporization. These components are embedded in a weak-form residual-minimization scheme with octree-adaptive domain decomposition, hierarchical Legendre test functions, and sequential sliding-window time marching. Effective absorptivity is inferred jointly with the network parameters, using sparse experimental melt pool profiles as supervision. Within a parametric study covering laser powers from 100 to 140 W and scan speeds from 1000 to 1500 mm/s, the predicted melt pool width, depth, and aspect ratio agree closely with FEM benchmarks and cross-sectional optical micrograph measurements across both supervised and held-out interpolation conditions, with total relative L₂ nodal temperature errors ranging from 3.23% to 6.75%. Following a one-time offline training investment of 15,323 s that simultaneously resolves the full parametric space, surrogate inference reduces per-condition query time from 3000–4000 s (FEM) to merely 4–5 s, delivering a speedup of two to three orders of magnitude and making the framework increasingly cost-effective for high-throughput parametric studies and digital-twin integration as the number of queried conditions grows. Full article

The demand for miniaturized high-temperature components necessitates advanced additive manufacturing techniques, yet the microstructural and mechanical consequences of scaling down the laser powder bed fusion (LPBF) process remain poorly understood. In this study, we systematically investigate the scaling effects of micro laser powder bed fusion (μ-LPBF) versus conventional LPBF on the phase transformation kinetics and performance of the near-α Ti65 alloy. Results demonstrate that μ-LPBF significantly enhances surface integrity, reducing the arithmetic mean roughness (Ra) by 59.5%. Microstructural characterization reveals that the extreme cooling rates intrinsic to the microscale melt pool induce a massive refinement of hierarchical α′ martensite and promote a highly randomized variant selection. Consequently, the strong building-direction crystallographic texture typical of LPBF is substantially weakened, and the proportion of high-angle grain boundaries increases to 91.6%. This microstructural homogenization effectively mitigates mechanical anisotropy, reducing the directional variance in the Schmid factor by 35%. In terms of mechanical properties, μ-LPBF demonstrates exceptional strengthening at both room temperature and 600 °C, achieving a room-temperature yield strength of 1297 MPa and an ultimate tensile strength of 1514 MPa, which represent increases of 16.5% and 8.6%, respectively, compared to those of conventional LPBF. These findings provide critical insights into defect suppression and multiscale microstructural control under extreme thermal gradients, paving the way for the fabrication of isotropic, high-strength micro devices. Full article

Laser powder bed fusion (LPBF) can fabricate intricate metal components but is prone to defects, such as porosity and cracks, that degrade performance. We present an in situ monitoring framework that fuses structure-borne acoustic emission (AE) and coaxial two-color pyrometry acquired synchronously at 1 MHz. Modality-specific encoders are pretrained separately, their latent representations are exported, and a lightweight feature-level fusion classifier with two binary heads predicts crack-like and porosity-like indications. Evaluation uses a held-out grouped experiment/build-machine-part split with independent Archimedes density and micro-CT ground truth. On the held-out test set, the fused model achieved F1 = 0.974 for crack-like detection and F1 = 0.987 for porosity-like detection, with AUROC = 0.998 and 0.993, respectively. Recall was 1.00 for both heads, corresponding to false-positive rates of 11.18% for crack-like and 0.945% for porosity-like indications. These results support synchronized AE-pyrometry fusion as a promising high-sensitivity in situ screening approach for LPBF. A later matched within-framework ablation campaign was also performed under stricter checkpoint-screening rules to compare AE + PY + Aux, AE + PY, AE-only, and PY-only variants under a common grouped-split protocol. Together, these results support multimodal monitoring while highlighting the need for explicit coupon/geometry-stratified reporting and for separately architecture-optimized unimodal baselines. Full article

Reliable property prediction and process selection in laser powder bed fusion are hindered by small, set-level datasets in which key morphology descriptors are intermittently missing, limiting both generalization and actionable co-design. A hybrid multimodal surrogate strategy is introduced that couples engineered process physics features with morphology proxies through a deployable two-stage embedding module and gradient-boosted tree regressors. Set-resolved inputs are assembled from L-PBF parameters, linear energy density and related energy-density variants, pore and prior-β grain summary statistics, and stress–strain-derived descriptors, followed by missingness-aware feature filtering, median imputation, and 5-fold GroupKFold evaluation grouped by set_id, with morphology embeddings learned on training folds and predicted when absent. Across six targets, the final deployable models achieve an RMSE/R² of 11.07 MPa/0.895 (yield), 13.88 MPa/0.873 (UTS), 0.677%/0.861 (elongation), and 2.38 GPa/0.663 (modulus), while roughness and hardness remain challenging (RMSE 2.31 μm and 16.54 HV; R² about 0.12 and 0.11). These surrogates enable constraint-aware candidate generation that identifies a concise set of manufacturing recipes balancing strength and surface objectives under uncertainty-aware screening. The resulting framework provides a practical blueprint for multimodal, small-data additive manufacturing studies and can be extended to richer microstructure measurements and prospective validation to accelerate functional and biomedical alloy development. Full article

To address the challenges associated with laser powder bed fusion (LPBF) of overhanging structures—namely warping deformation, powder adhesion, and inadequate forming accuracy—this study investigates the optimization of the support–part contact interface using Inconel 625 alloy. The objective is to achieve high-quality part formation with minimal support structures. A Taguchi experimental design was employed to systematically evaluate the effects of key block support parameters—tooth height, tooth top length, tooth base length, and tooth base spacing—on the forming performance of overhanging structures, with forming accuracy and support removability as the optimization targets. The results reveal that tooth top length significantly influences both the forming accuracy of overhanging specimens and the ease of support removal. Specifically, an increase in tooth top length leads to a rapid reduction in specimen deformation, but simultaneously increases the difficulty of support removal. When the tooth top length was set to 0.1 mm, all overhanging specimens failed to form successfully. Tooth base length also plays a critical role in support removability, with removal difficulty initially decreasing and then stabilizing as the tooth base length increases. Based on the trade-off between forming quality and support removability, the optimal parameter combination was identified as: tooth height of 0.4 mm, tooth top length of 0.7 mm, tooth base length of 1.0 mm, and tooth base spacing of 0.3 mm. A validation experiment conducted using this optimized configuration demonstrated good forming accuracy in the support contact area, with a deformation value of −0.208 mm, confirming the effectiveness and reliability of the proposed parameters. This study not only provides a theoretical foundation for the optimal design of block supports in LPBF but also offers experimental data and practical guidance for selecting support parameters in the fabrication of overhanging structures. Full article

Additive manufacturing by Selective Laser Melting (SLM) or, precisely, Laser Powder Bed Fusion (L-PBF), offers new opportunities for producing electrically functional metal components with tailored geometric designs and material properties. In this study, the electrical contact resistance and related properties of 3D-printed samples made from Al5086 aluminum alloy are tested. The benefits of Al5086 include flexibility without cracking, welding ability and exceptional resistance to corrosion in saltwater and industrial environments. This makes it an excellent candidate for power electric applications due to its good electrical conductivity and corrosion resistance. In this study, an analysis is performed to assess the impact of internal volumetric properties and surface parameters on general contact resistance performance. This analysis combines advanced testing procedures and parameter identification of the electric contact resistance model. This study investigates how these parameters affect contact resistance, which is a critical factor in the reliability of electrical devices. Electrical contact resistance was measured using a dedicated test setup that applied consistent pressure and maintained directional alignment. The results show that the printing direction of the samples slightly affects resistance values due to the continuity of current paths along the build direction, likely due to homogenous inter-layer boundaries and mechanical stress distribution. These findings suggest that both print orientation and internal structure must be considered when designing 3D-printed contact elements for electrical applications. Overall, this study demonstrates the feasibility of using L-PBF-fabricated aluminum components in electric applications where both electrical and structural performances are essential. Full article

To address the challenges of printing quality and dimensional accuracy in the fabrication of TC11 titanium alloy thin-walled components via laser powder bed fusion (L-PBF), this study systematically optimized the L-PBF process parameters and investigated the printing limits of thin-walled structures, providing theoretical and practical guidance for high-precision manufacturing. First, single-factor experiments were conducted to examine the effects of laser power, scanning speed, and hatch spacing on relative density. Subsequently, response surface analysis was performed using a Box–Behnken design to establish a predictive model with relative density and surface roughness as the response variables, enabling multi-objective parameter optimization. Based on the optimized parameters, a series of thin-walled structures with varying wall thicknesses were fabricated, the resulting printing defects were analyzed, and a mathematical model correlating wall thickness with limiting printing height was established. The response surface model exhibited excellent statistical significance, with an F-value of 0.9930 and a p-value of less than 0.0001, indicating a highly reliable fit. The coefficient of determination (R²) of the model was 0.9889, while the adjusted R² and predicted R² were 0.9747 and 0.9146, respectively, confirming the model’s good predictive capability. The optimal process parameters obtained through the model were a laser power of 190 W, a scanning speed of 1100 mm/s, and a hatch spacing of 0.10 mm. Validation experiments conducted under these conditions yielded a deviation of only 5.33% between the predicted and experimental comprehensive scores, demonstrating the accuracy of the model. A key achievement of this study is the establishment of a piecewise mathematical model relating wall thickness to limiting printing height: a cubic polynomial for wall thicknesses in the range of 0.2 ≤ t ≤ 0.5 mm ($h=107.5t^3-161.5t^2+106.7t-5.86$) and a quadratic polynomial for wall thicknesses in the range of 0.5 ≤ t ≤ 0.8 mm ($h=- 0.25t^2+34.89t+3.17$). This model enables accurate prediction of the formability of thin-walled structures. Full article

Laser powder bed fusion (LPBF) technology has now reached a significant level of commercial maturity, offering some of the most reliable solutions in the additive manufacturing (AM) field. However, AM processes may introduce defects that result in high variability of mechanical properties and low reproducibility. This entails the need to thoroughly understand the behavior of the materials used, studying their response to the different types of stresses typical of real-world applications. The research activity presented consists of the analysis of the mechanical properties of the aluminum alloy AlSi10Mg, which is widely used due to its good strength-to-density ratio. Focus is put on the response to axial, torsional, and combined axial-torsional static and fatigue strength, comparing as-built T6 heat-treated conditions. Full article

Laser Powder Bed Fusion (LPBF) enables the fabrication of complex titanium alloy components with high geometric freedom; however, surface integrity and tribological performance remain critical limitations for sliding-contact applications in biomedical and aerospace systems. In this study, the influence of in-layer laser remelting on the microstructure, surface topography, and dry sliding tribological behavior of LPBF-fabricated Ti-6Al-4V ELI (Grade 23) is systematically investigated. Disc-shaped specimens were produced using single-scan (SS) and double-scan (DS, in-layer remelting) strategies and tested in ball-on-disc configuration against AISI 52100 steel at a constant normal load of 10 N and three sliding speeds of 0.10, 0.15, and 0.20 m·s⁻¹. Microstructural and phase-related characteristics were analyzed by X-ray diffraction combined with Rietveld refinement and Warren–Averbach analysis, revealing that the DS strategy increases retained β-phase fraction (up to 5.2%) and promotes crystallite coarsening relative to the SS condition, without significantly altering bulk hardness. Surface morphology examined by SEM/EDS and AFM revealed a more homogeneous near-surface topography in the DS condition. Tribological results indicate that sliding speed governs steady-state friction and wear, with specific wear rates increasing progressively from 5.13 to 5.44 × 10⁻⁴ mm³·N⁻¹·m⁻¹ for SS and from 6.47 to 7.52 × 10⁻⁴ mm³·N⁻¹·m⁻¹ for DS across the investigated speed range. The DS specimens exhibited higher wear rates than the SS condition across all tested speeds, while steady-state COF values remained comparable between strategies, indicating that remelting-induced microstructural modifications affect material removal mechanisms without proportionally destabilizing the frictional regime. These findings suggest that in-layer laser remelting represents a process-integrated parameter with measurable consequences for surface integrity and tribological performance, though the generalizability of these results warrants validation across broader experimental conditions. Full article