Search Results (1,286)

In this paper, SiC and Si/SiC ceramics were fabricated using direct laser powder bed fusion with chemical vapor infiltration. Their microstructure, mechanical properties and the impacts of silicon addition were analyzed. The incorporation of silicon led to an increase in the relative density of the silicon carbide ceramics from 76.4% to 78.3% and the compression strength increased from 39 ± 13 MPa to 90 ± 8 MPa after laser powder bed fusion with chemical vapor infiltration. The melting and re-solidification of silicon allows the silicon to encapsulate the silicon carbide grains, changing the microstructure and the failure mechanism of the silicon carbide ceramics, resulting in a small amount of silicon residue. In the LPBF-CVI SiC ceramic specimen, the LPBF-formed SiC exhibits a microhardness of 24.2 ± 1.0 GPa. In LPBF-CVI Si/SiC, the spherical dual-phase structure displays a moderately increased hardness (25.9 ± 4.4 GPa), and the CVI-formed SiC exhibits a hardness of 55.3 ± 9.3 GPa. Full article

Laser powder bed fusion (LPBF) is an advanced additive manufacturing technology that is gaining increasing interest for biomedical implants because it can produce dense, patient-specific metallic components with controlled microstructures. This study investigated the LPBF fabrication of 316L stainless steel, which is widely used in orthopedic and dental implants, and examined the effects of laser power and scanning speed on the microstructure and mechanical properties relevant to biomedical applications. The study achieved 99.97% density and refined columnar and cellular austenitic grains, with optimized molten pool morphology. The optimal LPBF parameters, 190 W laser power and 700 mm/s, produced a tensile strength of 762.83 MPa and hardness of 253.07 HV_0.2, which exceeded the values of conventional cast 316L stainless steel. These results demonstrated the potential of optimized LPBF 316L stainless steel for functional biomedical applications that require high mechanical integrity and biocompatibility. Full article

This study systematically investigates the homogenization-induced Laves phase dissolution kinetics and recrystallization mechanisms in laser powder bed fusion (L-PBF) processed IN718 superalloy. The as-built material exhibits a characteristic fine dendritic microstructure with interdendritic Laves phase segregation and high dislocation density, featuring directional sub-grain boundaries aligned with the build direction. Laves phase dissolution demonstrates dual-stage kinetics: initial rapid dissolution (0–15 min) governed by bulk atomic diffusion, followed by interface reaction-controlled deceleration (15–60 min) after 1 h at 1150 °C. Complete dissolution of the Laves phase is achieved after 3.7 h at 1150 °C. Recrystallization initiates preferentially at serrated grain boundaries through boundary bulging mechanisms, driven by localized orientation gradients and stored energy differentials. Grain growth kinetics obey a fourth-power time dependence, confirming Ostwald ripening-controlled boundary migration via grain boundary diffusion. Such a study is expected to be helpful in understanding the microstructural development of L-PBF-built IN718 under heat treatments. Full article

This work expands the processing window of the laser powder bed fusion (LPBF) processing of WE43 magnesium alloy by evaluating laser powers and scanning speeds up to 400 W and 1200 mm/s, and their effect on densification, microstructure, and electrochemical performance. Relative density of 99.9% was achieved for 300 W and 800 mm/s, showing that the use of high laser power is not a limitation for the manufacturing of Mg alloys, as has been usually considered. Microstructural characterisation revealed refined grains and the presence of RE-rich intermetallic particles, while microhardness increased with height due to thermal gradients. Electrochemical testing in 3.5 wt.% NaCl solution, a more aggressive media than those already used, indicated that the corrosion of samples with density values below 99% is conditioned by the porosity; however, above this value, in the WE43, the corrosion evolution is more related to the microstructure of the samples, according to electrochemical evaluation. This study demonstrates the viability of high-energy LPBF processing for WE43, offering optimised mechanical and corrosion properties for biomedical and structural applications. Full article

Due to the high potential of shot peening to improve the surface quality of additively manufactured components, in this work, the influence on surface morphology and, thus, the surface topography and selected properties of the surface and subsurface regions of additively manufactured parts is analysed. For this, cubic specimens made of stainless steel 316L and AlSi10Mg were manufactured via powder bed fusion laser beam metal (PBF-LB/M), and subsequently, their “as-built” surfaces were shot peened. Shot peening was conducted with stainless steel or ceramic beads using pressures of 3 and 5 bar. The resulting morphologies were analysed regarding topography, microstructure and mechanical properties (hardness and cyclic deformation behaviour) in the subsurface region and the residual stresses. The results demonstrate a strong plastic deformation due to shot peening, resulting in a decreased surface roughness as well as an increased hardness and compressive residual stresses near the surface. These effects were generally more pronounced after using higher peening pressure and/or ceramic beads. Note that two sets of PBF-LB/M parameters were used to produce the AlSi10Mg specimens. The investigation of these specimens reveals an interrelation between the parameters used in shot peening and PBF-LB/M on the resulting surface morphology. Full article

This study aims to determine the optimal low-temperature stress relieving heat treatment that minimizes residual stresses while preserving corrosion resistance in Laser Powder Bed Fusion (L-PBF) processed Ti6Al4V alloy. Specifically, it investigates the effects of stress relieving at 400 °C, 600 °C, and 800 °C on microstructure, residual stress, and electrochemical performance. Specimens were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), and electrochemical techniques. A novel microcapillary electrochemical method was employed to precisely assess passive layer stability and corrosion behaviour under simulated oral conditions, including fluoride contamination and tensile loading. Results show that heat treatments up to 600 °C effectively reduce residual stress with minimal impact on corrosion resistance. However, 800 °C treatment leads to a phase transformation from α′ martensite to a dual-phase α + β structure, significantly compromising passive film integrity. The findings establish 600 °C as the optimal stress-relieving temperature for balancing mechanical stability and electrochemical performance in biomedical and aerospace components. Full article

The corrosion behavior of an additively manufactured Mg-1Zn alloy was investigated in both the transverse and longitudinal directions relative to the build direction, in the as-built condition and after annealing at 350 °C for 24 h under high vacuum. Microstructural characterization using XRD and SEM revealed the presence of magnesium oxide (MgO) and the absence of intermetallic second-phase particles. Optical microscopy (OM) images and Electron Backscatter Diffraction (EBSD) maps showed a highly complex grain morphology with anomalous, anisotropic shapes and a heterogeneous grain size distribution. The microstructure includes grains with a pronounced columnar morphology aligned along the build direction and is therefore characterized by a strong crystallographic texture. Electrochemical techniques, including PDP and EIS, along with gravimetric H₂ collection, concluded that the transverse plane exhibited greater corrosion resistance compared to the longitudinal plane. Additionally, an increase in cathodic kinetics was observed when comparing as-built with heat-treated samples. Full article

Laser beam powder bed fusion of metals (PBF-LB/M, or simply L-PBF) has emerged as one of the most competitive additive manufacturing technologies for producing complex metallic components with high precision, design freedom, and minimal material waste. Among the various categories of additive manufacturing processes, L-PBF stands out, paving the way for the execution of part designs with geometries previously considered unfeasible. Despite offering several advantages, parts with overhang features require the use of support structures to provide dimensional stability of the part. Support structures achieve this by resisting residual stresses generated during processing and assisting heat dissipation. Although the scientific community acknowledges the role of support structures in the success of L-PBF manufacturing, they have remained relatively underexplored in the literature. In this context, the present work investigated the impact of laser power and scanning speed on the dimensioning, integrity and tensile strength of single-walled block type support structures manufactured in AISI 316L stainless steel. The method proposed in this work is divided in two stages: processing parameter exploration, and mechanical characterization. The results indicated that support structures become more robust and resistant as laser power increases, and the opposite effect is observed with an increment in scanning speed. In addition, defects were detected at the interfaces between the bulk and support regions, which were crucial for the failure of the tensile test specimens. For a layer thickness corresponding to 0.060 mm, it was verified that the combination of laser power and scanning speed of 150 W and 500 mm/s resulted in the highest tensile resistance while respecting the dimensional deviation requirement. Full article

The study investigates the influence of microstructures on fatigue behavior and failure mechanisms of the α-β titanium alloy Ti6246, fabricated via Powder Bed Fusion-Laser Beam (PBF-LB). In particular, the investigation assesses the effect of two post-processing heat treatments, namely α-β annealing at 875 °C (AN875) and solution treatment at 825 °C followed by aging at 500 °C (STA825), on the alloy’s rotating and bending fatigue behavior. The results indicate that the STA825 condition provides superior fatigue resistance (+25%) compared to AN875, due to the presence of a finer bilamellar microstructure, characterized by thinner primary α lamellae (α_p) and a more homogeneous distribution of secondary α lamellae (α_s) within the β matrix. Additionally, an investigation conducted using the Kitagawa–Takahashi (KT) approach and the El-Haddad model, based on the relationship between the fatigue limit and defect sensitivity, revealed improved crack propagation resistance from pre-existing defects (ΔK_th) for the STA825 condition compared to AN875. Notably, the presence of fine α_s after aging for STA825 is effective in delaying crack nucleation and propagation at early stages, while refined α_p contributes to hindering macrocrack growth. The fatigue behavior of the STA825-treated Ti6246 alloy was even superior to that of the PBF-LB-processed Ti64, representing a viable alternative for the production of high-performance components in the automotive and aerospace sectors. Full article

To capture the complex metallic spatter and melt pool behavior during the rapid interaction between the laser and metal material, high-speed cameras are applied to record the laser powder bed fusion process and generate a large volume of image data. In this study, four deep learning algorithms are applied: YOLOv5, Fast R-CNN, RetinaNet, and EfficientDet. They are trained by the recorded videos to learn and extract information on spatter and melt pool behavior during the laser powder bed fusion process. The well-trained models achieved high accuracy and low loss, demonstrating strong capability in accurately detecting and tracking spatter and melt pool dynamics. A stability index is proposed and calculated based on the melt pool length change rate. Greater index value reflects a more stable melt pool. We found that more spatters were detected for the unstable melt pool, while fewer spatters were found for the stable melt pool. The spatter’s size can affect its initial ejection speed, and large spatters are ejected slowly while small spatters are ejected rapidly. In addition, more than 58% of detected spatters have their initial ejection angle in the range of 60–120$°$. These findings provide a better understanding of spatter and melt pool dynamics and behavior, uncover the influence of melt pool stability on spatter formation, and demonstrate the correlation between the spatter size and its initial ejection speed. This work will contribute to the extraction of important information from high-speed recorded videos for additive manufacturing to reduce waste, lower cost, enhance part quality, and increase process reliability. Full article

In the framework of hydrogen production and storage for clean energy generation, the resistance to hydrogen embrittlement of a newly developed austenitic stainless steel is presented. Gas-atomized metal powders prepared from secondary-sourced metals were employed to manufacture test specimens with Laser Powder Bed Fusion (LPBF) technology. After machining and exposure to a controlled, pressurized hydrogen atmosphere at high temperature, the effect of hydrogen charging on the mechanical performance under static and dynamic conditions was investigated. The stabilizing effect of the optimized chemical composition is reflected in the absence of degradation effects on Yield Stress (YS), Ultimate Tensile Stress (UTS), and fatigue life observed for specimens exposed to hydrogen. Moreover, despite a moderate reduction in the elongation at fracture observed by increasing the hydrogen charging time, ductility loss calculated as Relative Reduction of Area (RRA) remains substantially unaffected by the duration of exposure to hydrogen and demonstrates that the austenitic steel is capable of resisting hydrogen embrittlement (HE). Full article

Discontinuous fibers are commonly added to matrix materials in additive manufacturing to enhance properties, but such benefits may be constrained by print and fiber orientation. The additive processes of forming rasters and layers in powder bed fusion inherently cause anisotropy in printed parts. Many print parameters, such as laser, temperature, and hatch pattern, influence the anisotropy of tensile properties. This study characterizes fiber orientation attributed to recoating non-encapsulated fibers and the resulting anisotropic tensile properties. Tensile and fracture properties of polyamide 12 reinforced with 0%, 2.5%, 5%, and 10% discontinuous carbon fibers by volume were characterized in two primary print/tensile loading orientations: tensile loading parallel to the recoater (“horizontal specimens”) and tensile load along the build axis (“vertical specimens”). Density and fractographic analysis indicate a homogeneous mixture with low porosity and primary fiber orientation along the recoating direction for both print orientations. Neat specimens (zero fiber) loaded in either direction have similar tensile properties. However, fiber-reinforced vertical specimens have significantly reduced consistency and tensile strength as fiber content increased, while the opposite is true for horizontal specimens. These datasets and results provide a mechanism to tune material properties and improve the functionality of selectively laser-sintered fiber-reinforced parts through print orientation selection. These datasets could be used to customize functionally graded parts with multi-material selective laser-sintering manufacturing. Full article

This study explores the efficacy of magnetic abrasive finishing (MAF) with planetary kinematics for post-processing Inconel 939 components fabricated by laser powder bed fusion (LPBF). Given the critical limitations in surface quality of LPBF-produced parts—especially in hard-to-machine superalloys like Inconel 939—there is a pressing need for advanced, adaptable finishing techniques that can operate effectively on complex geometries. This research focuses on optimizing the process parameters—eccentricity, rotational speed, and machining time—to enhance surface integrity following preliminary vibratory machining. Custom-designed samples underwent sequential machining, including heat treatment and 4 h vibratory machining, before MAF was applied under controlled conditions using ferromagnetic Fe-Si abrasives. Surface roughness measurements demonstrated a significant reduction, achieving Ra values from 1.21 µm to below 0.8 µm in optimal conditions, representing more than a fivefold improvement compared to the as-printed state (5.6 µm). Scanning Electron Microscopy (SEM) revealed progressive surface refinement, with MAF effectively removing adhered particles left by prior processing. Statistical analysis confirmed the dominant influence of eccentricity on the surface profile parameters, particularly Rz. The findings validate the viability of MAF as a precise, controllable, and complementary finishing method for LPBF-manufactured Inconel 939 components, especially for geometrically complex or hard-to-reach surfaces. Full article

This study investigates the influence of process parameters on the fabrication and mechanical performance of Scalmalloy^® lattice structures produced via laser powder bed fusion (PBF-LB) and their mechanical responses at different cell size. A full-factorial design of experiments was employed to evaluate the effect of scan speed, hatch distance, and downskin power on internal porosity and dimensional accuracy. Regression models revealed significant relationships, with optimised parameters identified at a scan speed of 700 mm/s, hatch distance of 0.13 mm, and downskin power of 80 W. Mechanical characterisation through tensile tests of bulk samples and compression tests of lattice structures highlighted the strengthening effects of the heat treatment. Experimental data on quasi-elastic gradient and yield strength were compared to predictions from the Ashby–Gibson model, revealing a partial agreement but noticeable deviations attributed to cell geometry and manufacturing defects. The scaling laws observed differed from the classical model, particularly in the yield strength exponent, indicating the need for empirical models tailored to metallic lattices. This work provides key insights into the optimisation of PBF-LB parameters for Scalmalloy^® and underlines the complex interplay between process parameters, structural design, and mechanical behaviour. Full article

Manufacturing processes are inherently complex, multi-objective in nature, and highly sensitive to process parameter settings. This paper presents two simple and efficient optimization algorithms—Best–Worst–Random (BWR) and Best–Mean–Random (BMR)—developed to solve both constrained and unconstrained optimization problems of manufacturing processes involving single, multi-, and many-objectives. These algorithms are free from metaphorical inspirations and require no algorithm-specific control parameters, which often complicate other metaheuristics. Extensive testing reveals that BWR and BMR consistently deliver competitive, and often superior, performance compared to established methods. Their multi- and many-objective extensions, named MO-BWR and MO-BMR, respectively, have been successfully applied to tackle 2-, 3-, and 9-objective optimization problems in advanced manufacturing processes such as friction stir processing (FSP), ultra-precision turning (UPT), laser powder bed fusion (LPBF), and wire arc additive manufacturing (WAAM). To aid in decision-making, the proposed BHARAT can be integrated with MO-BWR and MO-BMR to identify the most suitable compromise solution from among a set of Pareto-optimal alternatives. The results demonstrate the strong potential of the proposed algorithms as practical tools for intelligent decision-making in real-world manufacturing applications. Full article