Exploring Piezoelectric Actuation towards Its Applications in Laser Powder Bed Fusion Additive Manufacturing.

Piezoelectric materials, which exhibit a charge distribution across the surfaces in reaction to mechanical strain, find significant utility in actuation and sensing applications. Apart from actuation applications like acoustic devices, motors, and vibration damping, an emerging domain for ultrasonic actuators lies in additive manufacturing processes. Ultrasonic waves applied during solidification aim to modulate grain structure and minimize defects. This research focuses on a fixture designed to facilitate and optimize ultrasonic wave propagation through the build plate in laser powder bed fusion additive manufacturing by utilizing a piezoelectric transducer. Three implementations of piezoelectric transducers were evaluated based on their out-of-plane ultrasonic velocity transmissions. It was determined that a thin plate adhered to the surface of the piezoelectric transducer yielded the most favorable outcomes for implementation, achieving 100% transmission of velocity and energy. Preliminary analysis of melt pool morphology and defects in single-track laser scanning experiments demonstrated the impact of ultrasound on solidification, hinting at a novel approach to enhancing the printability of alloys in laser powder bed fusion additive manufacturing processes. The optimal fixture and the explored transducing efficiency could further guide advanced ultrasound testing to enable in situ defect and texture detection during the additive manufacturing processes.

An Electrical Resistance Diagnostic for Conductivity Monitoring in Laser Powder Bed Fusion.

With the growing interest in metal additive manufacturing using laser powder bed fusion (LPBF), there is a need for advanced in-situ nondestructive evaluation (NDE) methods that can dynamically monitor manufacturing process-related variations, that can be used as a feedback mechanism to further improve the manufacturing process, leading to parts with improved microstructural properties and mechanical properties. Current NDE techniques either lack sensitivity beyond build layer, are costly or time-consuming, or are not compatible for in-situ integration. In this research, we develop an electrical resistance diagnostic for in-situ monitoring of powder fused regions during laser powder bed fusion printing. The technique relies on injecting current into the build plate and detecting voltage differences from conductive variations during printing using a simple, cheap four-point electrode array directly connected to the build plate. A computational model will be utilized to determine sensitivities of the approach, and preliminary experiments will be performed during the printing process to test the overall approach.

Hot isostatic pressing as an alternative thermo-mechanical treatment for metallic full-arch implant-supported frameworks obtained by additive and subtractive manufacturing technology: Vertical and horizontal fit, screw removal torque, and stress analysis.

PURPOSE: To assess vertical and horizontal fit, screw removal torque, and stress analysis (considered biomechanical aspects) of full-arch implant frameworks manufactured in Ti-6Al-4V through milling, and additive manufacturing Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM), and the effect of the thermo-mechanical treatment Hot Isostatic Pressing (HIP) as a post-treatment after manufacturing. MATERIAL AND METHODS: Maxillary full-arch implant frameworks were made by milling, DMLS, and EBM. The biomechanical assessments were screw removal torque, strain-gauge analyses, and vertical and horizontal marginal fits. The vertical fit was assessed by the single-screw test and with all screws tightened. All frameworks were submitted to a standardized HIP cycle (920°C, 1000 bar pressure, 2 h), and the tests were repeated (α = 0.05). RESULTS: At the initial time, milled frameworks presented higher screw removal torque values, and DMLS and EBM frameworks presented lower levels of strain. Using the single-screw test, milled and DMLS frameworks presented higher vertical fit values, and with all screws tightened and horizontally, higher fit values were found for milled frameworks, followed by DMLS and EBM. After HIP, milling and EBM frameworks presented higher screw removal torque values; the lowest strain values were found for EBM. Using the single-screw test, milled and DMLS frameworks presented higher vertical fit values, and with all screws tightened and horizontally no differences were found. CONCLUSIONS: DMLS and EBM full-arch frameworks presented adequate values of screw removal torque, strain, and marginal fit, although the worst values of marginal fit were found for EBM frameworks. The HIP cycle enhanced the screw removal torque of milled and EBM frameworks and reduced the strain values of milled frameworks. The HIP represents a reliable post-treatment for Ti-6Al-4V dental prostheses produced by milling and EBM technologies.

A Comparison of Solidification Structures and Submicroscale Cellular Segregation in Rapidly Solidified Stainless Steels Produced via Two-Piston Splat Quenching and Laser Powder Bed Fusion.

Fusion-based additive manufacturing techniques leverage rapid solidification (RS) conditions to create parts with complex geometries, unique microscale/nanoscale morphological features, and elemental segregation. Three custom composition stainless steel alloys with varying chromium equivalence to nickel equivalence ratio (Creq/Nieq) between 1.53 and 1.95 were processed using laser powder bed fusion (LPBF) and/or two-piston splat quenching (SQ) to produce solidification rates estimated between 0.4 and 0.8 m/s. Both scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were utilized to collect high-resolution images, electron backscatter diffraction (EBSD) phase identification, and measure cellular segregation. Similar features were observed in both LPBF and SQ samples including phase and microstructure, nanoscale oxide particles, cell size, and segregation behavior. However, dislocation pileup was observed along the cell boundaries only in the LPBF austenite solidified microstructure. Targeted adjustment of the SQ feedstock Cr and Ni concentrations, within the ASTM A240 specification for 316L resulted in no observable impact on the cell size, oxide particle size, or magnitude of segregation. Also, the amount of Ni segregation in the ferrite solidified microstructures did not significantly differ, regardless of Cr/Nieq or processing technique. SQ is demonstrated as capable of simulating RS rates and microstructures similar to LPBF for use as an alternative screening tool for new RS alloy compositions.

Eddy Current Sensors Optimization for Defect Detection in Parts Fabricated by Laser Powder Bed Fusion.

The production of parts by additive manufacturing is an important issue for the reduction in manufacturing costs and the creation of complex geometries. Optical inspection is often implemented in the machines during the manufacturing process in order to monitor the possible generated defects. However, it is also crucial to test the quality of the manufactured parts after their fabrication and monitor their health throughout their industrial lifetime. Therefore structural health monitoring (SHM) methods need to be studied or designed. In this paper, the eddy current method is used to control fabricated parts, as this technique is adapted to detect surface and shallow defects in conductive materials. Using simulations with the CIVA non-destructive testing software package, several sensors and their parameters were tested in order to determine the most optimal ones: a separate transmitter/receiver sensor and an isotropic sensor were finally designed. The comparison of these sensors' efficiency was made on the detection of notches and engraved letters based on simulation and experimental tests on parts fabricated by laser powder bed fusion (L-PBF) in order to determine the optimal sensor. The various tests showed that the isotropic sensor is the optimal one for the detection and characterization of defects.

Monitoring of Single-Track Melting States Based on Photodiode Signal during Laser Powder Bed Fusion.

Single track is the basis for the melt pool modeling and physics work in laser powder bed fusion (LPBF). The melting state of a single track is closely related to defects such as porosity, lack of fusion, and balling, which have a significant impact on the mechanical properties of an LPBF-created part. To ensure the reliability of part quality and repeatability, process monitoring and feedback control are emerging to improve the melting states, which is becoming a hot topic in both the industrial and academic communities. In this research, a simple and low-cost off-axial photodiode signal monitoring system was established to monitor the melting pools of single tracks. Nine groups of single-track experiments with different process parameter combinations were carried out four times and then thirty-six LPBF tracks were obtained. The melting states were classified into three classes according to the morphologies of the tracks. A convolutional neural network (CNN) model was developed to extract the characteristics and identify the melting states. The raw one-dimensional photodiode signal data were converted into two-dimensional grayscale images. The average identification accuracy reached 95.81% and the computation time was 15 ms for each sample, which was promising for engineering applications. Compared with some classic deep learning models, the proposed CNN could distinguish the melting states with higher classification accuracy and efficiency. This work contributes to real-time multiple-sensor monitoring and feedback control.

X-ray tomography for the advancement of laser powder bed fusion additive manufacturing.

X-ray computed tomography is a powerful tool to nondestructively inspect additively manufactured parts. Additive manufacturing of metals, especially laser powder bed fusion, is increasingly being adopted for serial production of critical components in aerospace, automotive and various other industries. The technology holds huge potential for more efficient material usage and light weighting of components, among the many advantages. As this new production method is being ramped up and refined in various industry sectors, X-ray tomography is critical to the advancement of the quality of the produced components. X-ray tomography allows the nondestructive evaluation of the structural integrity of the parts produced, which in turn provides confidence in the expected performance of the parts. Besides final inspection of parts for porosity/defects and dimensional tolerances for a pass/fail decision, X-ray tomography also has a critical role to play in advancing and improving the additive manufacturing processes. This process improvement refers to the inspection of small representative coupon samples on a microscopic scale, in order to optimize the process parameters such as laser power, speed, scan strategy and various others. In this work, we describe the evaluation of small solid cube coupon samples and lattice structure coupon samples. These examples are meant to improve the understanding of the potential of X-ray tomography in advancing additive manufacturing processes (in contrast to its usual use for nondestructive testing of final parts), thereby providing support towards qualification of these processes and the parts produced in these processes. X-ray tomography, therefore, plays a key role in the adoption and qualification of high-quality metal additive manufacturing.

Encoding Stability into Laser Powder Bed Fusion Monitoring Using Temporal Features and Pore Density Modelling.

In laser powder bed fusion (LPBF), melt pool instability can lead to the development of pores in printed parts, reducing the part's structural strength. While camera-based monitoring systems have been introduced to improve melt pool stability, these systems only measure melt pool stability in limited, indirect ways. We propose that melt pool stability can be improved by explicitly encoding stability into LPBF monitoring systems through the use of temporal features and pore density modelling. We introduce the temporal features, in the form of temporal variances of common LPBF monitoring features (e.g., melt pool area, intensity), to explicitly quantify printing stability. Furthermore, we introduce a neural network model trained to link these video features directly to pore densities estimated from the CT scans of previously printed parts. This model aims to reduce the number of online printer interventions to only those that are required to avoid porosity. These contributions are then implemented in a full LPBF monitoring system and tested on prints using 316L stainless steel. Results showed that our explicit stability quantification improved the correlation between our predicted pore densities and true pore densities by up to 42%.

3D Printed Cobalt-Chromium-Molybdenum Porous Superalloy with Superior Antiviral Activity.

COVID-19 pandemic and associated supply-chain disruptions emphasise the requirement for antimicrobial materials for on-demand manufacturing. Besides aerosol transmission, SARS-CoV-2 is also propagated through contact with virus-contaminated surfaces. As such, the development of effective biofunctional materials that can inactivate SARS-CoV-2 is critical for pandemic preparedness. Such materials will enable the rational development of antiviral devices with prolonged serviceability, reducing the environmental burden of disposable alternatives. This research reveals the novel use of Laser Powder Bed Fusion (LPBF) to 3D print porous Cobalt-Chromium-Molybdenum (Co-Cr-Mo) superalloy with potent antiviral activity (100% viral inactivation in 30 min). The porous material was rationally conceived using a multi-objective surrogate model featuring track thickness (tt) and pore diameter (ϕd) as responses. The regression analysis found the most significant parameters for Co-Cr-Mo track formation to be the interaction effects of scanning rate (Vs) and laser power (Pl) in the order PlVs>Vs>Pl. Contrastively, the pore diameter was found to be primarily driven by the hatch spacing (Sh). The study is the first to demonstrate the superior antiviral properties of 3D printed Co-Cr-Mo superalloy against an enveloped virus used as biosafe viral model of SARS-CoV-2. The material significantly outperforms the viral inactivation time of other broadly used antiviral metals such as copper and silver, as the material's viral inactivation time was from 5 h to 30 min. As such, the study goes beyond the current state-of-the-art in antiviral alloys to provide extra protection to combat the SARS-CoV-2 viral spread. The evolving nature of the COVID-19 pandemic brings new and unpredictable challenges where on-demand 3D printing of antiviral materials can achieve rapid solutions while reducing the environmental impact of disposable devices.

Biological and Corrosion Evaluation of In Situ Alloyed NiTi Fabricated through Laser Powder Bed Fusion (LPBF).

In this work, NiTi alloy parts were fabricated using laser powder bed fusion (LBPF) from pre-alloyed NiTi powder and in situ alloyed pure Ni and Ti powders. Comparative research on the corrosive and biological properties of both studied materials was performed. Electrochemical corrosion tests were carried out in phosphate buffered saline at 37 °C, and the degradation rate of the materials was described based on Ni ion release measurements. Cytotoxicity, bacterial growth, and adhesion to the surface of the fabricated coupons were evaluated using L929 cells and spherical Escherichia coli (E. coli) bacteria, respectively. The in situ alloyed NiTi parts exhibit slightly lower corrosion resistance in phosphate buffered saline solution than pre-alloyed NiTi. Moreover, the passive layer formed on in situ alloyed NiTi is weaker than the one formed on the NiTi fabricated from pre-alloyed NiTi powder. Furthermore, in situ alloyed NiTi and NiTi made from pre-alloyed powders have comparable cytotoxicity and biological properties. Overall, the research has shown that nitinol sintered using in situ alloyed pure Ni and Ti is potentially useful for biomedical applications.

Occupational exposure during metal additive manufacturing: A case study of laser powder bed fusion of aluminum alloy.

Occupational exposure during metal additive manufacturing (Laser Powder Bed Fusion) using an aluminum alloy (AlSi10Mg) was assessed. Background aerosols before manufacturing, powder sieving, machine loading, manufacturing, machine unloading, powder unpacking, and machine cleaning were analyzed. Measurements were taken simultaneously at the source, in the near field, and on the operator during five manufacturing cycles. Aerosol measurement devices and physico-chemical techniques were used to determine the particle number or mass concentration (DiSCmini, core particle counter and sampling cassette), particle size distribution (NanoScan, optical particle detector and impactor), and the shape/size and chemical compositions of the inhalable particles (laser diffraction, inductively coupled plasma spectroscopy, scanning electron microscopy, energy dispersive X-ray microanalysis, and Brunauer-Emmett-Teller Method). The laser powder-bed fusion machine emitted in the additive manufacturing room an inhalable fraction of 2.37 ± 0.35 mg/m3, with an aerosol number concentration ranging from 2 × 104 to 105 #/cm3 and a mass mean aerodynamic diameter of 318 nm. A relatively low concentration level was observed in the near field of the machine with an aerosol number concentration of ∼104 #/cm3. A higher concentration level on the operator was attained during the unpacking and cleaning steps, showing an inhalable fraction of 1.73 ± 0.30 mg/m3. Al and Mg nanoparticles were aerosolized at the source (inside the laser powder-bed fusion machine) with a particle size distribution of 153 nm for Al and 117 nm for Mg and an aerosol number concentration reaching ten times that of the background aerosol level. The number or mass concentration of particles in the room atmosphere was increased to double that of the background aerosol level at specific workstations during manufacturing. Metal additive manufacturing is a source of potential occupational exposure to airborne metal nanoparticles. Particle-counting instruments showed high numbers of nanoparticles and some important peaks of particles ranging from 10 nm to 10 µm or larger at specific work tasks in the Additive Manufacturing (AM) environment. A multimetric approach was used to characterize the particle emissions resulting from this type of additive manufacturing.

On thermal properties of metallic powder in laser powder bed fusion additive manufacturing.

Powder thermal properties play a critical role in laser powder-bed fusion (LPBF) additive manufacturing, specifically, the reduced effective thermal conductivity compared to that of the solid significantly affects heat conduction, which can influence the melt pool characteristics, and consequently, the part mechanical properties. This study intends to indirectly measure the thermal conductivity of metallic powder, nickel-based super alloy 625 (IN625) and Ti-6Al-4V (Ti64), in LPBF using a combined approach that consists of laser flash analysis, finite element (FE) heat transfer modeling and a multivariate inverse method. The test specimens were designed and fabricated by a LPBF system to encapsulate powder in a hollow disk to imitate powder-bed conditions. The as-built specimens were then subjected to laser flash testing to measure the transient thermal response. Next, an FE model replicate the hollow disk samples and laser flash testing was developed. A multi-point optimization algorithm was used to inversely extract the thermal conductivity of LPBF powder from the FE model based on the measured transient thermal response. The results indicate that the thermal conductivity of IN625 powder used in LPBF ranges from 0.65 W/(m·K) to 1.02 W/(m·K) at 100 °C and 500 °C, respectively, showing a linear relationship with the temperature. On the other hand, Ti64 powder has a lower thermal conductivity than IN625 powder, about 35% to 40% smaller. However, the thermal conductivity ratio of the powder to the respective solid counterpart is quite similar between the two materials, about 4.2% to 6.9% for IN625 and 3.4% to 5.2% for Ti64.

Ultrafast X-ray imaging of laser-metal additive manufacturing processes.

The high-speed synchrotron X-ray imaging technique was synchronized with a custom-built laser-melting setup to capture the dynamics of laser powder-bed fusion processes in situ. Various significant phenomena, including vapor-depression and melt-pool dynamics and powder-spatter ejection, were captured with high spatial and temporal resolution. Imaging frame rates of up to 10 MHz were used to capture the rapid changes in these highly dynamic phenomena. At the same time, relatively slow frame rates were employed to capture large-scale changes during the process. This experimental platform will be vital in the further understanding of laser additive manufacturing processes and will be particularly helpful in guiding efforts to reduce or eliminate microstructural defects in additively manufactured parts.

A Combined Experimental-Numerical Method to Evaluate Powder Thermal Properties in Laser Powder Bed Fusion.

Powder bed metal additive manufacturing (AM) utilizes a high-energy heat source scanning at the surface of a powder layer in a predefined area to be melted and solidified to fabricate parts layer by layer. It is known that powder bed metal AM is primarily a thermal process, and further, heat conduction is the dominant heat transfer mode in the process. Hence, understanding the powder bed thermal conductivity is crucial to process temperature predictions, because powder thermal conductivity could be substantially different from its solid counterpart. On the other hand, measuring the powder thermal conductivity is a challenging task. The objective of this study is to investigate the powder thermal conductivity using a method that combines a thermal diffusivity measurement technique and a numerical heat transfer model. In the experimental aspect, disk-shaped samples, with powder inside, made by a laser powder bed fusion (LPBF) system, are measured using a laser flash system to obtain the thermal diffusivity and the normalized temperature history during testing. In parallel, a finite element (FE) model is developed to simulate the transient heat transfer of the laser flash process. The numerical model was first validated using reference material testing. Then, the model is extended to incorporate powder enclosed in an LPBF sample with thermal properties to be determined using an inverse method to approximate the simulation results to the thermal data from the experiments. In order to include the powder particles' contribution in the measurement, an improved model geometry, which improves the contact condition between powder particles and the sample solid shell, has been tested. A multipoint optimization inverse heat transfer method is used to calculate the powder thermal conductivity. From this study, the thermal conductivity of a nickel alloy 625 powder in powder bed conditions is estimated to be 1.01 W/m K at 500°C. [DOI: 10.1115/1.4040877].

Making High Thermoelectric and Superior Mechanical Performance Nb0.88Hf0.12FeSb Half-Heusler via Additive Manufacturing.

Thermoelectric generators held great promise through energy harvesting from waste heat. Their practical application, however, is greatly constrained by poor raw material utilization and tedious processing in fabricating desired shapes. Herein, a state-of-the-art process is reported for 3D printing the half-Heusler (Nb0.88Hf0.12FeSb) thermoelectric material using laser powder bed fusion (LPBF). The multi-dimensional intra- and inter-granular defects created by this process greatly suppress thermal conductivity by providing numerous phonon scattering centers. The resulting LPBF-fabricated half-Heusler exhibits a high figure of merit ≈1.2 at 923 K and a single-leg maximum efficiency of ≈3.3% at a temperature difference (ΔT) of 371 K. Hafnium oxide nanoparticles generated during LPBF effectively prevent crack propagation, ensuring competent mechanical performance and reliable thermoelectric output. The findings highlight the significant potential of LPBF in driving the next industrial revolution of highly efficient and customizable thermoelectric materials.

Influence of Post-Heat Treatment on Corrosion Behaviour of Additively Manufactured CuSn10 by Laser Powder Bed Fusion.

This study investigates the influence of heat treatments on the corrosion behaviour of CuSn10 tin bronze, additively manufactured using Laser Powder Bed Fusion (LPBF). LPBF enables the creation of finely structured, anisotropic microstructures, whose corrosion behaviour is not yet well understood. After production, specimens were heat-treated at 320 °C, 650 °C, and in a two-stage treatment at 800 °C and 400 °C, followed by hardness and microstructure analysis. Corrosion tests were conducted using linear polarisation, salt spray, and immersion tests. The results show that heat treatments at 320 °C and 650 °C have no significant effect on the corrosion rate, while the two-stage treatment shows a slight improvement in corrosion resistance. Differences in microstructure and hardness were observed, with higher treatment temperatures leading to grain growth and tin precipitates. The formation of a passive protective layer was detected after 30 h of OCP measurement. Results from other studies on corrosion behaviour were partially reproducible. Differences could be attributed to varying chemical compositions and manufacturing parameters. These findings contribute to the understanding of the effects of heat treatments on the corrosion resistance of additively manufactured tin bronze and provide important insights for future applications in corrosive environments.