Design of dissimilar material joint for defect-free multi-material additive manufacturing via laser-directed energy deposition.

Additive manufacturing technology has advanced beyond creating optimized features, from strengthening materials to make them lightweight to fabricating multi-material combinations that offer functionalities beyond the capabilities of individual materials. In this study, a lamination method for laser-directed energy deposition (LDED) is developed to achieve dense multi-material features, and a design that combines different and dissimilar materials is developed. To evaluate these novel developments, two materials-AISI 316L stainless steel and Inconel 625-are introduced. Tensile specimens, fabricated via multi-material additive manufacturing using LDED, are subjected to tensile tests that are recorded on video for digital image correlation. After the tests, fracture surface analyses of the fractured specimens are performed via scanning electron microscopy, and optical monitoring analyses are performed on the specimens that are not subjected to the tensile tests. The results indicate that the specimens demonstrate varied mechanical properties due to the influence of lamination direction and order, which affect the formation of critical cracks and pores.

Laser Rescanning for Enhancing Mechanical Properties of Laser-Directed Energy-Deposited High-Manganese Steels.

This study investigates the effects of laser deposition and laser rescanning (LR) on the microstructure and mechanical properties of high-manganese steel (HMnS) deposited by laser-directed energy deposition (L-DED) comprising 24 wt.% Mn. Four types of laser deposition and LR strategies were investigated: unidirectional L-DED scanning without laser rescanning, L-DED scanning with 90° alterations in the laser scanning path on each layer without laser rescanning, unidirectional L-DED with laser rescanning in the same direction, and L-DED with laser rescanning with 90° alterations in the laser scanning path. The L-DED-processed HMnS had only a few small pores and exhibited a microstructure without any serious defects such as cracks. Additionally, a strong fibrous texture along the <101>/building direction of the fully austenite phase was found. The mechanical properties (microhardness and tensile strength) of HMnS were improved by the LR with a grain refinement effect and fine solidification cell size due to the significantly faster solidification rate in LR than that in L-DED.

Highly Sensitive Soft Pressure Sensors for Wearable Applications Based on Composite Films with Curved 3D Carbon Nanotube Structures.

Soft pressure sensors based on 3D microstructures exhibit high sensitivity in the low-pressure range, which is crucial for various wearable and soft touch applications. However, it is still a challenge to manufacture soft pressure sensors with sufficient sensitivity under small mechanical stimuli for wearable applications. This work presents a novel strategy for extremely sensitive pressure sensors based on the composite film with local changes in curved 3D carbon nanotube (CNT) structure via expandable microspheres. The sensitivity is significantly enhanced by the synergetic effects of heterogeneous contact of the microdome structure and changes of percolation network within the curved 3D CNT structure. The finite-element method simulation is used to comprehend the relationships between the sensitivity and mechanical/electrical behavior of microdome structure under the applied pressure. The sensor shows an excellent sensitivity (571.64 kPa-1 ) with fast response time (85 ms), great repeatability, and long-term stability. Using the developed sensor, a wireless wearable health monitoring system to avoid carpel tunnel syndrome is built, and a multi-array pressure sensor for realizing a variety of movements in real-time is demonstrated.

Influence of Post Heat Treatment Condition on Corrosion Behavior of 18Ni300 Maraging Steel Manufactured by Laser Powder Bed Fusion.

Laser powder bed fusion (LPBF) is a promising additive-manufacturing process for metallic materials. It has the advantage of flexibility in product design, such that various mechanical parts can be fabricated. However, because metal parts are built-up in a layer-by-layer manner, the material fabricated by LPBF has an anisotropic microstructure, which is important for the design of materials. In this study, the corrosion resistance of 18Ni300 maraging steel (MS) fabricated by LPBF was explored considering the building direction. Furthermore, the effects of heat treatment and aging on the microstructure and corrosion resistance were investigated. Sub-grain cells formed by rapid cooling in LPBF improve the corrosion resistance of MS. As a result, the as-built MS has the highest corrosion resistance. However, the sub-grain cells are eliminated by heat treatment or aging, which causes the deterioration of corrosion resistance. In the case of 18Ni300 MS, the cylindrical sub-grain cells are formed and aligned along the heat dissipation direction, which is similar to the building direction; thus, a significant anisotropy in corrosion resistance is found in the as-built MS. However, such anisotropy in corrosion resistance is diminished by heat treatment and aging, which eliminates the sub-grain cells.

Corrosion Resistance of Laser Powder Bed Fused AISI 316L Stainless Steel and Effect of Direct Annealing.

Alloy parts produced by an additive manufacturing method with rapid heat transfer from fast melting and solidification have different microstructures, characteristics, and performances compared with materials made by the conventional process. In this study, the corrosion and oxidation resistance of SS316L, which was prepared by the powder bed fusion process, was compared with those of cold-rolled SS316L. Additionally, the surface oxide film on stainless steel was thoroughly assessed since the film has the greatest influence on the corrosion and oxidation resistance. The effect of heat treatment on corrosion and oxidation resistance of SS316L fabricated by additive manufacturing was investigated. The SS316L has a microstructure formed by sub-grain cells, in which locally concentrated alloying elements form a stable passive film. As a result, it has a higher level of corrosion resistance and oxidation resistance than conventional cold-rolled materials. However, it was confirmed that the sub-grain cell was removed by heat treatment, which resulted in the degradation of corrosion and oxidation resistance.

Wear Behavior of Conventionally and Directly Aged Maraging 18Ni-300 Steel Produced by Laser Powder Bed Fusion.

This study aims to explore the wear performance of maraging 18Ni-300 steel, fabricated via laser powder bed fusion (LPBF). The building direction dependence of wear resistance was investigated with various wear loads and in terms of ball-on-disk wear tests. The effect of direct aging heat treatment, i.e., aging without solution heat treatment, on the wear performance was investigated by comparing the wear rates of directly aged samples, followed by solution heat treatment. The effect of counterpart material on the wear performance of the maraging steel was studied using two counterpart materials of bearing steel and ZrO2 balls. When the bearing steel ball was used as the counterpart material, both the as-built and heat-treated maraging steel produced by the LPBF showed pronounced building direction dependence on their wear performance when the applied wear load was sufficiently high. However, when the ZrO2 ball was used as the counterpart material, isotropic wear resistance was reported. The maraging steel produced by the LPBF demonstrated excellent wear resistance, particularly when it was aging heat-treated and the counterpart material was ZrO2. The directly aged sample showed wear performance almost the same as the sample solution heat-treated and then aged, indicating that direct aging can be used as an alternative post heat treatment for tribological applications of the maraging steels produced by LPBF.

Shape Memory and Mechanical Properties of Cold Rolled and Annealed Fe-17Mn-5Si-5Cr-4Ni-1Ti-0.3C Alloy.

In the present study, the shape, memory, and mechanical properties of cold-rolled and annealed Fe-17Mn-5Si-5Cr-4Ni-1Ti-0.3C (wt.%) alloy were investigated. The cold-rolled alloy was annealing heat-treated at different temperatures in the range of 500-900 °C for 30 min. The shape recovery behavior of the alloy was investigated using strip bending test followed by recovery heating. The microstructural evolution and the stress-strain response of the alloy heat-treated at different temperatures revealed that the recovery took place at a heat-treatment temperature higher than 600 °C. Recrystallization occurred when the heat-treatment temperature was higher than 800 °C. Meaningful shape recovery was observed only when the alloy was annealed at temperatures higher than 600 °C. The highest recovery strain of up to 2.56% was achieved with a pre-strain of 5.26% and recovery heating temperature of 400 °C, when the alloy was heat-treated at 700 °C. Conversely, the yield strength reduced significantly with increasing annealing heat-treatment temperature. The experimental observations presented in this paper provide a guideline for post-annealing heat-treatment when a good compromise between mechanical property and shape recovery performance is required.

Corrosion Resistance of Shape Recoverable Fe-17Mn-5Si-5Cr Alloy in Concrete Structures.

The shape memory effect of steel (i.e., Fe-Mn-Si alloys) enables the tensile strengthening of concrete against tensile stress and unexpected structural vibrations. For practical application, the corrosion resistance of shape-memorable Fe-based steel should be verified. In this study, the corrosion resistance of an Fe-based (Fe-16Mn-5Si-4Ni-5Cr-0.3C-1Ti) shape memory alloy (FSMA), a promising candidate for concrete reinforcement, was investigated by comparing it with general carbon steel (S400). The corrosion resistance of FSMA and S400 inserted in a cement mortar was evaluated using electrochemical methods. FSMA has a more stable passive oxide layer in aqueous solutions with various pH values. Thus, the corrosion resistance of the FSMA sample was much higher than that of the S400 carbon steel, which has a passivation layer in strongly alkaline solution. This stable oxide layer reduced the sensitivity of the corrosion resistance of FSMA to changes in the pH, compared to S400. Furthermore, owing to the stable passive oxide layer, FSMA exhibited a higher corrosion resistance in concrete and a lower decrease in corrosion resistance because of the neutralization of concrete. Therefore, FSMA is a promising candidate for providing reinforcement and reparability, resulting in stable and durable concrete.

Effects of Cooling Rate during Quenching and Tempering Conditions on Microstructures and Mechanical Properties of Carbon Steel Flange.

This study investigated the mechanical properties of steel in flanges, with the goal of obtaining high strength and high toughness. Quenching was applied alone or in combination with tempering at one of nine combinations of three temperatures TTEM and durations tTEM. Cooling rates at various flange locations during quenching were first estimated using finite element method simulation, and the three locations were selected for mechanical testing in terms of cooling rate. Microstructures of specimens were observed at each condition. Tensile test and hardness test were performed at room temperature, and a Charpy impact test was performed at -46 °C. All specimens had a multiphase microstructure composed of matrix and secondary phases, which decomposed under the various tempering conditions. Decrease in cooling rate (CR) during quenching caused reduction in hardness and strength but did not affect low-temperature toughness significantly. After tempering, hardness and strength were reduced and low-temperature toughness was increased. Microstructures and mechanical properties under the various tempering conditions and CRs during quenching were discussed. This work was based on the properties directly obtained from flanges under industrial processes and is thus expected to be useful for practical applications.

A Highly Sensitive and Flexible Capacitive Pressure Sensor Based on a Porous Three-Dimensional PDMS/Microsphere Composite.

In recent times, polymer-based flexible pressure sensors have been attracting a lot of attention because of their various applications. A highly sensitive and flexible sensor is suggested, capable of being attached to the human body, based on a three-dimensional dielectric elastomeric structure of polydimethylsiloxane (PDMS) and microsphere composite. This sensor has maximal porosity due to macropores created by sacrificial layer grains and micropores generated by microspheres pre-mixed with PDMS, allowing it to operate at a wider pressure range (~150 kPa) while maintaining a sensitivity (of 0.124 kPa-1 in a range of 0~ 15 kPa) better than in previous studies. The maximized pores can cause deformation in the structure, allowing for the detection of small changes in pressure. In addition to exhibiting a fast rise time (~167 ms) and fall time (~117 ms), as well as excellent reproducibility, the fabricated pressure sensor exhibits reliability in its response to repeated mechanical stimuli (2.5 kPa, 1,000 cycles). As an application, we develop a wearable device for monitoring repeated tiny motions, such as the pulse on the human neck and swallowing at the Adam's apple. This sensory device is also used to detect movements in the index finger and to monitor an insole system in real-time.

Numerical study to identify the effect of fluid presence on the mechanical behavior of the stents during coronary stent expansion.

In this study, structural analysis and one-way fluid-structure interaction (FSI) analysis were performed to identify the effect of fluid presence on the mechanical behavior of the stents during stent expansion. An idealized vessel model with stenosis was used for simulation, and stents made of metal and polymer were assumed, respectively. The bilinear model was applied to the stents, and the Mooney-Rivlin model was applied to the arterial wall and plaque. The blood used in the FSI analysis was assumed to be a non-Newtonian fluid. As a result of all numerical simulations, the von Mises stress, the first principal stress and the displacement were calculated as the mechanical behaviors. Through the comparison of the results of the structural analysis with those of the one-way FSI analysis, our results indicated the fluid had no significant influence on the expansion of the metal stent. However, it was found that the expansion of the polymer stent affected by the presence of fluid. These findings meant the one-way FSI technique was suggested to achieve an accurate analysis when targeting a polymer stent for numerical simulation.

Numerical study to evaluate the effect of a surface-based sensor on arterial tonometry.

Arterial tonometry is a widely used non-invasive blood pressure measurement method. In contrast to the cuff-based method, it is possible to obtain a continuous pressure profile with respect to systolic and diastolic pressures using this method. However, due to a requirement of arterial tonometry-that a sensor needs to be placed directly above a blood vessel-placement error is inevitable if the measurement device is only capable of measuring local regions. This study assumed that the plate sensor is flexible, thus reducing the placement error. We investigated the pressure distribution along the wrist surface rather than the local region through the contact simulation between the flexible plate sensor and the wrist. As a result, we concluded that there is a unique pressure distribution for any specific wrist, regardless of the length and position of the plate, and that it is possible to measure the blood pressure using the response at the wrist surface to the pressure inside the radial artery.

Finite Element Modeling of Tensile Deformation Behaviors of Iron Syntactic Foam with Hollow Glass Microspheres.

The elastoplastic deformation behaviors of hollow glass microspheres/iron syntactic foam under tension were modeled using a representative volume element (RVE) approach. The three-dimensional microstructures of the iron syntactic foam with 5 wt % glass microspheres were reconstructed using the random sequential adsorption algorithm. The constitutive behavior of the elastoplasticity in the iron matrix and the elastic-brittle failure for the glass microsphere were simulated in the models. An appropriate RVE size was statistically determined by evaluating elastic modulus, Poisson's ratio, and yield strength in terms of model sizes and boundary conditions. The model was validated by the agreement with experimental findings. The tensile deformation mechanism of the syntactic foam considering the fracture of the microspheres was then investigated. In addition, the feasibility of introducing the interfacial deboning behavior to the proposed model was briefly investigated to improve the accuracy in depicting fracture behaviors of the syntactic foam. It is thought that the modeling techniques and the model itself have major potential for applications not only in the study of hollow glass microspheres/iron syntactic foams, but also for the design of composites with a high modulus matrix and high strength reinforcement.

Influence of Partially Debonded Interface on Elasticity of Syntactic Foam: A Numerical Study.

The effect of interfacial bonding of glass hollow microspheres and a polymer matrix on the elastic properties of syntactic foam was investigated using representative volume element (RVE) models, including partially debonded interfaces. Finite element analysis, with models having different debonding geometries, was performed to numerically estimate the elastic behavior of the models. The models consisted of bonded and debonded regions of interfaces; the bonded region was treated as the perfectly bonded interface, while the Coulomb friction model was used to describe the debonded region with a small friction coefficient. The changes in the tensile and compressive moduli of the foams were investigated in terms of the degree of interfacial debonding and debonding geometry.

Finite element modeling for predicting the contact pressure between a foam mattress and the human body in a supine position.

In this paper, we generated finite element (FE) models to predict the contact pressure between a foam mattress and the human body in a supine position. Twenty-year-old males were used for three-dimensional scanning to produce the FE human models, which was composed of skin and muscle tissue. A linear elastic isotropic material model was used for the skin, and the Mooney-Rivlin model was used for the muscle tissue because it can effectively represent the nonlinear behavior of muscle. The contact pressure between the human model and the mattress was predicted by numerical simulation. The human models were validated by comparing the body pressure distribution obtained from the same human subject when he was lying on two different mattress types. The experimental results showed that the slope of the lower part of the mattress caused a decrease in the contact pressure at the heels, and the effect of bone structure was most pronounced in the scapula. After inserting a simple structure to function as the scapula, the contact pressure predicted by the FE human models was consistent with the experimental body pressure distribution for all body parts. These results suggest that the models proposed in this paper will be useful to researchers and designers of products related to the prevention of pressure ulcers.

Numerical study to indicate the vulnerability of plaques using an idealized 2D plaque model based on plaque classification in the human coronary artery.

Atherosclerosis is one of the leading causes of death in the world. In this study, an idealized 2D plaque model based on plaque classification in the coronary artery is developed. When creating the idealized 2D model for each plaque type (fibrocalcic, FC; fibrofatty, FT; calcified fibroatheroma, CaFA; fibroatheroma, FA; calcified thin-cap fibroatheroma, CaTCFA; thin-cap fibroatheroma, TCFA), the cap thickness and stenosis by diameter were set as variables. In order to establish the correlation between each plaque type and plaque rupture, a numerical simulation was performed and the stress and stress gradient were reviewed to analyze the mechanical behavior. Results show that both the TCFA and CaTCFA plaque types, which have the smallest cap thicknesses of the different types of plaque, showed relatively high stress values in the thin membrane when compared with the FT type. The FT type is considered to be relatively stable since it does not have necrotic core or a thin membrane. With a stenosis rate of 50% and a cap thickness of 60 µm, the TCFA and CaTCFA types showed approximately 11 and 110% higher stress values, respectively, and 679 and 1568% higher negative stress gradient values, respectively. In other words, the plaque types with thin caps, which have weak load-bearing capacities, showed high stress values and high negative stress gradients in the radial direction. It is understood that this result could indicate the possibility of plaque rupture.