scholarly journals A New Approach in the Design of Microstructured Ultralight Components to Achieve Maximum Functional Performance

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1588
Author(s):  
Amaia Calleja-Ochoa ◽  
Haizea Gonzalez-Barrio ◽  
Norberto López de Lacalle ◽  
Silvia Martínez ◽  
Joseba Albizuri ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Functional Performance ◽  
Minimum Weight ◽  
Turbine Blades ◽  
High Ratio ◽  
Metal Powders ◽  
Space Applications ◽  
New Approach

In the energy and aeronautics industry, some components need to be very light but with high strength. For instance, turbine blades and structural components under rotational centrifugal forces, or internal supports, ask for low weight, and in general, all pieces in energy turbine devices will benefit from weight reductions. In space applications, a high ratio strength/weight is even more important. Light components imply new optimal design concepts, but to be able to be manufactured is the real key enable technology. Additive manufacturing can be an alternative, applying radical new approaches regarding part design and components’ internal structure. Here, a new approach is proposed using the replica of a small structure (cell) in two or three orders of magnitude. Laser Powder Bed Fusion (L-PBF) is one of the most well-known additive manufacturing methods of functional parts (and prototypes as well), for instance, starting from metal powders of heat-resistant alloys. The working conditions for such components demand high mechanical properties at high temperatures, Ni-Co superalloys are a choice. The work here presented proposes the use of “replicative” structures in different sizes and orders of magnitude, to manufacture parts with the minimum weight but achieving the required mechanical properties. Printing process parameters and mechanical performance are analyzed, along with several examples.

Mechanical Properties of SiO2 vs. SiO2-TiO2 Bulk Glasses and Fibers

1991 ◽  
Vol 244 ◽  
Author(s):  
Suresh T. Gulati
Keyword(s):  
Mechanical Properties ◽  
Optical Fibers ◽  
Mechanical Performance ◽  
Fatigue Behavior ◽  
Deformation Mode ◽  
Strength Distribution ◽  
Fused Silica ◽  
Space Applications ◽  
Silica Glasses ◽  
Silica And Titania

ABSTRACTThe mechanical properties of silica and titania-doped silica glasses, in bulk and fiber forms, are presented. These include the elastic properties (E and ν), strength distribution (in tension and bending), fatigue behavior (dynamic and static loading) and fracture toughness. Following a brief review of above properties for fused silica and ULE™ glasses (Coming Codes 7940 and 7971), used primarily for space applications, the mechanical properties data for silica and titania-doped silica-clad optical fibers are presented. The enhancement of mechanical performance of titania-doped silica clad fiber is also discussed.The effect of titania doping on fundamental properties like stress-free activation energy, crack tip pH, and deformation mode of Si-O-Si bond is discussed. In addition, the crack velocity data obtained from DCDC specimens of homogeneous silica and titania-doped silica glasses are compared in an attempt to understand the role titania plays in improving the fatigue resistance of optical fibers.

scholarly journals Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1610 ◽  
Author(s):  
Paulo J. Morais ◽  
Bianca Gomes ◽  
Pedro Santos ◽  
Manuel Gomes ◽  
Rudolf Gradinger ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
High Performance ◽  
Mechanical Performance ◽  
Fluorescence Analysis ◽  
Cold Metal Transfer ◽  
Direction Parallel ◽  
X Ray ◽  
Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

scholarly journals Additive Manufacturing of High-Entropy Alloys: A Review

Entropy ◽  
2018 ◽  
Vol 20 (12) ◽  
pp. 937 ◽  
Author(s):  
Shuying Chen ◽  
Yang Tong ◽  
Peter Liaw
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
High Efficiency ◽  
Mechanical Performance ◽  
Heating Temperature ◽  
Intermetallic Phase ◽  
Solid Solution Phase ◽  
High Entropy Alloys ◽  
Scanning Method ◽  
High Entropy

Owing to the reduced defects, low cost, and high efficiency, the additive manufacturing (AM) technique has attracted increasingly attention and has been applied in high-entropy alloys (HEAs) in recent years. It was found that AM-processed HEAs possess an optimized microstructure and improved mechanical properties. However, no report has been proposed to review the application of the AM method in preparing bulk HEAs. Hence, it is necessary to introduce AM-processed HEAs in terms of applications, microstructures, mechanical properties, and challenges to provide readers with fundamental understanding. Specifically, we reviewed (1) the application of AM methods in the fabrication of HEAs and (2) the post-heat treatment effect on the microstructural evolution and mechanical properties. Compared with the casting counterparts, AM-HEAs were found to have a superior yield strength and ductility as a consequence of the fine microstructure formed during the rapid solidification in the fabrication process. The post-treatment, such as high isostatic pressing (HIP), can further enhance their properties by removing the existing fabrication defects and residual stress in the AM-HEAs. Furthermore, the mechanical properties can be tuned by either reducing the pre-heating temperature to hinder the phase partitioning or modifying the composition of the HEA to stabilize the solid-solution phase or ductile intermetallic phase in AM materials. Moreover, the processing parameters, fabrication orientation, and scanning method can be optimized to further improve the mechanical performance of the as-built-HEAs.

Mechanical Properties of Additively Manufactured Periodic Cellular Structures and Design Variations

2021 ◽  
pp. 1-48
Author(s):  
Derek G. Spear ◽  
Anthony N. Palazotto ◽  
Ryan A. Kemnitz
Keyword(s):  
Mechanical Properties ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Material Selection ◽  
Cellular Structures ◽  
New Approach ◽  
Triply Periodic ◽  
Superior Mechanical Properties ◽  
Manufacturing Technologies ◽  
Surface Thickness

Abstract Advances in manufacturing technologies have led to the development of a new approach to material selection, in that architectured designs can be created to achieve a specific mechanical objective. Cellular lattice structures have been at the forefront of this movement due to the ability to tailor their mechanical response through tuning of the topology, surface thickness, cell size, and cell density. In this work, the mechanical properties of additively manufactured periodic cellular lattices are evaluated and compared, primarily through the topology and surface thickness parameters. The evaluated lattices were based upon triply periodic minimal surfaces (TPMS), including novel variations on the base TPMS designs, which have not been tested previously. These lattices were fabricated out of Inconel 718 (IN718) through the selective laser melting (SLM) process. Specimens were tested under uniaxial compression, and the resultant mechanical properties were determined. Further discussion of the fabrication quality and deformation behavior of the lattices are provided. Results of this work indicate that the Diamond TPMS lattice has superior mechanical properties to the other lattices tested. Additionally, with the exception of the Primitive TPMS lattice, the base TPMS designs exhibited superior mechanical performance to their derivative lattice designs.

Validation of a low-cost selective powder deposition process through the characterization of tin bronze specimens

2021 ◽  
pp. 146442072110319
Author(s):  
Samuel Magalhães ◽  
Manuel Sardinha ◽  
Carlos Vicente ◽  
Marco Leite ◽  
Relógio Ribeiro ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Low Cost ◽  
Deposition Process ◽  
Metal Powders ◽  
Tin Bronze ◽  
Powder Deposition ◽  
Manufacturing Technologies ◽  
The Cost

Additive manufacturing technologies are becoming increasingly popular due to their advantages over traditional subtracting manufacturing technologies. Despite advances in this field, fixed and maintenance costs for additive manufacturing with metals remain high. The introduction of low-cost metal machines in the additive manufacturing market considerably reduces the cost of acquiring and maintaining this type of equipment. This work aims to establish the process requirements for a low-cost selective powder deposition process, and validate it through the production of specimens in the laboratory and evaluate their mechanical properties. Tin bronze specimens were produced under different manufacturing conditions, namely powder dimensions, type of crucible and coke, firing segments and casting strategy. The morphology and chemical composition of the specimens were carried out combining the scanning electron microscopy and energy dispersive X-Ray spectroscopy techniques, respectively. It was observed that crucibles and coke with impurities that react with the metal powders and infill in a reducing atmosphere have influence in the final quality of parts. Tested samples displayed high variability of results which can be correlated with different manufacturing conditions. The selection of the appropriate print parameters led to the manufacture of tin bronze specimens with mechanical properties comparable to those reported in the literature. Overall, low-cost selective powder deposition is a promising technology, if identified manufacturing issues are addressed.

Laser Additive Manufacturing of Novel Aluminum Based Nanocomposite Parts: Tailored Forming of Multiple Materials

2015 ◽  
Vol 138 (2) ◽  
Author(s):  
Dongdong Gu ◽  
Hongqiao Wang ◽  
Donghua Dai
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Microstructural Evolution ◽  
Mechanical Performance ◽  
Laser Energy ◽  
Dimensional Accuracy ◽  
Ring Structure ◽  
Multiple Materials ◽  
Depth Relationship ◽  
Tailored Forming

The present study has proved the feasibility to produce the bulk-form TiC/AlSi10Mg nanocomposite parts with the novel reinforcing morphology and enhanced mechanical properties by selective laser melting (SLM) additive manufacturing (AM) process. The influence of linear laser energy density (η) on the microstructural evolution and mechanical performance (e.g., densification level, microhardness, wear and tribological properties) of the SLM-processed TiC/AlSi10Mg nanocomposite parts was comprehensively studied, in order to establish an in-depth relationship between SLM process, microstructures, and mechanical performance. It showed that the TiC reinforcement in the SLM-processed TiC/AlSi10Mg nanocomposites experienced an interesting microstructural evolution with the increase of the applied η. At an elevated η above 600 J/m, a novel regularly distributed ring structure of nanoscale TiC reinforcement was tailored in the matrix due to the unique metallurgical behavior of the molten pool induced by the operation of Marangoni flow. The near fully dense TiC/AlSi10Mg nanocomposite parts (>98.5% theoretical density (TD)) with the formation of ring-structured reinforcement demonstrated outstanding mechanical properties. The dimensional accuracy of SLM-processed parts well met the demand of industrial application with the shrinkage rates of 1.24%, 1.50%, and 1.72% in X, Y, and Z directions, respectively, with the increase of η to 800 J/m. A maximum microhardness of 184.7 HV0.1 was obtained for SLM-processed TiC/AlSi10Mg nanocomposites, showing more than 20% enhancement as compared with SLM-processed unreinforced AlSi10Mg part. The high densification response combined with novel reinforcement of SLM-processed TiC/AlSi10Mg nanocomposite parts also led to the considerably low coefficient of friction (COF) of 0.28 and wear rate of 2.73 × 10−5 mm3 · N−1 · m−1. The present work accordingly provides a fundamental understanding of the tailored forming of lightweight multiple nanocomposite materials system by laser AM.

scholarly journals 3D Puzzle in Cube Pattern for Anisotropic/Isotropic Mechanical Control of Structure Fabricated by Metal Additive Manufacturing

Crystals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 959
Author(s):  
Naoko Ikeo ◽  
Hidetsugu Fukuda ◽  
Aira Matsugaki ◽  
Toru Inoue ◽  
Ai Serizawa ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Functional Performance ◽  
Three Dimensional ◽  
Material Design ◽  
Metal Additive Manufacturing ◽  
Anisotropic Mechanical Properties ◽  
Innovative Material ◽  
Living Tissues ◽  
Metal Additive

Metal additive manufacturing is a powerful tool for providing the desired functional performance through a three-dimensional (3D) structural design. Among the material functions, anisotropic mechanical properties are indispensable for enabling the capabilities of structural materials for living tissues. For biomedical materials to replace bone function, it is necessary to provide an anisotropic mechanical property that mimics that of bones. For desired control of the mechanical performance of the materials, we propose a novel 3D puzzle structure with cube-shaped parts comprising 27 (3 × 3 × 3) unit compartments. We designed and fabricated a Co–Cr–Mo composite structure through spatial control of the positional arrangement of powder/solid parts using the laser powder bed fusion (L-PBF) method. The mechanical function of the fabricated structure can be predicted using the rule of mixtures based on the arrangement pattern of each part. The solid parts in the cubic structure were obtained by melting and solidifying the metal powder with a laser, while the powder parts were obtained through the remaining nonmelted powders inside the structure. This is the first report to achieve an innovative material design that can provide an anisotropic Young’s modulus by arranging the powder and solid parts using additive manufacturing technology.

scholarly journals Effects of Polypropylene Fibers on the Mechanical Performance of a 3D Printable Mix

2021 ◽  
Vol 10 (8) ◽  
pp. 43-46
Author(s):  
Ankit Pal ◽  
A.K. Jain
Keyword(s):  
Mechanical Properties ◽  
Experimental Study ◽  
Additive Manufacturing ◽  
Industrial Revolution ◽  
Mechanical Performance ◽  
Polypropylene Fibers ◽  
Construction Sector ◽  
Construction Work ◽  
Fourth Industrial Revolution ◽  
Manufacturing Technique

Application of automation in construction work has now become need of the hour. Automation in construction work can be done by implementing a technique known as additive manufacturing technique. Use of additive manufacturing in construction sector has the potential to bring fourth industrial revolution by using 3D concrete printers. This paper is based ona parametric experimental study to evaluate the effect of Polypropylene (PP) fibers on mechanical properties of a 3D printable concrete. PP fibers were used invaryingpercentage ratio of 0.02, 0.04, 0.08, 0.12 and 0.16 of binder at constant W/B ratio.

Additive Manufacturing of Continuous Carbon Fiber Reinforced Thermoplastic Composites: An Investigation on Process-Impregnation-Property Relationship

2020 ◽  
Author(s):  
Gongshuo Wang ◽  
Zhenyuan Jia ◽  
Fuji Wang ◽  
Chuanhe Dong ◽  
Bo Wu
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Process Parameters ◽  
Mechanical Performance ◽  
Movement Speed ◽  
Fiber Reinforced ◽  
Influence Of Process Parameters ◽  
Continuous Carbon Fiber ◽  
Carbon Fiber Reinforced

Abstract Fused filament fabrication (FFF) is one of the most broadly used additive manufacturing technologies, which possesses the advantage of a reduction in fabrication time and cost for complex-structural parts. FFF-fabricated continuous carbon fiber reinforced thermoplastic (C-CFRTP) composites have seen their great potentials in the industry due to the extraordinary mechanical properties. However, the relationship among process parameters, impregnation percentage, and mechanical properties is still unknown, which has greatly hindered both the manufacturing and application of those advanced composite parts. For this reason, the influence of process parameters on the impregnation percentage and mechanical properties of C-CFRTP specimens has been investigated in this paper. The process-impregnation-properties relationship of FFF-fabricated C-CFRTP specimens has been revealed through theoretical analyses and experimental measurement. It could be concluded that the impregnation percentage served as the bridge connecting process parameters and mechanical properties, which would provide a great insight into the property improvement. The experimental results of microscopic measurement and mechanical tests indicated that the combination of low transverse movement speed, high nozzle temperature, and small layer thickness led to an improved impregnation percentage, which ultimately produced better mechanical properties. The findings in this work will guide the fabrication of C-CFRTP parts with excellent mechanical performance for practical engineering applications.

scholarly journals Influence of the Miniaturisation Effect on the Effective Stiffness of Lattice Structures in Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1442
Author(s):  
Guillaume Meyer ◽  
Florian Brenne ◽  
Thomas Niendorf ◽  
Christian Mittelstedt
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Effective Properties ◽  
Weight Ratio ◽  
Effective Stiffness ◽  
Analytical Models ◽  
Lattice Structures ◽  
Thin Walled ◽  
The Impact

Thin-walled and cellular structures are characterised by superior lightweight potential due to their advantageous stiffness to weight ratio. They find particular interest in the field of additive manufacturing due to robust and reproducible manufacturability. However, the mechanical performance of such structures strongly depends on the manufacturing process and resultant geometrical imperfections such as porosity, deviations in strut thickness or surface roughness, for which an understanding of their influence is crucially needed. So far, many authors conducted empirical investigations, while analytical methods are rarely applied. In order to obtain efficient design rules considering both mechanical properties and process induced characteristics, analytical descriptions are desirable though. Available analytical models for the determination of effective properties are mostly based on the simple advancement of beam theories, mostly ignoring manufacturing characteristics that, however, strongly influence the mechanical properties of additive manufactured thin-walled structures. One example is the miniaturisation effect, a microstructural effect that has been identified as one of the main drivers of the effective elasto-plastic properties of lightweight structures processed by additive manufacturing. The current work highlights the need to quantify further microstructural effects and to encourage combining them into mesostructural approaches in order to assess macrostructural effective properties. This multi-scale analysis of lattice structures is performed through a comparison between effective stiffness calculated through an analytical approach and compression tests of lattice structures, coupled with an investigation of the arrangement of their struts. In order to cover different potential loading scenarios, bending-dominated and stretch-dominated lattice structures made of the commonly used materials 316L and Ti6Al4V are considered, whereby the impact of microstructural phase transformation during processing is taken into account.

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