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The present work explores the capability of fabbricating low-alloyed metal parts through the layer-by-layer Selective Laser Melting (SLM) technique. The alloy used was AISI S2, which is a carbide-free tool steel made of 0,49%wt of Carbon. Such kind of steels are not popular as for Additive Manufacturing process due to their unpromising welding properties. However, obtained results demonstrated the feasibility of printing fully dense, defects-free with good surface quality low-alloyed steels. A process map containing the optimum set of parameters for the realisation of the S2 metal parts will be presented. Indications for the use of the same process map in the situations of different process conditions or different manufactured steels will be provided as well. Later, the printed pieces were subject to microstructural investigation under their as-build and heat-treated conditions. The outcomes showed a epitaxial grain growth strongly influenced by the scan strategy. Moreover, the outermost top layer consisted of supersaturated martensite which was characterized in order to gain information about the prior microstructure which was present. Whereas the rest of the cross-sections of the as-built samples were found to have bands of tempered martensite at various degrees of tempering. The cause was related to the complex thermal history of the SLM process. In order to achieve all the results several unique techniques have been used such as reverse Differential Thermal Analysis, post-processing heat treatment and nanoindentation. The latters were used in less common ways to obtain a deeper knowledge of the microstructure of S2 metal parts printed through SLM technique, showing promising results.
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Additive manufacturing (AM), more commonly known as 3D printing, has grown trememdously in recent years. It has shown its potential uses in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing, and local on-demand manufacturing are just some of its current benefits. The development of new materials and equipment has opened up new application possibilities, and equipment is quicker and cheaper to use when utilizing the new materials launched by vendors and material developers. AM has become more critical for the industry but also for academics. Since AM offers more design freedom than any other manufacturing process, it provides designers with the challenge of designing better and more efficient products.
Technology: general issues --- History of engineering & technology --- additive manufacturing --- modular design --- design-for-manufacturability --- design optimization --- part consolidation --- product re-design --- topology optimization --- design for additive manufacturing --- 3D printing --- aerospace --- full-life cycle manufacturing flow --- airfoil --- carbon fiber tubes --- telescoping spars --- chevrons --- porous scaffold design --- tetrahedral implicit surface modeling --- triply periodic minimal surface --- selective laser melting (SLM) --- Ti6Al4V --- structure-property relationship --- microstructure --- Hall-Petch relationship --- additive manufacturing --- modular design --- design-for-manufacturability --- design optimization --- part consolidation --- product re-design --- topology optimization --- design for additive manufacturing --- 3D printing --- aerospace --- full-life cycle manufacturing flow --- airfoil --- carbon fiber tubes --- telescoping spars --- chevrons --- porous scaffold design --- tetrahedral implicit surface modeling --- triply periodic minimal surface --- selective laser melting (SLM) --- Ti6Al4V --- structure-property relationship --- microstructure --- Hall-Petch relationship
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Additive manufacturing (AM), more commonly known as 3D printing, has grown trememdously in recent years. It has shown its potential uses in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing, and local on-demand manufacturing are just some of its current benefits. The development of new materials and equipment has opened up new application possibilities, and equipment is quicker and cheaper to use when utilizing the new materials launched by vendors and material developers. AM has become more critical for the industry but also for academics. Since AM offers more design freedom than any other manufacturing process, it provides designers with the challenge of designing better and more efficient products.
Technology: general issues --- History of engineering & technology --- additive manufacturing --- modular design --- design-for-manufacturability --- design optimization --- part consolidation --- product re-design --- topology optimization --- design for additive manufacturing --- 3D printing --- aerospace --- full-life cycle manufacturing flow --- airfoil --- carbon fiber tubes --- telescoping spars --- chevrons --- porous scaffold design --- tetrahedral implicit surface modeling --- triply periodic minimal surface --- selective laser melting (SLM) --- Ti6Al4V --- structure–property relationship --- microstructure --- Hall–Petch relationship --- n/a --- structure-property relationship --- Hall-Petch relationship
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Additive manufacturing (AM), more commonly known as 3D printing, has grown trememdously in recent years. It has shown its potential uses in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing, and local on-demand manufacturing are just some of its current benefits. The development of new materials and equipment has opened up new application possibilities, and equipment is quicker and cheaper to use when utilizing the new materials launched by vendors and material developers. AM has become more critical for the industry but also for academics. Since AM offers more design freedom than any other manufacturing process, it provides designers with the challenge of designing better and more efficient products.
additive manufacturing --- modular design --- design-for-manufacturability --- design optimization --- part consolidation --- product re-design --- topology optimization --- design for additive manufacturing --- 3D printing --- aerospace --- full-life cycle manufacturing flow --- airfoil --- carbon fiber tubes --- telescoping spars --- chevrons --- porous scaffold design --- tetrahedral implicit surface modeling --- triply periodic minimal surface --- selective laser melting (SLM) --- Ti6Al4V --- structure–property relationship --- microstructure --- Hall–Petch relationship --- n/a --- structure-property relationship --- Hall-Petch relationship
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In recent years, the industry has started to use parts printed by powder-based laser additive manufacturing (LAM) when precision and good mechanical properties are required. Applications can be found in the aerospace, automotive, and medical sectors. However, the powder materials available are often inadequate for contemporary processing tasks, and often generate process instabilities as well as porosities and defects in the resulting parts. This Special Issue, “New Frontiers in Materials Design for Laser Additive Manufacturing”, focuses on advances in material design and the development of laser additive manufacturing. Of particular interest are original papers dealing with metal and polymer powders for laser powder bed fusion or directed energy deposition. In this Special Issue, we are especially interested in answering the following questions: How can laser process parameters and material properties be adapted to the LAM process via the matrix modification (e.g., alloying, doping, compounding) of powders? How can powder properties like flowability, wetting, porosity, or (heterogeneous) nucleation be adapted to the LAM process via the surface modification of powders? How may calorimetry, high-speed videography, pyrometry, and online spectroscopy, as well as modeling, contribute to understanding dynamics of melting and recrystallization, in addition to the lateral distribution of the thermal process window?
Technology: general issues --- Chemical engineering --- powder bed fusion --- magnesium --- process development --- additive manufacturing --- PBF-LB/M --- tool steel (1.2709) --- nanocomposite --- microstructure --- mechanical properties --- laser powder bed fusion --- selective laser melting --- oxide dispersion strengthened steel --- phase-field model --- finite element simulation --- nanoparticle interaction --- pure copper --- short wavelength laser system --- green laser --- eddy-current method --- electrical conductivity --- polyamide 12 --- nanocomposites --- nanoparticles --- dispersion --- LB-PBF --- additively manufactured parts --- aluminum alloys --- intermetallics --- thermal exposure --- n/a --- aluminium alloys --- hot cracking --- rapid solidification --- differential fast scanning calorimetry --- undercooling --- grain size --- crack density
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This Special Issue book covers a wide scope in the research field of 3D-printing, including: the use of 3D printing in system design; AM with binding jetting; powder manufacturing technologies in 3D printing; fatigue performance of additively manufactured metals, such as the Ti-6Al-4V alloy; 3D-printing methods with metallic powder and a laser-based 3D printer; 3D-printed custom-made implants; laser-directed energy deposition (LDED) process of TiC-TMC coatings; Wire Arc Additive Manufacturing; cranial implant fabrication without supports in electron beam melting (EBM) additive manufacturing; the influence of material properties and characteristics in laser powder bed fusion; Design For Additive Manufacturing (DFAM); porosity evaluation of additively manufactured parts; fabrication of coatings by laser additive manufacturing; laser powder bed fusion additive manufacturing; plasma metal deposition (PMD); as-metal-arc (GMA) additive manufacturing process; and spreading process maps for powder-bed additive manufacturing derived from physics model-based machine learning.
Technology: general issues --- History of engineering & technology --- powder-bed additive manufacturing (AM) --- powder spreading --- spreading process map --- discrete element method (DEM) --- machine learning --- GMA additive manufacturing --- weld reinforcement --- visual features --- neural network --- selective laser melting --- magnesium alloys --- properties --- plasma metal deposition --- additive manufacturing --- 316L --- processing conditions --- mechanical properties --- microstructure --- virgin --- recycled --- metal powders --- laser powder bed fusion --- laser additive manufacturing --- 316l ss --- nickel alloy --- tribological behavior --- porosity --- rough surface --- ultrasonic testing --- convolutional neural network --- deep neural network --- multi-layer perceptron --- key performance indicators --- topology optimization --- design for additive manufacturing --- design for additive manufacturing services --- selective laser melting (SLM) --- laser powder bed fusion (LPBF) --- powder --- particle size distribution --- particle morphology --- powder layer density --- part density --- flowability --- Hausner ratio --- electron beam melting --- customized implant --- cost analysis --- fitting accuracy --- cranial reconstruction --- thin wall manufacturing --- process modelling --- ultrasonic vibration --- laser directed energy deposition --- coating --- TiC-TMC --- extremity --- revision --- limb salvage surgery --- 3D printing --- customized --- implant --- powder metallurgy --- simulated body fluid --- biomaterial --- fatigue --- titanium --- direct laser deposition --- Inconel 625 --- parametrisation --- microhardness --- preheating --- binder jetting --- sand casting --- aluminum alloy --- corrosion --- pressure drop --- heat exchanger --- surface textures --- dimples --- drag reduction --- powder-bed additive manufacturing (AM) --- powder spreading --- spreading process map --- discrete element method (DEM) --- machine learning --- GMA additive manufacturing --- weld reinforcement --- visual features --- neural network --- selective laser melting --- magnesium alloys --- properties --- plasma metal deposition --- additive manufacturing --- 316L --- processing conditions --- mechanical properties --- microstructure --- virgin --- recycled --- metal powders --- laser powder bed fusion --- laser additive manufacturing --- 316l ss --- nickel alloy --- tribological behavior --- porosity --- rough surface --- ultrasonic testing --- convolutional neural network --- deep neural network --- multi-layer perceptron --- key performance indicators --- topology optimization --- design for additive manufacturing --- design for additive manufacturing services --- selective laser melting (SLM) --- laser powder bed fusion (LPBF) --- powder --- particle size distribution --- particle morphology --- powder layer density --- part density --- flowability --- Hausner ratio --- electron beam melting --- customized implant --- cost analysis --- fitting accuracy --- cranial reconstruction --- thin wall manufacturing --- process modelling --- ultrasonic vibration --- laser directed energy deposition --- coating --- TiC-TMC --- extremity --- revision --- limb salvage surgery --- 3D printing --- customized --- implant --- powder metallurgy --- simulated body fluid --- biomaterial --- fatigue --- titanium --- direct laser deposition --- Inconel 625 --- parametrisation --- microhardness --- preheating --- binder jetting --- sand casting --- aluminum alloy --- corrosion --- pressure drop --- heat exchanger --- surface textures --- dimples --- drag reduction
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This Special Issue book covers a wide scope in the research field of 3D-printing, including: the use of 3D printing in system design; AM with binding jetting; powder manufacturing technologies in 3D printing; fatigue performance of additively manufactured metals, such as the Ti-6Al-4V alloy; 3D-printing methods with metallic powder and a laser-based 3D printer; 3D-printed custom-made implants; laser-directed energy deposition (LDED) process of TiC-TMC coatings; Wire Arc Additive Manufacturing; cranial implant fabrication without supports in electron beam melting (EBM) additive manufacturing; the influence of material properties and characteristics in laser powder bed fusion; Design For Additive Manufacturing (DFAM); porosity evaluation of additively manufactured parts; fabrication of coatings by laser additive manufacturing; laser powder bed fusion additive manufacturing; plasma metal deposition (PMD); as-metal-arc (GMA) additive manufacturing process; and spreading process maps for powder-bed additive manufacturing derived from physics model-based machine learning.
powder-bed additive manufacturing (AM) --- powder spreading --- spreading process map --- discrete element method (DEM) --- machine learning --- GMA additive manufacturing --- weld reinforcement --- visual features --- neural network --- selective laser melting --- magnesium alloys --- properties --- plasma metal deposition --- additive manufacturing --- 316L --- processing conditions --- mechanical properties --- microstructure --- virgin --- recycled --- metal powders --- laser powder bed fusion --- laser additive manufacturing --- 316l ss --- nickel alloy --- tribological behavior --- porosity --- rough surface --- ultrasonic testing --- convolutional neural network --- deep neural network --- multi-layer perceptron --- key performance indicators --- topology optimization --- design for additive manufacturing --- design for additive manufacturing services --- selective laser melting (SLM) --- laser powder bed fusion (LPBF) --- powder --- particle size distribution --- particle morphology --- powder layer density --- part density --- flowability --- Hausner ratio --- electron beam melting --- customized implant --- cost analysis --- fitting accuracy --- cranial reconstruction --- thin wall manufacturing --- process modelling --- ultrasonic vibration --- laser directed energy deposition --- coating --- TiC-TMC --- extremity --- revision --- limb salvage surgery --- 3D printing --- customized --- implant --- powder metallurgy --- simulated body fluid --- biomaterial --- fatigue --- titanium --- direct laser deposition --- Inconel 625 --- parametrisation --- microhardness --- preheating --- binder jetting --- sand casting --- aluminum alloy --- corrosion --- pressure drop --- heat exchanger --- surface textures --- dimples --- drag reduction --- n/a
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Additive manufacturing (AM) methods have grown and evolved rapidly in recent years. AM for polymers is particularly exciting and has great potential in transformative and translational research in many fields, such as biomedicine, aerospace, and even electronics. The current methods for polymer AM include material extrusion, material jetting, vat polymerization, and powder bed fusion. In this Special Issue, state-of-the-art reviews and current research results, which focus on the process–structure–properties relationships in polymer additive manufacturing, are reported. These include, but are not limited to, assessing the effect of process parameters, post-processing, and characterization techniques.
Technology: general issues --- History of engineering & technology --- Materials science --- tray location --- build direction --- surface finish --- matte --- glossy --- magnetic polymer composites --- anisotropic properties --- dual-cure resin --- polymer casting --- additive manufacturing --- thermoplastic polyurethane --- polylactic acid --- trachea scaffold --- 3D filament --- selective laser sintering --- di-carboxylic acids --- plasticizers --- solid oral forms --- printability --- heating temperature --- Peano curve --- composite --- PolyJet 3D printing --- rule of mixture --- multi-material printing --- biodegradable polyesters --- polyglycolic acid (PGA) --- fused deposition modeling (FDM) --- triply periodic minimal surfaces (TPMS) --- mechanical property --- poly(lactic acid) --- optimization --- simulation --- finite element analysis (FEA) --- polymers --- material jetting --- 3D printing --- airfoil --- aerodynamic model --- design of experiments --- surface roughness --- photopolymerization --- curing strategy --- reaction heat --- shrinkage and warpage --- powder bed fusion --- laser sintering --- isothermal --- low temperature laser sintering --- selective laser melting --- tray location --- build direction --- surface finish --- matte --- glossy --- magnetic polymer composites --- anisotropic properties --- dual-cure resin --- polymer casting --- additive manufacturing --- thermoplastic polyurethane --- polylactic acid --- trachea scaffold --- 3D filament --- selective laser sintering --- di-carboxylic acids --- plasticizers --- solid oral forms --- printability --- heating temperature --- Peano curve --- composite --- PolyJet 3D printing --- rule of mixture --- multi-material printing --- biodegradable polyesters --- polyglycolic acid (PGA) --- fused deposition modeling (FDM) --- triply periodic minimal surfaces (TPMS) --- mechanical property --- poly(lactic acid) --- optimization --- simulation --- finite element analysis (FEA) --- polymers --- material jetting --- 3D printing --- airfoil --- aerodynamic model --- design of experiments --- surface roughness --- photopolymerization --- curing strategy --- reaction heat --- shrinkage and warpage --- powder bed fusion --- laser sintering --- isothermal --- low temperature laser sintering --- selective laser melting
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Additive manufacturing is already actively used in various high-tech industries today. At the same time, there is a certain limitation and imperfection of known and widely used conventional materials when they are used in additive manufacturing. In this regard, extensive research and development are aimed at the advancements of new materials by adjusting the chemical compositions of conventional alloys, new equipment with expanded functionality and the ability to work with a wide range of materials that were previously not available for additive manufacturing. This Special Issue covers a wide scope of additive manufacturing processes, comprising investigation, characterization of materials and their properties, development and application of new materials, structures designed for additive manufacturing, as well as processes and techniques that will expand the potential applications of layer-by-layer synthesis.
Technology: general issues --- Chemical engineering --- additive manufacturing --- binder jetting --- silicon carbide --- spray drying --- pyrolysis --- n/a --- direct laser deposition (DLD) --- direct metal deposition --- additive manufacturing (AM) --- corrosion resistant steel --- heat treatment (HT) --- maraging steel --- microstructure --- mechanical characteristics --- selective laser melting --- titanium alloy --- mechanical alloying --- powder bed fusion --- nitinol --- direct laser deposition --- heat transfer --- mass transfer --- hydrodynamics --- simulation of the melt pool --- alloys --- Ti-6Al-4V --- direct energy deposition --- thermal history --- annealing --- phase composition --- tensile properties --- tungsten carbides --- cobalt --- nanopowder --- synthesis --- granulation --- spheroidization --- DC thermal plasma --- lead-free piezoceramic --- barium titanate --- sintering --- piezoelectric properties --- titanium alloys --- multimaterial 3D printing --- graded materials --- mechanical properties --- stress relaxation --- elevated temperatures --- pure tungsten --- selective electron beam melting (SEBM) --- porosity --- soft-magnetic alloy --- FeSiB --- magnetic properties
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Laser processing has become more relevant today due to its fast adaptation to the most critical technological tasks, its ability to provide processing in the most rarefied and aggressive mediums (vacuum conditions), its wide field of potential applications, and the green aspects related to the absence of industrial cutting chips and dust. With the development of 3D production, laser processing has received renewed interest associated with its ability to achieve pointed to high-precision powder melting or sintering. New technologies and equipment, which improve and modify optical laser parameters, contribute to better absorption of laser energy by metals or powder surfaces and allow for multiplying laser power that can positively influence the industrial spread of the laser in mass production and advance the existing manufacturing methods. The latest achievements in laser processing have become a relevant topic in the most authoritative scientific journals and conferences in the last half-century. Advances in laser processing have received multiple awards in the most prestigious competitions and exhibitions worldwide and at international scientific events. The Special Issue is devoted to the most recent achievements in the laser processing of various materials, such as cast irons, tool steels, high entropy alloys, hard-to-remelt materials, cement mortars, and post-processing and innovative manufacturing based on a laser.
Technology: general issues --- History of engineering & technology --- composition --- laser bionic unit --- tensile properties --- wear resistance --- laser remelting --- ductile iron --- bionic crack blocked unit --- repair discontinuously --- thermal fatigue crack --- laser melting --- biomimetic model --- brake pads --- surface wear --- laser cladding --- high entropy alloy --- specific energy --- phase transformation --- anticorrosion steel --- hardness --- laser powder bed fusion --- microroughness --- tensile test --- corrosion susceptibility --- defocusing --- microstructure --- offset --- stress relief heat treatment --- ultrasonic peening --- surface roughness --- laser polishing --- quadratic laser spot --- tool steel 1.2379 --- area rate --- cement-based material --- laser scabbling --- microstructural analysis --- chemical analysis --- thermal properties --- laser treatment --- cast irons --- mechanical properties --- wear --- energy excess --- heat diffusion --- laser beam mode --- numerical simulation --- profiling --- power density distribution --- thermal conductivity --- surface cleaning --- selective laser melting --- atmospheric plasma sources --- dielectric barrier discharge --- nickel alloy --- titanium alloy --- n/a
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