The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully ci...The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully circumvent defects in Ti-6Al-4V deposits for LAAM_(p) and LAAM_(w),respectively.With the optimized process parameters,robust interfaces were achieved between powder/wire deposits and the forged substrate,as well as between powder and wire deposits.Microstructure characterization results revealed the epitaxial prior β grains in the deposited Ti-6Al-4V,wherein the powder deposit was dominated by a finerα′microstructure and the wire deposit was characterized by lamellar α phases.The mechanisms of microstructure formation and correlation with mechanical behavior were analyzed and discussed.The mechanical properties of the interfacial samples can meet the requirements of the relevant Aerospace Material Specifications(AMS 6932)even without post heat treatment.No fracture occurred within the interfacial area,further suggesting the robust interface.The findings of this study highlighted the feasibility of combining LAAM_(p) and LAAM_(w) in the direct manufacturing of Ti-6Al-4V parts in accordance with the required dimensional resolution and deposition rate,together with sound strength and ductility balance in the as-built condition.展开更多
Titanium(Ti)alloys are widely used in high-tech fields like aerospace and biomedical engineering.Laser additive manufacturing(LAM),as an innovative technology,is the key driver for the development of Ti alloys.Despite...Titanium(Ti)alloys are widely used in high-tech fields like aerospace and biomedical engineering.Laser additive manufacturing(LAM),as an innovative technology,is the key driver for the development of Ti alloys.Despite the significant advancements in LAM of Ti alloys,there remain challenges that need further research and development efforts.To recap the potential of LAM high-performance Ti alloy,this article systematically reviews LAM Ti alloys with up-to-date information on process,materials,and properties.Several feasible solutions to advance LAM Ti alloys are reviewed,including intelligent process parameters optimization,LAM process innovation with auxiliary fields and novel Ti alloys customization for LAM.The auxiliary energy fields(e.g.thermal,acoustic,mechanical deformation and magnetic fields)can affect the melt pool dynamics and solidification behaviour during LAM of Ti alloys,altering microstructures and mechanical performances.Different kinds of novel Ti alloys customized for LAM,like peritecticα-Ti,eutectoid(α+β)-Ti,hybrid(α+β)-Ti,isomorphousβ-Ti and eutecticβ-Ti alloys are reviewed in detail.Furthermore,machine learning in accelerating the LAM process optimization and new materials development is also outlooked.This review summarizes the material properties and performance envelops and benchmarks the research achievements in LAM of Ti alloys.In addition,the perspectives and further trends in LAM of Ti alloys are also highlighted.展开更多
Tailoring thermal history during additive manufacturing(AM)offers a feasible approach to customise the microstructure and properties of materials without changing alloy compositions or post-heat treatment,which is gen...Tailoring thermal history during additive manufacturing(AM)offers a feasible approach to customise the microstructure and properties of materials without changing alloy compositions or post-heat treatment,which is generally overlooked as it is hard to achieve in commercial materials.Herein,a customised Fe-Ni-Ti-Al maraging steel with rapid precipitation kinetics offers the opportunity to leverage thermal history during AM for achieving large-range tunable strength-ductility combinations.The Fe-Ni-Ti-Al steel was processed by laser-directed energy deposition(LDED)with different deposition strategies to tailor the thermal history.As the phase transformation and in-situ formation of multi-scale secondary phases of the Fe-Ni-Ti-Al steel are sensitive to the thermal histories,the deposited steel achieved a large range of tuneable mechanical properties.Specifically,the interlayer paused deposited sample exhibits superior tensile strength(∼1.54 GPa)and moderate elongation(∼8.1%),which is attributed to the formation of unique hierarchical structures and the in-situ precipitation of high-densityη-Ni_(3)(Ti,Al)during LDED.In contrast,the substrate heating deposited sample has an excellent elongation of 19.3%together with a high tensile strength of 1.24 GPa.The achievable mechanical property range via tailoring thermal history in the LDED-built Fe-Ni-Ti-Al steel is significantly larger than most commercial materials.The findings highlight the material customisation along with AM’s unique thermal history to achieve versatile mechanical performances of deposited materials,which could inspire more property or function manipulations of materials by AM process control or innovation.展开更多
In this study, the flow characteristics and behaviors of virgin and recycled Inconel powder for powder-bed additive manufacturing （AM） were studied using different powder characterization techniques. The results rev...In this study, the flow characteristics and behaviors of virgin and recycled Inconel powder for powder-bed additive manufacturing （AM） were studied using different powder characterization techniques. The results revealed that the particle size distribution （PSD） for the selective laser melting （SLM） process is typically in the range from 15 μm to 63 μm. The flow rate of virgin Inconel powder is around 28 s·（50 g）^-1. In addition, the packing density was found to be 60%. The rheological test results indicate that the virgin powder has reasonably good flowability compared with the recycled powder. The inter-relation between the powder characteristics is discussed herein. A propeller was successfully printed using the powder. The results suggest that Inconel powder is suitable for AM and can be a good reference for researchers who attempt to pro- duce AM powders.展开更多
Magnesium alloys remain critical in the context of light-weighting and advanced devices. The increased utilisation of magnesium(Mg)each year reveals growing demand for its Mg-based alloys. Additive manufacturing(AM) p...Magnesium alloys remain critical in the context of light-weighting and advanced devices. The increased utilisation of magnesium(Mg)each year reveals growing demand for its Mg-based alloys. Additive manufacturing(AM) provides the possibility to directly manufacture components in net-shape, providing new possibilities and applications for the use of Mg-alloys, and new prospects in the utilisation of novel physical structures made possible from ‘3D printing’. The review herein seeks to holistically explore the additive manufacturing of Mg-alloys to date, including a synopsis of processes used and properties measured(with a comparison to conventionally prepared Mg-alloys). The challenges and possibilities of AM Mg-alloys are critically elaborated for the field of mechanical metallurgy.展开更多
Globularαphases can significantly improve the ductility of titanium alloys.Cyclic heat treatment(CHT)has been proved to be an effective way to induce the formation of globularαphases inα+βtitanium alloy Ti-6Al-4V ...Globularαphases can significantly improve the ductility of titanium alloys.Cyclic heat treatment(CHT)has been proved to be an effective way to induce the formation of globularαphases inα+βtitanium alloy Ti-6Al-4V fabricated by laser aided additive manufacturing(LAAM).However,there is no prior research reporting methods for obtaining globularαphases in LAAM-built near-αtitanium alloys.This work investigated the cyclic heat treatment(CHT)procedures suitable for the LAAM-built near-αtitanium alloy Ti-6Al-2Sn-4Zr-2Mo(Ti6242)to attain the globularαphases.The results show that 980℃ is the most suitable upper temperature limit for CHT.However,it is difficult to achieve a high volume fraction of the globularαphases in the LAAM-built Ti6242 alloys through CHT,which is ascribed to the low composition gradient caused by moreα-stabilizing elements and fewerβ-stabilizing elements.The as-built sample demonstrated elongation of 6.3%,which is lower than the AMS 4919J standard(elongation≥10%).After 980℃ CHT and 980℃ CHT with solution heat-treatment,the formation of the globularαphases significantly increased the elongation to 13.5%and 12.9%,respectively.Although the mechanical strength is reduced after heat-treatment,the room-temperature tensile properties still exceed the AMS 4919J standard.Fractography examination showed that the as-built sample exhibited a mixed brittle and ductile fracture behavior,while the 980℃ CHT and 980℃ CHT with solution heat-treated samples displayed ductile fracture.展开更多
Magnesium(Mg)and its alloys have recently gained increasing attention in the biomedical field as promising biodegradable materials with harmless degradation products.Magnesium-based alloys have a wide range of biomedi...Magnesium(Mg)and its alloys have recently gained increasing attention in the biomedical field as promising biodegradable materials with harmless degradation products.Magnesium-based alloys have a wide range of biomedical applications because of their outstanding biocompatibility and unique mechanical properties.Widespread use of Mg-based biomedical devices eliminates the need for post-healing biomaterial removal surgery and minimizes the negative consequences of the implantation of permanent biomaterials,including stress shielding and undesired metal ion release in the body.This paper provides a literature review on the properties and manufacturing methods of Mgbased alloys for biomedical applications,including orthopedic implants,cardiovascular applications,surgical wires and staplers,and antitumor activities.Each application of Mg-based biomaterials is investigated from a biological perspective,including matching functional properties,biocompatibility,host tissue responses,and anti-microbial strategies,along with potential additive manufacturing technologies for these applications.Finally,an outlook is presented to provide recommendations for Mg-based biomaterials in the future.展开更多
Additive manufacturing(AM)is gaining traction in the manufacturing industry for the fabrication of components with complex geometries using a variety of materials.Selective laser melting(SLM)is a common AM technique t...Additive manufacturing(AM)is gaining traction in the manufacturing industry for the fabrication of components with complex geometries using a variety of materials.Selective laser melting(SLM)is a common AM technique that is based on powder-bed fusion(PBF)to process metals;however,it is currently focused only on the fabrication of macroscale and mesoscale components.This paper reviews the state of the art of the SLM of metallic materials at the microscale level.In comparison with the direct writing techniques that are commonly used for micro AM,micro SLM is attractive due to a number of factors,including a faster cycle time,process simplicity,and material versatility.A comprehensive evaluation of various research works and commercial systems for the fabrication of microscale parts using SLM and selective laser sintering(SLS)is conducted.In addition to identifying existing issues with SLM at the microscale,which include powder recoating,laser optics,and powder particle size,this paper details potential future directions.A detailed review of existing recoating methods in powder-bed techniques is conducted,along with a description of emerging efforts to implement dry powder dispensing methods in the AM domain.A number of secondary finishing techniques for AM components are reviewed,with a focus on implementation for microscale features and integration with micro SLM systems.展开更多
It is well-known that grain refiners can tailor the microstructure and enhance the mechanical properties of titanium alloys fabricated by additive manufacturing(AM). However, the intrinsic mechanisms of Ni addition on...It is well-known that grain refiners can tailor the microstructure and enhance the mechanical properties of titanium alloys fabricated by additive manufacturing(AM). However, the intrinsic mechanisms of Ni addition on AM-built Ti–6Al–4V alloy is not well established. This limits its industrial applications. This work systematically investigated the influence of Ni additive on Ti–6Al–4V alloy fabricated by laser aided additive manufacturing(LAAM). The results showed that Ni addition yields three key effects on the microstructural evolution of LAAM-built Ti–6Al–4V alloy.(a) Ni additive remarkably refines the prior-β grains, which is due to the widened solidification range. As the Ni addition increased from 0 to 2.5 wt. %, the major-axis length and aspect ratio of the prior-β grains reduced from over 1500 μm and 7 to 97.7 μm and1.46, respectively.(b) Ni additive can discernibly induce the formation of globular α phase,which is attributed to the enhanced concentration gradient between the β and α phases. This is the driving force of globularization according to the termination mass transfer theory. The aspect ratio of the α laths decreased from 4.14 to 2.79 as the Ni addition increased from 0 to2.5 wt. %.(c) Ni as a well-known β-stabilizer and it can remarkably increase the volume fraction of β phase. Room-temperature tensile results demonstrated an increase in mechanical strength and an almost linearly decreasing elongation with increasing Ni addition. A modified mathematical model was used to quantitatively analyze the strengthening mechanism. It was evident from the results that the α lath phase and the solid solutes contribute the most to the overall yield strength of the LAAM-built Ti–6Al–4V–x Ni alloys in this work. Furthermore, the decrease in elongation with increasing Ni addition is due to the deterioration in deformability of the β phase caused by a large amount of solid-solution Ni atoms. These findings can accelerate the development of additively manufactured titanium alloys.展开更多
In this investigation,a picosecond laser was employed to fabricate surface textures on a Stavax steel substrate,which is a key material for mold fabrication in the manufacturing of various polymer products.Three main ...In this investigation,a picosecond laser was employed to fabricate surface textures on a Stavax steel substrate,which is a key material for mold fabrication in the manufacturing of various polymer products.Three main types of surface textures were fabricated on a Stavax steel substrate:periodic ripples,a two-scale hierarchical two-dimensional array of micro-bumps,and a micro-pits array with nanoripples.The wettability of the laser-textured Stavax steel surface was converted from its original hydrophilicity into hydrophobicity and even super-hydrophobicity after exposure to air.The results clearly show that this super-hydrophobicity is mainly due to the surface textures.The ultrafast laserinduced catalytic effect may play a secondary role in modifying the surface chemistry so as to lower the surface energy.The laser-induced surface textures on the metal mold substrates were then replicated onto polypropylene substrates via the polymer injection molding process.The surface wettability of the molded polypropylene was found to be changed from the original hydrophilicity to superhydrophobicity.This developed process holds the potential to improve the performance of fabricated plastic products in terms of wettability control and easy cleaning.展开更多
Inspired by the sophisticated artificial leather garment industry and toward enhancing wearability of energy storage devices, we demonstrate a polyurethane artificial leather supercapacitor with large sheet electrodes...Inspired by the sophisticated artificial leather garment industry and toward enhancing wearability of energy storage devices, we demonstrate a polyurethane artificial leather supercapacitor with large sheet electrodes embedded in theleather layer simultaneously working as a polyelectrolyte. This design totally reserves textiles underneath and thus addresses the well-known challenge of wearing comfortability. It provides a revolutionary configuration of wearable supercapacitors: the artificial leather on garment is also a supercapacitor.Unlike the polyvinyl alcohol-based acidic electrolytes, which are widely used, sodium chloride is used to modify the intrinsically fluorescent polyurethane leather for ionic transportation, which has no harm to human. The fluorescent leather supercapacitor is easily transferrable from any arbitrary substrates to form various patterns, enabling multifunctionalities of practical wearability, fashion, and energy storage.展开更多
Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a corr...Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.展开更多
Binder jet printing(BJP)is a state-of-the-art additive manufacturing technique for producing porous magnesium structures.Porous MgZn-Zr based BJP samples were assessed for corrosion performance in simulated body fluid...Binder jet printing(BJP)is a state-of-the-art additive manufacturing technique for producing porous magnesium structures.Porous MgZn-Zr based BJP samples were assessed for corrosion performance in simulated body fluids by electrochemical and hydrogen evolution measurements.The corrosion rates of the BJP specimens were significantly higher than solid controls,even after accounting for their larger surface areas,suggesting that the BJP microstructure is detrimental to corrosion performance.X-ray computed tomography revealed nonuniform corrosion within the porous structure,with corrosion products forming on the pore walls.Impregnating the pores with hydroxyapatite or polymers greatly improved the corrosion resistance of the BJP samples.展开更多
With the concepts of Industry 4.0 and smart manufacturing gaining popularity,there is a growing notion that conventional manufacturing will witness a transition toward a new paradigm,targeting innovation,automation,be...With the concepts of Industry 4.0 and smart manufacturing gaining popularity,there is a growing notion that conventional manufacturing will witness a transition toward a new paradigm,targeting innovation,automation,better response to customer needs,and intelligent systems.Within this context,this review focuses on the concept of cyber–physical production system(CPPS)and presents a holistic perspective on the role of the CPPS in three key and essential drivers of this transformation:data-driven manufacturing,decentralized manufacturing,and integrated blockchains for data security.The paper aims to connect these three aspects of smart manufacturing and proposes that through the application of data-driven modeling,CPPS will aid in transforming manufacturing to become more intuitive and automated.In turn,automated manufacturing will pave the way for the decentralization of manufacturing.Layering blockchain technologies on top of CPPS will ensure the reliability and security of data sharing and integration across decentralized systems.Each of these claims is supported by relevant case studies recently published in the literature and from the industry;a brief on existing challenges and the way forward is also provided.展开更多
Ultra-precision machining is an effective approach to achieve high dimension accuracy and surface finish required in optical and laser components. An extensive study using a two-axis diamond turning machine is conduct...Ultra-precision machining is an effective approach to achieve high dimension accuracy and surface finish required in optical and laser components. An extensive study using a two-axis diamond turning machine is conducted to machine the reflector arrays used for laser diode beam shaping. To position the workpiece precisely, theoretical analysis is made so that the dimensional accuracy can be achieved. Investigations into machining burr reduction are carried out. With the process developed, reflectors with optical surface finish of 8 nm in Ra and minimized burr size of less than 0.5 μm have been achieved.展开更多
Metallic biomaterials have been widely used in the field of medical implants for replacement purposes and/or for regeneration of tissue.Metals such as stainless steel(316 L),cobalt-chromium alloys and titanium alloys(...Metallic biomaterials have been widely used in the field of medical implants for replacement purposes and/or for regeneration of tissue.Metals such as stainless steel(316 L),cobalt-chromium alloys and titanium alloys(Ti-6Al-4 V)are widely used as metallic implants today.However,they often exhibit unsatisfactory results such as stress shielding,the release of toxic ions and are often permanent and invasive–where a second surgery is required to remove the implant once the bone is fully healed.Magnesium as a biomaterial have attracted much attention recently due to its excellent biocompatibility,similar mechanical properties to bone and biodegradability.Unlike other metals and bio ceramics,the ability for magnesium alloys to undergo biodegradation eliminates the requirement for a second surgery to remove the implant.Additionally,the degradation of magnesium releases Mg2+ions,which stimulates metabolism as they are a cofactor in numerous numbers of enzymes.Despite the advantages of magnesium alloys,the rapid degradation of magnesium proved to be challenging as the implant is unable to retain its structural integrity sufficiently enough to act as an implant.To improve the corrosion resistance of magnesium alloys,researchers have been working on the synthesis and characterization of Mg-based bulk metallic glasses,which can significantly improve the corrosion resistance of Mg-based alloys.This paper is a comprehensive review that compiles,analyzes and critically discusses the recent literature on the latest understanding of the processing,mechanical and biological characteristics of Mg-based bulk metallic glasses.展开更多
Human beings have witnessed unprecedented developments since the 1760s using precision tools and manufacturing methods that have led to ever-increasing precision,from millimeter to micrometer,to single nanometer,and t...Human beings have witnessed unprecedented developments since the 1760s using precision tools and manufacturing methods that have led to ever-increasing precision,from millimeter to micrometer,to single nanometer,and to atomic levels.The modes of manufacturing have also advanced from craft-based manufacturing in the Stone,Bronze,and Iron Ages to precisioncontrollable manufacturing using automatic machinery.In the past 30 years,since the invention of the scanning tunneling microscope,humans have become capable of manipulating single atoms,laying the groundwork for the coming era of atomic and close-to-atomic scale manufacturing(ACSM).Close-to-atomic scale manufacturing includes all necessary steps to convert raw materials,components,or parts into products designed to meet the user’s specifications.The processes involved in ACSM are not only atomically precise but also remove,add,or transform work material at the atomic and close-to-atomic scales.This review discusses the history of the development of ACSM and the current state-of-the-art processes to achieve atomically precise and/or atomic-scale manufacturing.Existing and future applications of ACSM in quantum computing,molecular circuitry,and the life and material sciences are also described.To further develop ACSM,it is critical to understand the underlying mechanisms of atomic-scale and atomically precise manufacturing;develop functional devices,materials,and processes for ACSM;and promote high throughput manufacturing.展开更多
Pipeline plays a vital role in transporting fluids like oils, water, and petrochemical substances for longer distances. Based on the materials they carry</span><span style="white-space:normal;font-size:1...Pipeline plays a vital role in transporting fluids like oils, water, and petrochemical substances for longer distances. Based on the materials they carry</span><span style="white-space:normal;font-size:10pt;font-family:"">,</span><span style="white-space:normal;font-size:10pt;font-family:""> prolonged usage may cause the initiation of defects in the pipeline. These defects occur due to the formed salt deposits, chemical reaction happens between the inner surface and the transferring substance, prevailing environmental conditions, etc. These defects, if not identified earlier may lead to significant losses to the industry. In this work, an in-line inspection system utilizes the nondestructive way for analyzing the internal defects in the petrochemical pipeline. This system consists of a pipeline inspection robot having two major units namely the visual inspection unit and the power carrier unit. The visual inspection unit makes use of a ring-type laser diode and the camera. The laser diode serves as a light source for capturing good quality images of inspection. This unit is controlled by the Arduino in the power carrier unit which provides the necessary movement throughout the pipe. The inspected images captured by the camera are further processed with the aid of NI vision assistant software. After applying the processing function parameters provided by this software, the defect location can be clearly visualized with high precision. Three sets of defects are introduced in a Polylactide (PLA) pipe based on its position and angle along the circumference of the pipe. Further, this robot system serves as a real-time interactive image synchronization system for acquiring the inspected images. By comparing the actual and calculated defect size, the error percentage obtained was less than 5%.展开更多
We report the generation of high energy 2μm picosecond pulses from a thulium-doped fiber master oscillator power amplifier system.The all-fiber configuration was realized by a flexible large-mode area photonic crysta...We report the generation of high energy 2μm picosecond pulses from a thulium-doped fiber master oscillator power amplifier system.The all-fiber configuration was realized by a flexible large-mode area photonic crystal fiber(LMA-PCF).The amplifier output is a linearly-polarized 1.5 ns,100 kHz pulse train with a pulse energy of up to 250μJ.Pulse compression was achieved with(2+2)-pass chirped volume Bragg grating(CVBG)to obtain a 2.8 ps pulse width with a total pulse energy of 46μJ.The overall system compactness was enabled by the all-fiber amplifier design and the multi-pass CVBG-based compressor.The laser output was then used to demonstrate high-speed direct-writing capability on a temperature-sensitive biomaterial to change its topography(i.e.fabricate microchannels,foams and pores).The topographical modifications of biomaterials are known to influence cell behavior and fate which is potentially useful in many cell and tissue engineering applications.展开更多
基金financially supported by the Agency for Science,Technology and Research(A*Star),Republic of Singapore,under the Aerospace Consortium Cycle 12“Characterization of the Effect of Wire and Powder Deposited Materials”(No.A1815a0078)。
文摘The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully circumvent defects in Ti-6Al-4V deposits for LAAM_(p) and LAAM_(w),respectively.With the optimized process parameters,robust interfaces were achieved between powder/wire deposits and the forged substrate,as well as between powder and wire deposits.Microstructure characterization results revealed the epitaxial prior β grains in the deposited Ti-6Al-4V,wherein the powder deposit was dominated by a finerα′microstructure and the wire deposit was characterized by lamellar α phases.The mechanisms of microstructure formation and correlation with mechanical behavior were analyzed and discussed.The mechanical properties of the interfacial samples can meet the requirements of the relevant Aerospace Material Specifications(AMS 6932)even without post heat treatment.No fracture occurred within the interfacial area,further suggesting the robust interface.The findings of this study highlighted the feasibility of combining LAAM_(p) and LAAM_(w) in the direct manufacturing of Ti-6Al-4V parts in accordance with the required dimensional resolution and deposition rate,together with sound strength and ductility balance in the as-built condition.
基金financially supported by the Young Individual Research Grants(Grant No:M22K3c0097)Singapore RIE 2025 plan and Singapore Aerospace Programme Cycle 16(Grant No:M2215a0073)led by C Tan+2 种基金supported by the Singapore A*STAR Career Development Funds(Grant No:C210812047)the National Natural Science Foundation of China(52174361 and 52374385)the support by US NSF DMR-2104933。
文摘Titanium(Ti)alloys are widely used in high-tech fields like aerospace and biomedical engineering.Laser additive manufacturing(LAM),as an innovative technology,is the key driver for the development of Ti alloys.Despite the significant advancements in LAM of Ti alloys,there remain challenges that need further research and development efforts.To recap the potential of LAM high-performance Ti alloy,this article systematically reviews LAM Ti alloys with up-to-date information on process,materials,and properties.Several feasible solutions to advance LAM Ti alloys are reviewed,including intelligent process parameters optimization,LAM process innovation with auxiliary fields and novel Ti alloys customization for LAM.The auxiliary energy fields(e.g.thermal,acoustic,mechanical deformation and magnetic fields)can affect the melt pool dynamics and solidification behaviour during LAM of Ti alloys,altering microstructures and mechanical performances.Different kinds of novel Ti alloys customized for LAM,like peritecticα-Ti,eutectoid(α+β)-Ti,hybrid(α+β)-Ti,isomorphousβ-Ti and eutecticβ-Ti alloys are reviewed in detail.Furthermore,machine learning in accelerating the LAM process optimization and new materials development is also outlooked.This review summarizes the material properties and performance envelops and benchmarks the research achievements in LAM of Ti alloys.In addition,the perspectives and further trends in LAM of Ti alloys are also highlighted.
基金financially supported by the Career Development Fund(Grant No.C210112051)under the Agency for Science,Technology and Research(A*STAR)of Singapore2022 MTC Young Individual Research Grants(Grant No:M22K3c0097)under Singapore Research,Innovation and Enterprise(RIE)2025 Plan,led by C Tan。
文摘Tailoring thermal history during additive manufacturing(AM)offers a feasible approach to customise the microstructure and properties of materials without changing alloy compositions or post-heat treatment,which is generally overlooked as it is hard to achieve in commercial materials.Herein,a customised Fe-Ni-Ti-Al maraging steel with rapid precipitation kinetics offers the opportunity to leverage thermal history during AM for achieving large-range tunable strength-ductility combinations.The Fe-Ni-Ti-Al steel was processed by laser-directed energy deposition(LDED)with different deposition strategies to tailor the thermal history.As the phase transformation and in-situ formation of multi-scale secondary phases of the Fe-Ni-Ti-Al steel are sensitive to the thermal histories,the deposited steel achieved a large range of tuneable mechanical properties.Specifically,the interlayer paused deposited sample exhibits superior tensile strength(∼1.54 GPa)and moderate elongation(∼8.1%),which is attributed to the formation of unique hierarchical structures and the in-situ precipitation of high-densityη-Ni_(3)(Ti,Al)during LDED.In contrast,the substrate heating deposited sample has an excellent elongation of 19.3%together with a high tensile strength of 1.24 GPa.The achievable mechanical property range via tailoring thermal history in the LDED-built Fe-Ni-Ti-Al steel is significantly larger than most commercial materials.The findings highlight the material customisation along with AM’s unique thermal history to achieve versatile mechanical performances of deposited materials,which could inspire more property or function manipulations of materials by AM process control or innovation.
基金financial support provided by A*STAR Additive Manufacturing Centre (AMC) Initiative: Work package 1-High temperature materials development for 3D additive manufacturing (142680088)
文摘In this study, the flow characteristics and behaviors of virgin and recycled Inconel powder for powder-bed additive manufacturing （AM） were studied using different powder characterization techniques. The results revealed that the particle size distribution （PSD） for the selective laser melting （SLM） process is typically in the range from 15 μm to 63 μm. The flow rate of virgin Inconel powder is around 28 s·（50 g）^-1. In addition, the packing density was found to be 60%. The rheological test results indicate that the virgin powder has reasonably good flowability compared with the recycled powder. The inter-relation between the powder characteristics is discussed herein. A propeller was successfully printed using the powder. The results suggest that Inconel powder is suitable for AM and can be a good reference for researchers who attempt to pro- duce AM powders.
基金support from Australian National University Futures Schemethe support from the first Singapore-Germany Academic-Industry (2 + 2) international collaboration grant (Grant No.: A1890b0050)。
文摘Magnesium alloys remain critical in the context of light-weighting and advanced devices. The increased utilisation of magnesium(Mg)each year reveals growing demand for its Mg-based alloys. Additive manufacturing(AM) provides the possibility to directly manufacture components in net-shape, providing new possibilities and applications for the use of Mg-alloys, and new prospects in the utilisation of novel physical structures made possible from ‘3D printing’. The review herein seeks to holistically explore the additive manufacturing of Mg-alloys to date, including a synopsis of processes used and properties measured(with a comparison to conventionally prepared Mg-alloys). The challenges and possibilities of AM Mg-alloys are critically elaborated for the field of mechanical metallurgy.
基金supported by Agency for Science,Technology and Research(A∗Star),the Republic of Singapore,under the IAF-PP program‘Integrated large format hybrid manufacturing using wire-fed and powder-blown technology for LAAM process’(Grant No:A1893a0031).
文摘Globularαphases can significantly improve the ductility of titanium alloys.Cyclic heat treatment(CHT)has been proved to be an effective way to induce the formation of globularαphases inα+βtitanium alloy Ti-6Al-4V fabricated by laser aided additive manufacturing(LAAM).However,there is no prior research reporting methods for obtaining globularαphases in LAAM-built near-αtitanium alloys.This work investigated the cyclic heat treatment(CHT)procedures suitable for the LAAM-built near-αtitanium alloy Ti-6Al-2Sn-4Zr-2Mo(Ti6242)to attain the globularαphases.The results show that 980℃ is the most suitable upper temperature limit for CHT.However,it is difficult to achieve a high volume fraction of the globularαphases in the LAAM-built Ti6242 alloys through CHT,which is ascribed to the low composition gradient caused by moreα-stabilizing elements and fewerβ-stabilizing elements.The as-built sample demonstrated elongation of 6.3%,which is lower than the AMS 4919J standard(elongation≥10%).After 980℃ CHT and 980℃ CHT with solution heat-treatment,the formation of the globularαphases significantly increased the elongation to 13.5%and 12.9%,respectively.Although the mechanical strength is reduced after heat-treatment,the room-temperature tensile properties still exceed the AMS 4919J standard.Fractography examination showed that the as-built sample exhibited a mixed brittle and ductile fracture behavior,while the 980℃ CHT and 980℃ CHT with solution heat-treated samples displayed ductile fracture.
基金supported by National Research Foundation of Korea(NRF)grants funded by the Korean Government(MSIT)[grant numbers RS-2023-00207763 and NRF-2022R1A2C2010350].
文摘Magnesium(Mg)and its alloys have recently gained increasing attention in the biomedical field as promising biodegradable materials with harmless degradation products.Magnesium-based alloys have a wide range of biomedical applications because of their outstanding biocompatibility and unique mechanical properties.Widespread use of Mg-based biomedical devices eliminates the need for post-healing biomaterial removal surgery and minimizes the negative consequences of the implantation of permanent biomaterials,including stress shielding and undesired metal ion release in the body.This paper provides a literature review on the properties and manufacturing methods of Mgbased alloys for biomedical applications,including orthopedic implants,cardiovascular applications,surgical wires and staplers,and antitumor activities.Each application of Mg-based biomaterials is investigated from a biological perspective,including matching functional properties,biocompatibility,host tissue responses,and anti-microbial strategies,along with potential additive manufacturing technologies for these applications.Finally,an outlook is presented to provide recommendations for Mg-based biomaterials in the future.
基金financial support from the Science and Engineering Research Council,Agency for Science,Technology and Research(A*STAR),Singapore(142 68 00088)
文摘Additive manufacturing(AM)is gaining traction in the manufacturing industry for the fabrication of components with complex geometries using a variety of materials.Selective laser melting(SLM)is a common AM technique that is based on powder-bed fusion(PBF)to process metals;however,it is currently focused only on the fabrication of macroscale and mesoscale components.This paper reviews the state of the art of the SLM of metallic materials at the microscale level.In comparison with the direct writing techniques that are commonly used for micro AM,micro SLM is attractive due to a number of factors,including a faster cycle time,process simplicity,and material versatility.A comprehensive evaluation of various research works and commercial systems for the fabrication of microscale parts using SLM and selective laser sintering(SLS)is conducted.In addition to identifying existing issues with SLM at the microscale,which include powder recoating,laser optics,and powder particle size,this paper details potential future directions.A detailed review of existing recoating methods in powder-bed techniques is conducted,along with a description of emerging efforts to implement dry powder dispensing methods in the AM domain.A number of secondary finishing techniques for AM components are reviewed,with a focus on implementation for microscale features and integration with micro SLM systems.
基金supported by the Agency for Science,Technology and Research(A*Star),Republic of Singapore under the IAF-PP program‘Integrated large format hybrid manufacturing using wire-fed and powder-blown technology for LAAM process’,Grant No.A1893a0031the Academy of Sciences Project of Guangdong Province,Grant No.2016GDASRC-0105。
文摘It is well-known that grain refiners can tailor the microstructure and enhance the mechanical properties of titanium alloys fabricated by additive manufacturing(AM). However, the intrinsic mechanisms of Ni addition on AM-built Ti–6Al–4V alloy is not well established. This limits its industrial applications. This work systematically investigated the influence of Ni additive on Ti–6Al–4V alloy fabricated by laser aided additive manufacturing(LAAM). The results showed that Ni addition yields three key effects on the microstructural evolution of LAAM-built Ti–6Al–4V alloy.(a) Ni additive remarkably refines the prior-β grains, which is due to the widened solidification range. As the Ni addition increased from 0 to 2.5 wt. %, the major-axis length and aspect ratio of the prior-β grains reduced from over 1500 μm and 7 to 97.7 μm and1.46, respectively.(b) Ni additive can discernibly induce the formation of globular α phase,which is attributed to the enhanced concentration gradient between the β and α phases. This is the driving force of globularization according to the termination mass transfer theory. The aspect ratio of the α laths decreased from 4.14 to 2.79 as the Ni addition increased from 0 to2.5 wt. %.(c) Ni as a well-known β-stabilizer and it can remarkably increase the volume fraction of β phase. Room-temperature tensile results demonstrated an increase in mechanical strength and an almost linearly decreasing elongation with increasing Ni addition. A modified mathematical model was used to quantitatively analyze the strengthening mechanism. It was evident from the results that the α lath phase and the solid solutes contribute the most to the overall yield strength of the LAAM-built Ti–6Al–4V–x Ni alloys in this work. Furthermore, the decrease in elongation with increasing Ni addition is due to the deterioration in deformability of the β phase caused by a large amount of solid-solution Ni atoms. These findings can accelerate the development of additively manufactured titanium alloys.
基金the Agency for Science Technology and Research (A*STAR) of Singapore for financial support
文摘In this investigation,a picosecond laser was employed to fabricate surface textures on a Stavax steel substrate,which is a key material for mold fabrication in the manufacturing of various polymer products.Three main types of surface textures were fabricated on a Stavax steel substrate:periodic ripples,a two-scale hierarchical two-dimensional array of micro-bumps,and a micro-pits array with nanoripples.The wettability of the laser-textured Stavax steel surface was converted from its original hydrophilicity into hydrophobicity and even super-hydrophobicity after exposure to air.The results clearly show that this super-hydrophobicity is mainly due to the surface textures.The ultrafast laserinduced catalytic effect may play a secondary role in modifying the surface chemistry so as to lower the surface energy.The laser-induced surface textures on the metal mold substrates were then replicated onto polypropylene substrates via the polymer injection molding process.The surface wettability of the molded polypropylene was found to be changed from the original hydrophilicity to superhydrophobicity.This developed process holds the potential to improve the performance of fabricated plastic products in terms of wettability control and easy cleaning.
基金Funding of Harbin Institute of Technology (Shenzhen) (DD45001015)NSFC/RGC Joint Research Scheme (Project N_City U123/15)+2 种基金the Science Technology and Innovation Committee of Shenzhen Municipality (JCYJ20130401145617276 and R-IND4903)City University of Hong Kong (PJ7004645)the Hong Kong Polytechnic University (1-BBA3) supported this work
文摘Inspired by the sophisticated artificial leather garment industry and toward enhancing wearability of energy storage devices, we demonstrate a polyurethane artificial leather supercapacitor with large sheet electrodes embedded in theleather layer simultaneously working as a polyelectrolyte. This design totally reserves textiles underneath and thus addresses the well-known challenge of wearing comfortability. It provides a revolutionary configuration of wearable supercapacitors: the artificial leather on garment is also a supercapacitor.Unlike the polyvinyl alcohol-based acidic electrolytes, which are widely used, sodium chloride is used to modify the intrinsically fluorescent polyurethane leather for ionic transportation, which has no harm to human. The fluorescent leather supercapacitor is easily transferrable from any arbitrary substrates to form various patterns, enabling multifunctionalities of practical wearability, fashion, and energy storage.
基金supported by National Hi-tech Research and Development Program of China (863 Program, Grant No. 2009AA44302)Scientific Research Fund of Hunan Provincial Education Department, China (Grant No. 10C1259)+2 种基金Hunan Provincial Planned Science and Technology Project of China (Grant No. 2011FJ3231)National Natural Science Foundation of China (Grant No. 51005194)Open Innovation Platform of Hunan College Fund, China (Grant No. 10K063)
文摘Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.
基金the first Singapore-Germany Academic-Industry(2+2)international collaboration grant(Grant No.:A1890b0050)Agency for Science,Technology and Research(A^(*)STAR),under the RIE2020 Advanced Manufacturing and Engineering(AME)Programmatic Grant No.A1881b0061support of a scholarship from the A^(*)STAR Graduate Academy。
文摘Binder jet printing(BJP)is a state-of-the-art additive manufacturing technique for producing porous magnesium structures.Porous MgZn-Zr based BJP samples were assessed for corrosion performance in simulated body fluids by electrochemical and hydrogen evolution measurements.The corrosion rates of the BJP specimens were significantly higher than solid controls,even after accounting for their larger surface areas,suggesting that the BJP microstructure is detrimental to corrosion performance.X-ray computed tomography revealed nonuniform corrosion within the porous structure,with corrosion products forming on the pore walls.Impregnating the pores with hydroxyapatite or polymers greatly improved the corrosion resistance of the BJP samples.
文摘With the concepts of Industry 4.0 and smart manufacturing gaining popularity,there is a growing notion that conventional manufacturing will witness a transition toward a new paradigm,targeting innovation,automation,better response to customer needs,and intelligent systems.Within this context,this review focuses on the concept of cyber–physical production system(CPPS)and presents a holistic perspective on the role of the CPPS in three key and essential drivers of this transformation:data-driven manufacturing,decentralized manufacturing,and integrated blockchains for data security.The paper aims to connect these three aspects of smart manufacturing and proposes that through the application of data-driven modeling,CPPS will aid in transforming manufacturing to become more intuitive and automated.In turn,automated manufacturing will pave the way for the decentralization of manufacturing.Layering blockchain technologies on top of CPPS will ensure the reliability and security of data sharing and integration across decentralized systems.Each of these claims is supported by relevant case studies recently published in the literature and from the industry;a brief on existing challenges and the way forward is also provided.
文摘Ultra-precision machining is an effective approach to achieve high dimension accuracy and surface finish required in optical and laser components. An extensive study using a two-axis diamond turning machine is conducted to machine the reflector arrays used for laser diode beam shaping. To position the workpiece precisely, theoretical analysis is made so that the dimensional accuracy can be achieved. Investigations into machining burr reduction are carried out. With the process developed, reflectors with optical surface finish of 8 nm in Ra and minimized burr size of less than 0.5 μm have been achieved.
文摘Metallic biomaterials have been widely used in the field of medical implants for replacement purposes and/or for regeneration of tissue.Metals such as stainless steel(316 L),cobalt-chromium alloys and titanium alloys(Ti-6Al-4 V)are widely used as metallic implants today.However,they often exhibit unsatisfactory results such as stress shielding,the release of toxic ions and are often permanent and invasive–where a second surgery is required to remove the implant once the bone is fully healed.Magnesium as a biomaterial have attracted much attention recently due to its excellent biocompatibility,similar mechanical properties to bone and biodegradability.Unlike other metals and bio ceramics,the ability for magnesium alloys to undergo biodegradation eliminates the requirement for a second surgery to remove the implant.Additionally,the degradation of magnesium releases Mg2+ions,which stimulates metabolism as they are a cofactor in numerous numbers of enzymes.Despite the advantages of magnesium alloys,the rapid degradation of magnesium proved to be challenging as the implant is unable to retain its structural integrity sufficiently enough to act as an implant.To improve the corrosion resistance of magnesium alloys,researchers have been working on the synthesis and characterization of Mg-based bulk metallic glasses,which can significantly improve the corrosion resistance of Mg-based alloys.This paper is a comprehensive review that compiles,analyzes and critically discusses the recent literature on the latest understanding of the processing,mechanical and biological characteristics of Mg-based bulk metallic glasses.
基金The authors gratefully acknowledge the support from the National Science Foundation of China(Grant Nos.51320105009,61635008,and 61675149)and the Science Foundation Ireland(SFI)(Grant Nos.15/RP/B3208 and 18/FIP/3555).
文摘Human beings have witnessed unprecedented developments since the 1760s using precision tools and manufacturing methods that have led to ever-increasing precision,from millimeter to micrometer,to single nanometer,and to atomic levels.The modes of manufacturing have also advanced from craft-based manufacturing in the Stone,Bronze,and Iron Ages to precisioncontrollable manufacturing using automatic machinery.In the past 30 years,since the invention of the scanning tunneling microscope,humans have become capable of manipulating single atoms,laying the groundwork for the coming era of atomic and close-to-atomic scale manufacturing(ACSM).Close-to-atomic scale manufacturing includes all necessary steps to convert raw materials,components,or parts into products designed to meet the user’s specifications.The processes involved in ACSM are not only atomically precise but also remove,add,or transform work material at the atomic and close-to-atomic scales.This review discusses the history of the development of ACSM and the current state-of-the-art processes to achieve atomically precise and/or atomic-scale manufacturing.Existing and future applications of ACSM in quantum computing,molecular circuitry,and the life and material sciences are also described.To further develop ACSM,it is critical to understand the underlying mechanisms of atomic-scale and atomically precise manufacturing;develop functional devices,materials,and processes for ACSM;and promote high throughput manufacturing.
文摘Pipeline plays a vital role in transporting fluids like oils, water, and petrochemical substances for longer distances. Based on the materials they carry</span><span style="white-space:normal;font-size:10pt;font-family:"">,</span><span style="white-space:normal;font-size:10pt;font-family:""> prolonged usage may cause the initiation of defects in the pipeline. These defects occur due to the formed salt deposits, chemical reaction happens between the inner surface and the transferring substance, prevailing environmental conditions, etc. These defects, if not identified earlier may lead to significant losses to the industry. In this work, an in-line inspection system utilizes the nondestructive way for analyzing the internal defects in the petrochemical pipeline. This system consists of a pipeline inspection robot having two major units namely the visual inspection unit and the power carrier unit. The visual inspection unit makes use of a ring-type laser diode and the camera. The laser diode serves as a light source for capturing good quality images of inspection. This unit is controlled by the Arduino in the power carrier unit which provides the necessary movement throughout the pipe. The inspected images captured by the camera are further processed with the aid of NI vision assistant software. After applying the processing function parameters provided by this software, the defect location can be clearly visualized with high precision. Three sets of defects are introduced in a Polylactide (PLA) pipe based on its position and angle along the circumference of the pipe. Further, this robot system serves as a real-time interactive image synchronization system for acquiring the inspected images. By comparing the actual and calculated defect size, the error percentage obtained was less than 5%.
基金Agency for Science,Technology and Research(A^*STAR)Singapore through the X-ray Photonics Programme(1426500052)A^*STAR Graduate Academy through the A^*STAR Graduate Scholarship.
文摘We report the generation of high energy 2μm picosecond pulses from a thulium-doped fiber master oscillator power amplifier system.The all-fiber configuration was realized by a flexible large-mode area photonic crystal fiber(LMA-PCF).The amplifier output is a linearly-polarized 1.5 ns,100 kHz pulse train with a pulse energy of up to 250μJ.Pulse compression was achieved with(2+2)-pass chirped volume Bragg grating(CVBG)to obtain a 2.8 ps pulse width with a total pulse energy of 46μJ.The overall system compactness was enabled by the all-fiber amplifier design and the multi-pass CVBG-based compressor.The laser output was then used to demonstrate high-speed direct-writing capability on a temperature-sensitive biomaterial to change its topography(i.e.fabricate microchannels,foams and pores).The topographical modifications of biomaterials are known to influence cell behavior and fate which is potentially useful in many cell and tissue engineering applications.
