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This study aims to address the limited understanding of the complex correlations among strut size, structural orientation and process parameters in selective laser melting (SLM)-fabricated lattice structures. By investigating the effects of crucial process parameters, strut diameter and angle on the microstructure and mechanical performance of AlSi10Mg struts, the research seeks to enhance the surface morphologies, microstructures and mechanical properties of AM lattice structures, enabling their application in various engineering fields, including medical science and space technologies.

This comprehensive study investigates SLM-fabricated AlSi10Mg strut structures, examining the effects of process parameters, strut diameter and angle on densification behavior and microstructural characteristics. By analyzing microstructure, geometrical properties, melt pool morphology and mechanical properties using optical microscopy, scanning electron microscope, energy dispersive X-ray spectroscopy and microhardness tests, the research addresses existing gaps in knowledge on fine lattice strut elements and their impact on surface morphology and microstructure.

The study revealed that laser energy, power density and strut inclination angle significantly impact the microstructure, geometrical properties and mechanical performance of SLM-produced AlSi10Mg struts. Findings insight enable the optimization of SLM process parameters to produce lattice structures with enhanced surface morphologies, microstructures and mechanical properties, paving the way for applications in medical science and space technologies.

This study uniquely investigates the effects of processing parameters, strut diameter and inclination angle on SLM-fabricated AlSi10Mg struts, focusing on fine lattice strut elements with diameters as small as 200 µm. Unlike existing literature, it delves into the complex correlations among strut size, structural orientation and process parameters to understand their impact on microstructure, geometrical imperfections and mechanical properties. The study provides novel insights that contribute to the optimization of SLM process parameters, moving beyond the typically recommended guidelines from powder or machine suppliers.

Powder bed fusion-laser beam (PBF-LB) is a rapidly growing manufacturing technology for producing Al-Si alloys. This technology can be used to produce high-pressure die-casting (HPDC) prototypes. The purpose of this paper is to understand the similarities and differences in the microstructures and properties of PBF-LB and HPDC alloys.

PBF-LB AlSi10Mg and HPDC AlSi10Mn plates with different thicknesses were manufactured. Iso-thermal heat treatment was conducted on PBF-LB bending plates. A detailed meso-micro-nanostructure analysis was performed. Tensile, bending and microhardness tests were conducted on both alloys.

The PBF-LB skin was highly textured and softer than its core, opposite to what is observed in the HPDC alloy. Increasing sample thickness increased the bulk strength for the PBF-LB alloy, contrasting with the decrease for the HPDC alloy. In addition, the tolerance to fracture initiation during bending deformation is greater for the HPDC material, probably due to its stronger skin region.

This knowledge is crucial to understand how geometry of parts may affect the properties of PBF-LB components. In particular, understanding the role of geometry is important when using PBF-LB as a HPDC prototype.

This is the first comprehensive meso-micro-nanostructure comparison of both PBF-LB and HPDC alloys from the millimetre to nanometre scale reported to date that also considers variations in the skin versus core microstructure and mechanical properties.

In this study, two postprocessing techniques, namely, conventional burnishing (CB) and ultrasonic-assisted burnishing (UAB), were applied to improve the fatigue behavior of 316 L stainless steel fabricated through selective laser melting (SLM). The effects of these processes on surface roughness, porosity, microhardness and fatigue performance were experimentally investigated. The purpose of this study is to evaluate the feasibility and effectiveness of ultrasonic-assisted burnishing as a preferred post-processing technique for enhancing the fatigue performance of additively manufactured components.

All samples were subjected to a sandblasting process. Next, the samples were divided into three distinct groups. The first group (as-Built) did not undergo any additional postprocessing, apart from sandblasting. The second group was treated with CB, while the third group was treated with ultrasonic-assisted burnishing. Finally, all samples were evaluated based on their surface roughness, porosity, microhardness and fatigue performance.

The results revealed that the initial mean surface roughness (Ra) of the as-built sample was 11.438 µm. However, after undergoing CB and UAB treatments, the surface roughness decreased to 1.629 and 0.278 µm, respectively. Notably, the UAB process proved more effective in eliminating near-surface pores and improving the microhardness of the samples compared to the CB process. Furthermore, the fatigue life of the as-built sample, initially at 66,000 cycles, experienced a slight improvement after CB treatment, reaching 347,000 cycles. However, the UAB process significantly enhanced the fatigue life of the samples, extending it to 620,000 cycles.

After reviewing the literature, it can be concluded that UAB will exceed the capabilities of CB in terms of enhancing the surface roughness and, subsequently, the fatigue performance of additive manufactured (AM) metals. However, the actual impact of the UAB process on the fatigue life of AM products has not yet been thoroughly researched. Therefore, in this study, this paper used the burnishing process to enhance the fatigue life of 316 L stainless steel produced through the SLM process.

Productivity is often cited as a key barrier to the adoption of metal laser-based powder bed fusion (ML-PBF) technology for mass production. Newer generations of this technology work to overcome this by introducing more lasers or dramatically different processing techniques. Current generation ML-PBF machines are typically not capable of taking on additional hardware to maximise productivity due to inherent design limitations. Thus, any increases to be found in this generation of machines need to be implemented through design or adjusting how the machine currently processes the material. The purpose of this paper is to identify the most beneficial existing methodologies for the optimisation of productivity in existing ML-PBF equipment so that current users have a framework upon which they can improve their processes.

The review method used here is the preferred reporting items for systematic review and meta-analysis (PRISMA). This is complemented by using an artificial intelligence-assisted literature review tool known as Elicit. Scopus, WEEE, Web of Science and Semantic Scholar databases were searched for articles using specific keywords and Boolean operators.

The PRIMSA and Elicit processes resulted in 51 papers that met the criteria. Of these, 24 indicated that by using a design of experiment approach, processing parameters could be created that would increase productivity. The other themes identified include scan strategy (11), surface alteration (11), changing of layer heights (17), artificial neural networks (3) and altering of the material (5). Due to the nature of the studies, quantifying the effect of these themes on productivity was not always possible. However, studies citing altering layer heights and processing parameters indicated the greatest quantifiable increase in productivity with values between 10% and 252% cited. The literature, though not always explicit, depicts several avenues for the improvement of productivity for current-generation ML-PBF machines.

This systematic literature review provides trends and themes that aim to influence and support future research directions for maximising the productivity of the ML-PBF machines.

This study used an indentation-based mechanical testing framework for the mechanical characterization of laser powder bed fusion (LPBF) processed Inconel 718 on a wrought Inconel 718 substrate. The purpose of the paper is to investigate the effectiveness of the indentation-based approach for localized mechanical evaluation.

The LPBF-processed wrought substrate was sectioned into three sections for microstructural and mechanical characterization. A 3D heat source model was used for the thermal analysis of the interface region. The developed interface region is probed using the Knoop hardness indenter in different orientations to determine the textural anisotropy and mechanical behavior of the region.

LPBF process develops a melted interface zone (MIZ) at the deposition-substrate interface. The MIZ exhibited a coarse grain structure region along with a larger primary dendritic arm spacing (PDAS), signifying a slower cooling rate. FE modeling of the LPBF process reveals heat accumulation in the substrate along with intrinsic heat treatment (IHT) induced due to layer-wise processing. The obtained yield locus shows strong anisotropy in the deposition region, whereas reduced anisotropy with a nearly uniform ellipse locus for the MIZ regions. This reduced anisotropy is attributable to IHT and heat accumulation in the substrate.

An alternative localized mechanical characterization tool has been investigated in this work. The approach proved sensitive to thermal variations during LPBF processing in an isolated region which extends its suitability to variable geometry parts. Moreover, the approach could serve as a screening tool for parts made from dissimilar metals.

Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel.

A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy.

The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm³) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation.

This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.

Metal laser-powder-bed-fusion using laser-beam parts are particularly susceptible to contamination due to particles attached to the surface. This may compromise so-called technical cleanliness (e.g. in NASA RPTSTD-8070, ASTM G93, ISO 14952 or ISO 16232), which is important for many 3D-printed components, such as implants or liquid rocket engines. The purpose of the presented comparative study is to show how cleanliness is improved by design and different surface treatment methods.

Convex and concave test parts were designed, built and surface-treated by combinations of media blasting, electroless nickel plating and electrochemical polishing. After cleaning and analysing the technical cleanliness according to ASTM and ISO standards, effects on particle contamination, appearance, mass and dimensional accuracy are presented.

Contamination reduction factors are introduced for different particle sizes and surface treatment methods. Surface treatments were more effective for concave design features, however, the initial and resulting absolute particle contamination was higher. Results further indicate that there are trade-offs between cleanliness and other objectives in design. Design guidelines are introduced to solve conflicts in design when requirements for cleanliness exist.

This paper recommends designing parts and corresponding process chains for manufacturing simultaneously. Incorporating post-processing characteristics into the design phase is both feasible and essential. In the experimental study, electroless nickel plating in combination with prior glass bead blasting resulted in the lowest total remaining particle contamination. This process applied for cleanliness is a novelty, as well as a comparison between the different surface treatment methods.

The purpose of this paper is to investigate the effect of laser peening (LP) on mechanical and wear properties of 304 stainless steel sheet.

Three-dimensional morphology, micro-hardness and micro-structure of shocked samples were tested. The wear amount, wear track morphology and wear mechanism were also characterized under dry sliding wear using Al₂O₃ ceramics ball.

The LP treatment generates deformation twins that contribute to the grain refinement and hardness increase. The wear test displays that the wear mechanism of samples is mainly abrasive wear and oxidation wear at 10 N load. While at 30 N, the delamination and adhesion areas of treated sample are reduced visibly compared to untreated ones.

This study specifically investigates the mechanical and wear properties of 304 stainless steel after the direct action of LP on its surface, which shows an effective improvement on the wear resistance. For example, the wear loss of processed sample is reduced by 19% at 30 N, the friction coefficient decreases from 0.4714 to 0.4308 and the groove depth is reduced from 78.1 to 74.4 µm under same condition.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2024-0007/

The purpose of this study is therefore to detail an additive manufacturing process for printing TiD parts for implant applications. Titanium–diamond (TiD) is a new composite that provides biocompatible three-dimensional multimaterial structures. Thus, the authors report a powder-deposition and print optimization strategy to overcome the dual-functionality gap by printing bulk TiD parts. However, despite favorable customization outcomes, relatively few additive manufacturing (AM) feedstock powders offer the biocompatibility required for medical implant and device technologies.

AM offers a platform to fabricate customized patient-specific parts. Developing feedstock that can be 3D printed into specific 3D structures while providing a favorable interface with the human tissue remains a challenge. Using laser metal deposition, feedstock powder comprising diamond and titanium was co-printed into TiD parts for mechanical testing to determine optimal manufacturing parameters.

TiD parts were fabricated comprising 30% and 50% diamond. The composite powder had a Hausner ratio of 1.13 and 1.21 for 30% and 50% TiD, respectively. The flow analysis (Carney flow) for TiD 30% and 50% was 7.53 and 5.15 g/s. The authors report that the printing-specific conditions significantly affect the integrity of the printed part and thus provide the optimal manufacturing parameters for structural integrity as determined by micro-computed tomography, nanoindentation and biocompatibility of TiD parts. The hardness, ultimate tensile strength and yield strength for TiD are 4–6 GPa (depending on build position), 426 MPa and 375 MPa, respectively. Furthermore, the authors show that increasing diamond composition to 30% results in higher osteoblast viability and lower bacteria count than titanium.

In this study, the authors provide a clear strategy to manufacture TiD parts with high integrity, performance and biocompatibility, expanding the material feedstock library and paving the way to customized diamond implants. Diamond is showing strong potential as a biomedical material; however, upscale is limited by conventional techniques. By optimizing AM as the avenue to make complex shapes, the authors open up the possibility of patient-specific diamond implant solutions.

This study aims to improve the acceleration in the additive manufacturing (AM) process. AM tools, such as extrusion heads, jets, electric arcs, lasers and electron beams (EB), experience negligible forces. However, their speeds are limited by the positioning systems. In addition, a thin tool must travel several kilometers in tiny motions with several turns while realizing the AM part. Hence, acceleration is a more significant limiting factor than the velocity or precision for all except EB.

The sawtooth (ST) scanning strategy presented in this paper minimizes the time by combining three motion features: zigzag scan, 45º or 135º rotation for successive layers in G00 to avoid the CNC interpolation, and modifying these movements along 45º or 135º into sawtooth to halve the turns.

Sawtooth effectiveness is tested using an in-house developed Sand AM (SaAM) apparatus based on the laser–powder bed fusion AM technique. For a simple rectangle layer, the sawtooth achieved a path length reduction of 0.19%–1.49% and reduced the overall time by 3.508–4.889 times, proving that sawtooth uses increased acceleration more effectively than the other three scans. The complex layer study reduced calculated time by 69.80%–139.96% and manufacturing time by 47.35%–86.85%. Sawtooth samples also exhibited less dimensional variation (0.88%) than zigzag 45° (12.94%) along the build direction.

Sawtooth is limited to flying optics AM process.

Development of scanning strategy for flying optics AM process to reduce the warpage by improving the acceleration.