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This paper aims at building a discharge model for the power cable bellows based on plasma energy deposition and analyzing the discharge ablation problem.

Aiming at the multiphysical mechanism of the discharge ablation process, a multiphysical field model based on plasma energy deposition is established to analyze the discharge characteristics of the power cable bellows. The electrostatic field, plasma characteristics, energy deposition and temperature field are analyzed. The discharge experiment is also carried out for result validation.

The physical mechanism of the bellows ablative effect caused by partial discharge is studied. The results show that the electric field intensity between the aluminum sheath and the buffer layer easily exceeds the pressure resistance value of air breakdown. On the plasma surface of the buffer layer, the electron density is about 4 × 1,019/m³, and the average temperature of electrons is about 3.5 eV. The energy deposition analysis using the Monte Carlo method shows that the electron range in the plasma is very short. The release will complete within 10 nm, and it only takes 0.1 s to increase the maximum temperature of the buffer layer to more than 1,000 K, thus causing various thermal effects.

Its physical process involves the distortion of electric field, formation of plasma, energy deposition of electrons, and abrupt change of temperature field.

Directed energy deposition (DED) with laser powder-feed is an additive manufacturing process that is used to produce metallic components by simultaneously providing a supply of energy from a laser and mass from a powder aerosol. The breadth of alloys used in DED is currently limited to a very small range as compared to wrought or cast alloys. The purpose of this paper is to develop the new alloys for DED is limited because current models to predict operational processing parameters are computationally expensive and trial-and-error based experiments are both expensive and time-consuming.

In this research, an agile DED model is presented to predict the geometry produced by a single layer deposit.

The utility of the model is demonstrated for type 304 L stainless steel and the significance of the predicted deposition regimes is discussed. The proposed model incorporates concepts from heat transfer, welding and laser cladding; and integrates them with experimental fits and physical models that are relevant to DED.

The utility of the model is demonstrated for type 304 L stainless steel and the significance of the predicted deposition regimes is discussed.

This study aims to review the recent advancements in high entropy alloys (HEAs) called high entropy materials, including high entropy superalloys which are current potential alternatives to nickel superalloys for gas turbine applications. Understandings of the laser surface modification techniques of the HEA are discussed whilst future recommendations and remedies to manufacturing challenges via laser are outlined.

Materials used for high-pressure gas turbine engine applications must be able to withstand severe environmentally induced degradation, mechanical, thermal loads and general extreme conditions caused by hot corrosive gases, high-temperature oxidation and stress. Over the years, Nickel-based superalloys with elevated temperature rupture and creep resistance, excellent lifetime expectancy and solution strengthening L12 and γ´ precipitate used for turbine engine applications. However, the superalloy’s density, low creep strength, poor thermal conductivity, difficulty in machining and low fatigue resistance demands the innovation of new advanced materials.

HEAs is one of the most frequently investigated advanced materials, attributed to their configurational complexity and properties reported to exceed conventional materials. Thus, owing to their characteristic feature of the high entropy effect, several other materials have emerged to become potential solutions for several functional and structural applications in the aerospace industry. In a previous study, research contributions show that defects are associated with conventional manufacturing processes of HEAs; therefore, this study investigates new advances in the laser-based manufacturing and surface modification techniques of HEA.

The AlxCoCrCuFeNi HEA system, particularly the Al0.5CoCrCuFeNi HEA has been extensively studied, attributed to its mechanical and physical properties exceeding that of pure metals for aerospace turbine engine applications and the advances in the fabrication and surface modification processes of the alloy was outlined to show the latest developments focusing only on laser-based manufacturing processing due to its many advantages.

It is evident that high entropy materials are a potential innovative alternative to conventional superalloys for turbine engine applications via laser additive manufacturing.

This paper aims to present a systematic approach in the literature survey related to metal additive manufacturing (AM) processes and its multi-physics continuum modelling approach for its better understanding.

A systematic review of the literature available in the area of continuum modelling practices adopted for the powder bed fusion (PBF) AM processes for the deposition of powder layer over the substrate along with quantification of residual stress and distortion. Discrete element method (DEM) and finite element method (FEM) approaches have been reviewed for the deposition of powder layer and thermo-mechanical modelling, respectively. Further, thermo-mechanical modelling adopted for the PBF AM process have been discussed in detail with its constituents. Finally, on the basis of prediction through thermo-mechanical models and experimental validation, distortion mitigation/minimisation techniques applied in PBF AM processes have been reviewed to provide a future direction in the field.

The findings of this paper are the future directions for the implementation and modification of the continuum modelling approaches applied to PBF AM processes. On the basis of the extensive review in the domain, gaps are recommended for future work for the betterment of modelling approach.

This paper is limited to review only the modelling approach adopted by the PBF AM processes, i.e. modelling techniques (DEM approach) used for the deposition of powder layer and macro-models at process scale for the prediction of residual stress and distortion in the component. Modelling of microstructure and grain growth has not been included in this paper.

This paper presents an extensive review of the FEM approach adopted for the prediction of residual stress and distortion in the PBF AM processes which sets the platform for the development of distortion mitigation techniques. An extensive review of distortion mitigation techniques has been presented in the last section of the paper, which has not been reviewed yet.

Selective laser melting (SLM) is an advanced rapid prototyping or additive manufacturing technology that uses high power density laser to fabricate metal/alloy components with minimal geometric constraints. The SLM process is multi-physics in nature and its study requires development of complex simulation tools. The purpose of this paper is to study – for the first time, to the best of the authors’ knowledge – the electromagnetic wave interactions and thermal processes in SLM based dense powder beds under the full-wave formalism and identify prospective metal powder bed particle distributions that can substantially improve the absorption rate, SLM volumetric deposition rate and thereby the overall build time.

We present a self-consistent thermo-optical model of the laser-matter interactions pertaining to SLM. The complex electromagnetic interactions and thermal effects in the dense metal powder beds are investigated by means of full-wave finite difference simulations. The model allows for accurate simulations of the excitation of gap, bulk and surface electromagnetic resonance modes, the energy transport across the particles, time dependent local permittivity variations under the incident laser intensity, and the thermal effects (joule heating) due to electromagnetic energy dissipation.

Localized gap and surface plasmon polariton resonance effects are identified as possible mechanisms toward improved absorption in small and medium size titanium powder beds. Furthermore, the observed near homogeneous temperature distributions across the metal powders indicates fast thermalization processes and allows for development of simple analytical models to describe the dynamics of the SLM process.

To the best of the authors’ knowledge, for the first time the electromagnetic interactions and thermal processes with dense powder beds pertaining to SLM processes are investigated under full-wave formalism. Explicit description is provided for important SLM process parameters such as critical laser power density, saturation temperature and time to melt. Specific guidelines are presented for improved energy efficiency and optimization of the SLM process deposition rates.

Direct energy deposition (DED) is an additive manufacturing process that allows to produce metal parts with complex shapes. DED process depends on several parameters, including laser power, deposition rate and powder feeding rate. It is important to control the manufacturing process to study the influence of the operating parameters on the final characteristics of these parts and to optimize them. Computational modeling helps engineers to address these challenges. This paper aims to establish a framework for the development, verification and application of meshless methods and surrogate models to the DED process.

Finite pointset method (FPM) is used to solve conservation equations involved in the DED process. A surrogate model is then established for the DED process using design of experiments with powder feeding rate, laser power and scanning speed as input parameters. The surrogate model is constructed using neutral networks (NN) approximations for the prediction of maximum temperature, clad angle and dilution.

The simulations of thin wall built of Ti-6Al-4V titanium alloy clearly demonstrated that FPM simulation is successful in predicting temperature distribution for different process conditions and compare favorably with experimental results from the literature. A methodology has been developed for obtaining a surrogate model for DED process.

This methodology shows how to achieve realistic simulations of DED process and how to construct a surrogate model for further use in optimization loop.

The usage of additive manufacturing (AM) technology in industries has reached up to 50 per cent as prototype or end-product. However, for AM products to be directly used as final products, AM product should be produced through advanced quality control process, which has a capability to be able to prove and reach their desire repeatability, reproducibility, reliability and preciseness. Therefore, there is a need to review quality-related research in terms of AM technology and guide AM industry in the future direction of AM development.

This paper overviews research progress regarding the QC in AM technology. The focus of the study is on manufacturing quality issues and needs that are to be developed and optimized, and further suggests ideas and directions toward the quality improvement for future AM technology. This paper is organized as follows. Section 2 starts by conducting a comprehensive review of the literature studies on progress of quality control, issues and challenges regarding quality improvement in seven different AM techniques. Next, Section 3 provides classification of the research findings, and lastly, Section 4 discusses the challenges and future trends.

This paper presents a review on quality control in seven different techniques in AM technology and provides detailed discussions in each quality process stage. Most of the AM techniques have a trend using in-situ sensors and cameras to acquire process data for real-time monitoring and quality analysis. Procedures such as extrusion-based processes (EBP) have further advanced in data analytics and predictive algorithms-based research regarding mechanical properties and optimal printing parameters. Moreover, compared to others, the material jetting progresses technique has advanced in a system integrated with closed-feedback loop, machine vision and image processing to minimize quality issues during printing process.

This paper is limited to reviewing of only seven techniques of AM technology, which includes photopolymer vat processes, material jetting processes, binder jetting processes, extrusion-based processes, powder bed fusion processes, directed energy deposition processes and sheet lamination processes. This paper would impact on the improvement of quality control in AM industries such as industrial, automotive, medical, aerospace and military production.

Additive manufacturing technology, in terms of quality control has yet to be reviewed.

This paper aims to analyse the effects derived from the presence of residual coolant from machining operations on the Directed Energy Deposition of AISI H13 tool steel and the quality of the resulting part.

In the present paper, the effectiveness of various cleaning techniques, including laser vaporising and air blasting, applied to different water/oil concentrations are studied. For this purpose, single-layer and multi-layer depositions are performed. Besides, the influence of the powder adhered to the coolant residues remaining on the surface of the workpiece is analysed. In all cases, cross-sections are studied in-depth, including metallographic, microhardness, scanning electron microscopy and crack mechanism analyses.

The results show that, although no significant differences were found for low oil concentrations when remarkably high oil concentrations were used the deposited material cracked, regardless of the cleaning technique applied. The crack initiation and propagation mechanisms have been analysed, concluding that the presence of oil leads to hydrogen induced cracking.

High oil concentration residues from previous machining operations in hybrid manufacturing led to hydrogen induced cracking when working with AISI H13 tool steel. The results obtained will help in defining future hybrid manufacturing processes that combine additive and subtractive operations.

The purpose of this paper is to overview the literature about the environmental performance of additive manufacturing (AM) and to evaluate the use of life cycle assessment (LCA) on these studies.

This study was based on the systematic literature review.

The investigation found that most authors were concerned about the energy consumption of the AM equipment, which is the subject studied by 87% of articles. In addition, 25% of the studies used LCA at least in some level, making a global environment assessment to evaluate the environmental impacts of AM. By analyzing research studies, it was possible to find signs that AM could be a lower environmental impact process, when compared with traditional manufacturing. However, this assumption is not valid in all cases because there are many variables that may affect environmental results.

Due to the increase on the usage of this type of technology by industries, studies on the environmental performance of this process became relevant.

The purpose of this study is to prepare a state-of-the-art review on advanced ceramic materials including their fabrication techniques, characteristics, applications and wettability.

This review paper presents the various types of advanced ceramic materials according to their compounding elements, fabrication techniques of advanced ceramic powders as well as their consolidation, their characteristics, applications and wetting properties. Hydrophobic/hydrophilic properties of advanced ceramic materials are described in the paper with their state-of-the-art application areas. Optical properties of fine ceramics with their intrinsic characteristics are also presented within. Special focus is given to the brief description of application-based manipulation of wetting properties of advanced ceramics in the paper.

The study of wetting/hydrophobicity/hydrophilicity of ceramic materials is important by which it can be further modified to achieve the required applications. It also makes some sense that the material should be tested for its wetting properties when it is going to be used in some important applications like biomedical and dental. Also, these advanced ceramics are now often used in the fabrication of filters and membranes to purify liquid/water so the study of wetting characteristics of these materials becomes essential. The optical properties of advanced ceramics are equally making them suitable for many state-of-the-art applications. Dental, medical, imaging and electronics are the few sectors that use advanced ceramics for their optical properties.

This review paper includes various advanced ceramic materials according to their compounding elements, different fabrication techniques of powders and their consolidation, their characteristics, various application area and hydrophobic/hydrophilic properties.