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Advances in Modelling and Numerical Evolution of Additive Manufacturing

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (15 July 2023) | Viewed by 8870

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Special Issue Editor

Dr. Lei Yang

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Guest Editor

Department of Mechanical Design and Manufacturing, Wuhan University of Technology, Wuhan, China
Interests: metal additive manufacturing; lightweight design; continuous carbon fiber reinforced composites

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), also known as 3D printing, is a transformative approach to industrial production that enables the creation of lighter, stronger parts and systems. Additive manufacturing uses data computer-aided-design (CAD) software or 3D object scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes. However, it is difficult to precisely control the microstructure and shape during these point-by-point and layer-by-layer manners. To optimize the parameters and predict defects, we need first to understand the vigorous reactions between the additive materials and the heat sources, such as the thermophysical phenomena with fast nonlinear phase transitions between solid and liquid phases during powder bed fusion (PBF) and the chemical cross-linked reactions during Stereolithography (SLA).

Modelling and simulation will play a critical role in this new era, enhancing traditional trial and error approaches for the design and optimization of components and materials. It can help both from a fundamental understanding of the underlying physical processes and enable the accelerated design to reduce the qualification cycle of additive manufactured parts.

Therefore, we would like to invite you to submit your original research to this Special Issue entitled “Advances in Modelling and Numerical Evolution of Additive Manufacturing”. The scope of this Special Issue includes all aspects of research or reviews related to modelling and numerical simulation of additive manufacturing. Additive manufacturing technologies include, but are not limited to, Selective Laser Melting (SLM), Selective Laser Sintering (SLS), Laser Engineered Net Shaping (LENS) and Stereolithography (SLA), Fused Deposition Modelling (FDM).

Prof. Dr. Lei Yang
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

modelling of additive manufacturing processes
numerical simulation
discrete element method (DEM)
finite element method (FEM)
finite volume method (FVM)
lattice Boltzmann method (LBM)
molten pool flow behaviour
parameter optimization
defect prediction

Published Papers (4 papers)

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Research

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18 pages, 19874 KiB

Open AccessArticle

Effects of Powder Characteristics and Chemical Composition on the Properties of 25Cr7Ni Stainless Steel Fabricated by Laser-Powder Bed Fusion and Evaluation of Process Simulation

by Arulselvan Arumugham Akilan, Swapnil Kumar, Mohammad Qasim Shaikh, Ravi K. Enneti and Sundar V. Atre

Metals 2023, 13(8), 1476; https://doi.org/10.3390/met13081476 - 16 Aug 2023

Viewed by 1544

Abstract

The 25Cr7Ni stainless steel alloy system is gaining increasing interest in the oil and gas industry because of its combination of high strength and corrosion resistance properties. However, very few studies on the effects of starting powder attributes and chemical composition on the as-printed properties of 25Cr7Ni stainless steel fabricated through laser-powder bed fusion (L-PBF) exist in the literature. This study examined the influence of powder attributes and chemical composition on the samples from gas atomized and water atomized 25Cr7Ni stainless steel powders, fabricated through L-PBF, on their as-printed microstructure and properties. The mechanical properties that were examined included ultimate tensile strength (UTS), elongation (%), and hardness. The corrosion behavior was also studied using linear sweep voltammetry in 3.5 wt.% NaCl solution. The evolved phases were characterized using optical and scanning electron microscopy, as well as through X-ray diffraction. The gas atomized powders, with their spherical and uniform morphology, yielded as-printed parts of higher relative densities when compared to water atomized powders, with irregular morphology due to better powder bed compaction. The higher densification obtained in the L-PBF samples from gas atomized powders translated into the highest UTS, hardness, and yield strength among the L-PBF samples from water atomized powders and wrought–annealed 25Cr7Ni stainless steel. The presence of higher amounts of N and Mn in the chemical composition of the gas atomized powders over water atomized powders promoted the presence of retained austenite in the corresponding L-PBF samples. Higher amounts of Mo, combined with austenite content, yielded a higher corrosion resistance in the L-PBF samples from the gas atomized powder than in the L-PBF samples from the water atomized powders. The latter part of the work is focused on the evaluation of simulation parameters for analyzing the fabrication procedure for the L-PBF process using Simufact software. For a given set of process parameters, Simufact provides the distortion and internal stresses developed in the printed parts as output. The present study sought to evaluate the process simulation by comparing the experimental observations in terms of the part distortion achieved in a stainless steel cube fabricated through L-PBF with Simufact process simulation obtained using the same set of process parameters. Full article

(This article belongs to the Special Issue Advances in Modelling and Numerical Evolution of Additive Manufacturing)

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13 pages, 3987 KiB

Open AccessFeature PaperArticle

Multi-Phase Field Method for Solidification Microstructure Evolution for a Ni-Based Alloy in Wire Arc Additive Manufacturing

by Sukeharu Nomoto, Masahiro Kusano, Houichi Kitano and Makoto Watanabe

Metals 2022, 12(10), 1720; https://doi.org/10.3390/met12101720 - 14 Oct 2022

Cited by 4 | Viewed by 1842

Abstract

Wire arc additive manufacturing achieves high efficiency and low costs by using a melting wire for directional depositions. Thermal analyses and the finite element method have been applied to predict residual stress and the deformation of fabricated parts. For Ni-based alloy production, a method for predicting solidification microstructure evolution with segregation is needed in order to design precise heat treatment procedures. In this study, a multi-phase field method coupled with a CALPHAD database is developed to simulate the solidification microstructure evolution of a practical Ni-based alloy. Thermal analyses of a wire arc additive manufacturing model were performed by the process modeling of multi-pass depositions with a running cyclic arc. Solidification microstructure evolution was obtained using the temperature profile in each deposited layer by the multi-phase field method. These predicted microstructures are compared with experimental measurements. It is confirmed that the multi-phase field method coupled with the CALPHAD database is effective for predicting solidification microstructure and segregation in the engineering of Ni-based alloys. Full article

(This article belongs to the Special Issue Advances in Modelling and Numerical Evolution of Additive Manufacturing)

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Review

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21 pages, 8794 KiB

Open AccessReview

New Insights into the Mechanical Properties, Functional Fatigue, and Structural Fatigue of Ni-Ti Alloy Porous Structures

by Dianyu Tang, Yong Hu and Lei Yang

Metals 2023, 13(5), 931; https://doi.org/10.3390/met13050931 - 10 May 2023

Viewed by 1354

Abstract

Ni-Ti shape memory alloys (SMAs) are widely noticed and have captured great interest due to their unique shape memory effect and super elasticity. Porous Ni-Ti SMAs have the typical characteristics of both porous metals as well as shape memory alloys. Because of the uneven stress distribution, cyclic loading has a more significant effect on the phase transformation and plastic deformation of Ni-Ti porous compared with Ni-Ti bulk. This paper overviews the structural and functional fatigue experiments and numerical simulation progress of Ni-Ti porous. The factors affecting the fatigue performance of the Ni-Ti lattice structure and the methods for enhancing its fatigue performance are elaborated. More importantly, the point of the coupling analysis of structural fatigue performance and functional fatigue performance is proposed for the study of porous Ni-Ti shape memory alloys. Full article

(This article belongs to the Special Issue Advances in Modelling and Numerical Evolution of Additive Manufacturing)

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22 pages, 3062 KiB

Open AccessReview

Design Optimization Method Based on Artificial Intelligence (Hybrid Method) for Repair and Restoration Using Additive Manufacturing Technology

by Hiyam Adil Habeeb, Dzuraidah Abd Wahab, Abdul Hadi Azman and Mohd Rizal Alkahari

Metals 2023, 13(3), 490; https://doi.org/10.3390/met13030490 - 27 Feb 2023

Cited by 3 | Viewed by 3520

Abstract

The concept of repair and restoration using additive manufacturing (AM) is to build new metal layers on a broken part. It is beneficial for complex parts that are no longer available in the market. Optimization methods are used to solve product design problems to produce efficient and highly sustainable products. Design optimization can improve the design of parts to improve the efficiency of the repair and restoration process using additive manufacturing during the end-of-life (EoL) phase. In this paper, the objective is to review the strategies for remanufacturing and restoration of products during or at the EoL phase and facilitate the process using AM. Design optimization for remanufacturing is important to reduce repair and restoration time. This review paper focuses on the main challenges and constraints of AM for repair and restoration. Various AI techniques, including the hybrid method that can be integrated into the design of AM, are analyzed and presented. This paper highlights the research gap and provides recommendations for future research directions. In conclusion, the combination of artificial neural network (ANN) algorithms with genetic algorithms as a hybrid method is a key solution in solving limitations and is the future for repair and restoration using additive manufacturing. Full article

(This article belongs to the Special Issue Advances in Modelling and Numerical Evolution of Additive Manufacturing)

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