Search Results (72)

To address surface defects and enhance the wear resistance of 316L stainless steel parts fabricated by Selective Laser Melting (SLM), this study applied shot peening (SP) surface treatment to the SLM-processed samples. Ball-on-disk tribological tests were systematically conducted under water-lubricated conditions to investigate the evolution of surface morphology, microstructure, microhardness, and tribological performance before and after SP. The results indicate that SP induced severe plastic deformation in the surface layer, effectively refining the coarse columnar crystals and melt pool structures characteristic of SLM, and forming a crystalline hardened layer with a depth of 70–80 μm. Consequently, the surface microhardness increased by 21.97% compared to the un-peened samples. Under loads of 20 N and 30 N, the coefficient of friction (COF) of the SP-treated samples decreased by 16.36% and 12.4%, while the wear rate was reduced by 17.09% and 14.9%, respectively. In this load range, the samples primarily exhibited uniform plowing and localized adhesive wear, demonstrating significantly improved resistance to plastic deformation and crack initiation. However, when the load increased to 40 N, intense stress and thermal effects diminished the strengthening benefits of SP, resulting in no significant difference in tribological performance between the SP-treated and untreated samples. At this stage, the dominant wear mechanism transitioned to severe plastic deformation, extensive delamination, and thermally induced adhesion. Full article

Selective laser melting (SLM) is a 3D printing technology for precision manufacturing. Owing to its high forming accuracy, parts fabricated by SLM can often be used directly without secondary machining. Consequently, the stress field in the structure, especially local stress concentration in small regions, is of great importance. Building on our previous work, this study proposes an accurate and efficient thermo-mechanical analysis method that combines a computational fluid dynamics (CFD) model and a finite element method (FEM) model for stress prediction in micrometer-scale SLM. Compared with the conventional element birth–death method, the present model more faithfully reproduces the SLM process and the post-solidification morphology and stress distribution. Numerical simulation of a single-track TC4 scan shows that pronounced surface undulations and lack-of-fusion regions exhibit significant stress concentration: the local residual stress can reach approximately 900 MPa, whereas regions with relatively smooth surface geometry exhibit stresses of about 650 MPa. This indicates a clear positive correlation between surface quality and stress concentration. The results provide a new theoretical basis for understanding defect formation mechanisms, spatial stress distribution, and scan-path optimization in SLM components. Full article

The quality of SLM formed parts is one of the key factors of the promotion and application of additive manufacturing technology. The scanning strategy fundamentally affects the fatigue life of SLM 316L stainless steel parts by regulating residual stress, defect distribution, and microstructure. Three different scanning strategies (meander scanning, stripe scanning, and chessboard scanning) were adopted to prepare the specimens. High cycle fatigue loading was applied to SLM 316L stainless steel specimens prepared by different scanning strategies. The thermal conductivity characteristics during the SLM part forming process were analyzed based on scanning electron microscopy observations of microstructure of SLM specimens, and the mechanism of residual stress and internal defect generation were revealed. The scanning direction determines the growth direction of the grains, thereby affecting the anisotropy and overall fatigue performance of SLM 316L stainless steel parts. The scanning path determines the overlap and lap joint of the melt pool, directly affecting the number, size, and location of pores and incomplete fusion defects. The scanning strategy affects the distribution and magnitude of residual stresses by changing the path of heat source movement. Theoretical analysis and experimental verification results indicate that the selection of a scanning strategy is an effective method for optimizing the fatigue performance of SLM parts. Full article

Selective Laser Melting (SLM) of 316L stainless steel exhibits great potential prospects for engineering applications due to its high strength, high forming freedom, and low material waste. However, due to the unique processing technology of additive manufacturing, challenges related to the microstructure and differences in the mechanical properties of the formed parts are inevitable. To investigate the influence of building direction and grain boundary strength on the fracture parameters of SLM 316L stainless steel, electron backscatter diffraction (EBSD) experiments were conducted to characterize the microstructure of SLM 316L stainless-steel specimens. A representative volume element (RVE) model reflecting the microstructure of SLM 316L stainless steel was established based on a combination of the crystal plastic finite element method (CPFEM) and UMAT subroutine technology. The crystal plasticity parameters were determined by comparing the results of tensile tests. Cohesive elements were employed and inserted at the grain boundaries of the polycrystalline RVE to simulate the intergranular fracture behavior of SLM 316L stainless steel under uniaxial tensile loading. The damage and fracture mechanisms of the material at the microscale were analyzed. The simulated tensile stress–strain curves were in good agreement with the experimental results; hence, the combined CPFEM model is suitable for characterizing the mechanical response and fracture behavior of the SLM 316L stainless steel. The results revealed that cracks initiate at stress concentration sites and propagate along grain boundaries with increasing external load, ultimately leading to rupture. Additionally, the building direction influences the location of microcracks and their propagation significantly. Full article

22MnCrNiMo steel, a high-strength low-alloy material, is primarily used in the production of mooring chains for offshore oil platforms, offshore wind turbines, and ships. The application of additive manufacturing technology allows for the direct fabrication of seamless mooring chains. This paper investigates the selective laser melting (SLM) process parameters for 22MnCrNiMo mooring chain steel, analyzing the effects of different process parameters on the microstructure, phase composition, and mechanical properties of the steel. The experimental results demonstrate that under the laser parameters of 200 W laser power, 800 mm/s scanning speed, 30 μm layer thickness, and 110 μm scanning spacing, the SLM-formed parts exhibit the best comprehensive mechanical properties, with a microhardness of 513.2 HV0.5, a tensile strength of 1223 MPa, a yield strength of 1114 MPa, an elongation of 8.5%, and an impact energy of 127 J. This study reveals the microstructure evolution and the mechanism of enhanced mechanical properties in SLM-fabricated 22MnCrNiMo steel, providing a new approach for the preparation of high-performance mooring chains using 22MnCrNiMo steel. Full article

In order to obtain high-performance 3D printed parts, this study focuses on the key performance indicator of impact toughness. The parametric modeling software Rhino 6 is used to design impact specimens, and the laser selective melting equipment DiMetal-100, independently developed by the South China University of Technology, is used to manufacture impact specimens. Subsequently, the CoCrMo alloy parts were annealed using an MXQ1600-40 box-type atmosphere furnace and subjected to impact testing using a cantilever beam impact testing machine XJV-22. Fractal theory was applied to analyze the fractal behavior of the resulting impact fracture surfaces. The research results indicate that the 3D-printed impact specimens exhibited excellent surface quality, characterized by brightness, low roughness, and the absence of significant defects such as warping or deformation. In terms of annealing treatment, lower annealing temperatures did not improve the impact performance of SLM-formed CoCrMo alloy parts but instead led to a decrease in toughness. While increasing the annealing temperature can improve toughness to some extent, the effect is limited. Furthermore, the relationship between impact energy and heat treatment temperature exhibits a U-shaped trend. The fractal dimension analysis shows that the parts annealed in a 1200 °C furnace have the highest fractal dimension and better toughness performance. This study introduces a novel approach by comprehensively integrating advanced 3D printing technology, annealing processes, and fractal theory analysis to systematically investigate the influence of annealing temperature on the impact properties of 3D-printed CoCrMo alloy parts, thereby establishing a solid foundation for the application of high-performance 3D printed parts. Full article

Residual stress (RS) is one of the main reasons for component failure during an additive manufacturing (AM) process, especially using selective laser melting (SLM) technology. This paper reviews RS’s investigation methods, formation mechanisms and regularities of distribution. When considering recent research progress, studies indicate that the dominant stress is primarily attributed to thermal stress induced by significant laser temperature gradients during the rapid melting and forming process, which subsequently transforms into RS upon cooling to room temperature, as verified by simulation and experiments. Then, the distribution regularities of RS are analyzed. SLM RS gradually increases when it is measured from the surface layer to the substrate. In the plane direction, at the center and edge of the part, tensile stresses are found; as for the middle area, which is the transition area of compressive stress, the whole plane stress remains in an equilibrium state. Based on the forementioned conclusions, the three-dimensional distribution diagram of RS on the sample was constructed. Finally, the strategic approaches for stress mitigation are briefly discussed. The excessive stress in forming can be reduced by process parameter matching, and the RS can be greatly remitted by pre-treatment/post-treatment, so as to improve the quality of formed parts. This review provides a valuable theoretical basis for practical applications of SLM. Full article

With superior manufacturing freedom capability, Selective Laser Melting (SLM) technology is capable of fabricating high-strength Ti-6Al-2Zr-1Mo-1V (TA15) complex titanium alloy parts, thereby finding extensive applications in the aerospace sector. This paper primarily investigates the influence of process parameters on the relative density, microstructure, and mechanical properties of SLMed TA15 under conditions of similar laser linear energy density. The results indicate that the laser linear energy density significantly affects the single-track morphology of SLMed TA15; excessive energy density leads to keyhole defects, while insufficient energy density causes balling phenomena, resulting in discontinuous clad tracks. When the laser linear energy density is appropriate, the scanning spacing affects the forming density of the parts, with both excessively large and small spacings having adverse effects. With a fixed scanning spacing of 100 μm, high-density samples can be produced within a suitable range of linear energy density. However, when the laser linear energy density is comparable, a lower scanning speed leads to heat accumulation, causing in situ decomposition of the α’ martensite and the formation of coarser α + β phases, which reduces strength and hardness but improves plasticity. At a laser power of 90 W, a scanning speed of 400 mm/s, and a scanning spacing of 100 μm, the specimen exhibits a tensile strength of 1233 MPa and an elongation of 8.4%, achieving relatively excellent comprehensive properties. Full article

Aiming at the high-value application of rare earth elements lanthanum (La), an Al-50% La alloy was selected and prepared in a vacuum medium-frequency induction furnace. The geometric characteristics of the Al-50% La alloy powders were compared and studied, with the powders prepared by two different methods: mechanical pulverization and gas atomization. The results showed that an Al-49.09% La master alloy was obtained, and the only intermediate phase containing La in the experimental alloy was Al₁₁La₃. From the perspectives of chemical and phase composition, La has a high yield. Additionally, an Al-La alloy with controllable rare earth intermediate phases can be obtained. The Al-La alloy powders prepared by the mechanical pulverization method are irregular in shape, but the particle size is relatively small, ranging from 0.25 to 66.9 μm. Submicron powders were obtained, with 4.38% of the powders having an equivalent particle size of less than 1 μm. Considering the characteristic of the selective laser melting (SLM) process forming micro-melt pools, a small amount of submicron Al-La alloy powders prepared by the mechanical pulverization method can be used as a trace additive for SLM preparation of CP-Ti. The powders prepared by gas atomization have good sphericity, with a particle size range of 1.65 to 76.0 μm. Among them, the powders with a size of 2–10 μm account for 75.52%, and this part of the powders can be used for the powder metallurgy preparation of composite materials. Full article

As a type of additive manufacturing technology, SLM has made significant progress in the aerospace sector because of its capacity to swiftly and effectively form metals and their composites. This work investigates the impact of laser power (260, 280, 300, 320, 340 W) on the performance of a 1.0 wt.% CeO₂/Al6061 alloy prepared by SLM, including the forming quality (surface morphology and density), self-corrosion rate (SCR), and electrochemical behavior. The experimental outcomes suggest that as the laser power rises, the surface roughness exhibits an initial decline followed by an increase, whereas the density undergoes an initial increase and subsequently decreases. The SCR demonstrates a pattern of initial decrease followed by an increase as the laser power is incremented. When the laser power increases, the electrochemical activity shows the same trend. When the laser power is 280 W, the density of the sample is 98.63%, and the SCR is 2.243 × 10⁻⁴ g/cm²·min. The induced resistance of the sample caused by hydrogen evolution is small, at 7.827 × 10⁻²⁰ Ω·cm², and the polarization resistance reaches 8.048 × 10⁻¹ Ω·cm², suggesting superior resistance to corrosion on the part of the sample. The laser power affects the SCR and electrochemical performance of the sample by influencing its molding quality. At the laser power of 280 W, the formation quality of the sample is optimal, and the sample exhibits lower SCR and more stable electrochemical activity. Full article

Objective: This study aimed to assess and compare the internal fit of custom-made posts and cores fabricated using digital impressions (DI) and conventional vinyl polysiloxane (VPS) impressions in restorative dentistry. Materials and Methods: A typodont tooth model, simulating the anatomy of the root canal of a central incisor, was utilized for the study. Two groups were formed, Group A and Group B, and each group provided a total of 18 impressions of two types: DIs and VPS impressions. In Group A, posts and cores (PCs) were fabricated using Selective Laser Melting (SLM) from the DIs. Meanwhile, in Group B, conventionally cast (CC) PCs were created from the VPS impressions. Silicone replicas of the internal surfaces were produced, and measurements were made at seven different points for each group. A statistical analysis was performed to assess the differences in internal fit between the two impression techniques. Results: The results revealed a statistically significant difference in mean internal fit between Group A (DI and SLM) and Group B (VPS and CC), with Group A exhibiting a mean internal fit of 182.6 µm and Group B showing a mean of 205.9 µm. While both groups demonstrated considerable variability in internal fit measurements, the digital impression technique showed promise for achieving superior internal fit, with a significantly greater fit for measuring points on sides and the most apical part of the post for Group A. Variations were observed across different measuring points, emphasizing the impact of impression technique on specific regions within the tooth. Conclusion: This study contributes to the growing body of knowledge in digital dentistry by highlighting the potential benefits of DIs in achieving a superior internal fit for custom-made PCs. Clinicians may consider the advantages of digital techniques to enhance the precision of their restorative procedures, although further research is warranted to evaluate the clinical impact of these findings. Full article

To enhance the wear resistance of nickel-based high-temperature alloys, IN718/WC composites were prepared via selective laser melting (SLM). The optimal molding process parameters of IN718/WC composites were determined using a combination of experimental and simulation methods. Based on the SEM images of the composites, a gradient transition layer was found to form between the WC particles and the IN718 matrix, and the γ′ and γ″ reinforcing phases dispersed into the matrix, providing lubrication and reducing wear during friction. The influence of WC content on the wear resistance of the composites was investigated. When the WC content was 5%, the molded parts showed optimal wear resistance, the friction coefficient fluctuated steadily, the degree of wear was low, and the amount of wear was reduced to 0.02973 mm³. The average friction coefficient and wear volume of the molded parts with similar contents decreased by 26.95% and 4.27%, respectively, compared with the pure IN718-molded parts. This study provides a case study and guidance for further optimization of the molding process for nickel matrix high-temperature composites prepared using the SLM method. Full article

The incorporation of additive manufactured (AM) metal parts to real assemblies is a crucial issue for the increasing of their industrial utilization. The presented research is devoted to the electron beam welding (EBW) of dissimilar steel joints. Dissimilarity is defined by the various types of steel and manufacturing processes used for the creation of specimens. Conventional AISI 316 stainless steel, selective laser melted (SLM) SS 316L stainless steel, and SLM M300 maraging steel were welded at variable parameters in the form of a welding current and a welding velocity. EBW joints were evaluated considering the macroscopic and microscopic characteristics, as well as a reached microhardness. The obtained preliminary results represent important input data for the follow-up experiments focused on the setting of optimal EBW parameters of welding the dissimilar joints including SLM products, with the consideration of their basic macroscopical and microscopical characteristics, mechanical properties, and residual stresses. Full article

In this study, the size of molten pool and the porosity of parts under different processing parameters are studied using numerical simulation. According to the results, the appropriate processing parameters were selected to simulate the temperature and residual stress distribution during the forming process of body-centered cube (BCC), face-centered cube (FCC) and rhombic dodecahedron (Dode) lattice structures. In addition, three lattice structures were fabricated via selective laser melting (SLM) technology, and quasi-static compression experiments were carried out to study their mechanical properties. The results show that the high temperature parts of the three structures are all under the node and their adjacent pillars, and the closer to the nodes, the higher the temperature. The residual stress of the Dode structure is the highest, reaching 1218.2 MPa. It is also found that the residual stress in the Z direction is the largest, which plays a dominant role in the forming process. Through compression experiments, it is found that diagonal shear failure occurs in all three lattice structures, and Dode shows the best compression performance. Full article

In order to solve the loosening problem caused by stress shielding of femoral stem prostheses in clinical practice, an optimization design method of a personalized porous titanium alloy femoral stem is proposed. According to the stress characteristics of the femur, the porous unit cell structures (TO-C, TO-T, TO-B) under three different loads of compression, torsion, and bending were designed by topology optimization. The mechanical properties and permeability of different structures were studied. Combined with the porous structure optimization, a personalized radial gradient porous titanium alloy femoral stem was designed and manufactured by selective laser melting (SLM) technology. The results show that the TO-B structure has the best comprehensive performance among the three topologically optimized porous types, which is suitable for the porous filling structure of the femoral stem, and the SLM-formed porous femoral stem has good quality. The feasibility of the personalized design and manufacture of porous titanium alloy implants is verified, which can provide a theoretical basis for the optimal design of implants in different parts. Full article