Structure and Properties Modification in Additive Manufacturing

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Crystals crystals	2.4	4.2	2011	11.1 Days	CHF 2100
Eng eng	-	2.1	2020	21.5 Days	CHF 1200
Materials materials	3.1	5.8	2008	13.9 Days	CHF 2600
Journal of Manufacturing and Materials Processing jmmp	3.3	5.1	2017	16.5 Days	CHF 1800
Quantum Beam Science qubs	1.3	2.8	2017	22 Days	CHF 1600

13 pages, 8360 KiB

Open AccessArticle

Structure Evolution and Properties Modification for Reaction-Bonded Silicon Carbide

by Wei Li, Ge Zhang, Congcong Cui, Jianxun Bao, Conghui Guo, Chuanxiang Xu, Wei Zhang and Wanli Zhu

Materials 2022, 15(24), 8721; https://doi.org/10.3390/ma15248721 - 7 Dec 2022

Cited by 3 | Viewed by 2572

Abstract

Complex structure reaction-bonded silicon carbide (RB-SiC) can be prepared by reactive melt infiltration (RMI) and digital light processing (DLP). However, the strength and modulus of RB-SiC prepared by DLP are not sufficient, due to its low solid content (around 40 vol.%), compared with [...] Read more.

Complex structure reaction-bonded silicon carbide (RB-SiC) can be prepared by reactive melt infiltration (RMI) and digital light processing (DLP). However, the strength and modulus of RB-SiC prepared by DLP are not sufficient, due to its low solid content (around 40 vol.%), compared with the traditional fabrication techniques (solid content > 60 vol.%). With this understanding, a new method to improve the properties of RB-SiC was proposed, by the impregnation of composite precursor into the porous preform. The composite precursor was composed of phenolic (PF) resin and furfuryl alcohol (FA). PF and FA were pyrolyzed at 1850 °C to obtain amorphous carbon and graphite into the porous preform, respectively. The effects of multiphase carbon on the microstructure and performance of RB-SiC was studied. When the mass ratio of PF to FA was 1/4, the solid content of RB-SiC increased from 40 vol.% to 68.6 vol.%. The strength, bulk density and modulus were 323.12 MPa, 2.94 g/cm³ and 348.83 Gpa, respectively. This method demonstrated that the reaction process between liquid Si and carbon could be controlled by the introduction of multiphase carbon into the porous preforms, which has the potential to regulate the microstructure and properties of RB-SiC prepared by additive manufacturing or other forming methods. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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15 pages, 2603 KiB

Open AccessArticle

The Investigation of New Phosphate–Titanite Glasses According to Optical, Physical, and Shielding Properties

by Khalid I. Hussein, Mohammed S. Alqahtani, Khloud J. Alzahrani, Heba Y. Zahran, Ali M. Alshehri, Ibrahim S. Yahia, Manuela Reben and El Sayed Yousef

Crystals 2022, 12(7), 941; https://doi.org/10.3390/cryst12070941 - 4 Jul 2022

Cited by 3 | Viewed by 2047

Abstract

The melt-quenching approach was used to prepare phosphate–titanite glasses with the composition P₂O₅-Na₂O-CaO-8KF-CaCl₂-xTiO₂ (where x = 2, 4, and 6) in a mol %. The optical, physical, and shielding properties, such as the mass [...] Read more.

The melt-quenching approach was used to prepare phosphate–titanite glasses with the composition P₂O₅-Na₂O-CaO-8KF-CaCl₂-xTiO₂ (where x = 2, 4, and 6) in a mol %. The optical, physical, and shielding properties, such as the mass attenuation coefficient (MAC), half-value layer (HVL), effective electron density (N_eff), and effective atomic number (Z_eff), of the glasses were investigated at energies ranging between 15 and 200 keV. The shielding parameters were investigated using recently developed software (MIKE). The optical properties were examined using devices such as UV-Vis-NIR spectroscopy over wavelengths ranging between 190 and 2500 nm. The reported results showed that increasing the concentration of TiO₂ led to an increase in the density from 2.657 to 2.682 g/cm³ and an increase in the OPD from 66.055 to 67.262 mol/L, while the molar volume (V_M) and oxygen molar volume (V_O) decreased from 39.21 to 39.101 cm³/mol and from 15.139 to 14.867 cm³/mol, respectively. The energy gap was found to decrease from 3.403 to 3.279 eV when the TiO₂ concentration increased. Furthermore, as the surface plasmon resonance of TiO₂ increases, so does its third-order susceptibility, non-linear refractive indices, linear attenuation, and mass attenuation. The shielding performance evaluation indicates that the most suitable energy range is between 15 and 50 keV. Based on the results, the PCKNT3 glass sample exhibits the highest attenuation performance of all of the samples tested. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 635 KiB

Open AccessReview

A Review of the Latest Developments in the Field of Additive Manufacturing Techniques for Nuclear Reactors

by Hui Li, Xiaolong Fu, Liping Zhang, Yixiong Zhang, Lu Jiang and Zhuo Pu

Crystals 2022, 12(7), 918; https://doi.org/10.3390/cryst12070918 - 28 Jun 2022

Cited by 5 | Viewed by 3707

Abstract

This review paper provides insights the into current developments in additive manufacturing (AM) techniques. The comprehensive presentations about AM methods, material properties (i.e., irradiation damage, as-built defects, residual stresses and fatigue fracture), experiments, numerical simulations and standards are discussed as well as their [...] Read more.

This review paper provides insights the into current developments in additive manufacturing (AM) techniques. The comprehensive presentations about AM methods, material properties (i.e., irradiation damage, as-built defects, residual stresses and fatigue fracture), experiments, numerical simulations and standards are discussed as well as their advantages and shortages for the application in the field of nuclear reactor. Meanwhile, some recommendations that need to be focused on are presented to advance the development and application of AM techniques in nuclear reactors. The knowledge included in this paper can serve as a baseline to tailor the limitations, utilize the superiorities and promote the wide feasibilities of the AM techniques for wide application in the field of nuclear reactors. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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17 pages, 2828 KiB

Open AccessArticle

Contact-Free Support Structures for the Direct Metal Laser Melting Process

by Alican Çelik, Emre Tekoğlu, Evren Yasa and Mehmet Şeref Sönmez

Materials 2022, 15(11), 3765; https://doi.org/10.3390/ma15113765 - 25 May 2022

Cited by 10 | Viewed by 5919

Abstract

Although Direct Metal Laser Melting (DMLM), a powder bed fusion (PBF) Additive Manufacturing (AM) for metallic materials, provides many advantages over conventional manufacturing such as almost unlimited design freedom, one of its main limitations is the need for support structures beneath overhang surfaces. [...] Read more.

Although Direct Metal Laser Melting (DMLM), a powder bed fusion (PBF) Additive Manufacturing (AM) for metallic materials, provides many advantages over conventional manufacturing such as almost unlimited design freedom, one of its main limitations is the need for support structures beneath overhang surfaces. Support structures are generally in contact with overhang surfaces to physically prop them up; therefore, they need to be removed after manufacturing due to not constituting a part of the main component design. The removal of supports is a process sequence adding extra time and cost to the overall manufacturing process and could result in damaging the main component. In this study, to examine the feasibility of contact-free supports for overhang surfaces in the DMLM process, coupons with these novel types of supports were prepared from CoCrMo alloy powder. This study aims to understand the effect of two parameters: the gap distance between supports and overhang surfaces and the inclination angle of overhang surfaces, on the surface topography and microstructural properties of these surfaces. Visual inspection, roughness measurements, and optical microscopy were utilized as characterization methods The roughness parameters (Ra, Rq, and Rz) were obtained using the focus variation method, and optical microscope analysis was performed on the cross-sections of the overhang surfaces to investigate the sub-surface microstructure and surface topology. Results showed that contact-free supports have a positive effect on decreasing surface roughness at all build angles when the gap distance is correctly set to avoid sintering of the powder in between the overhang and supports or to avoid too large gaps eliminating the desired effect of the higher thermal conductivity. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 3518 KiB

Open AccessArticle

Effects of n-Al₂O₃ and μ-TiCN on Microstructure and Mechanical Properties of Al₂O₃ Composite Ceramics Manufactured by Material Extrusion and Photo-Polymerization Combined Process

by Xin He, Jie Xu and Weixi Ji

Crystals 2022, 12(5), 745; https://doi.org/10.3390/cryst12050745 - 23 May 2022

Cited by 2 | Viewed by 2539

Abstract

Alumina (Al₂O₃) composite ceramics with different composition ratio and particle-size distribution were fabricated by the material extrusion and photo-polymerization combined process (MEX-PPM) based on additive-manufacturing (AM) technology in our previous work. These particles were nanosized Al₂O₃ [...] Read more.

Alumina (Al₂O₃) composite ceramics with different composition ratio and particle-size distribution were fabricated by the material extrusion and photo-polymerization combined process (MEX-PPM) based on additive-manufacturing (AM) technology in our previous work. These particles were nanosized Al₂O₃ (n-Al₂O₃), micron-sized TiCN (μ-TiCN) and Al₂O₃. Effects of n-Al₂O₃ and μ-TiCN on Al₂O₃ composite ceramics were investigated by characterizing the volume density, EDS spectrum, mechanical properties and microstructure of the prepared samples. It was found that n-Al₂O₃ had a significant effect on the hardness of Al₂O₃ composite ceramics, μ-TiCN, with excellent performance in density, flexural strength and fracture toughness. The Al₂O₃ composite ceramics with optimum contents of 10 wt % n-Al₂O₃ and 30 wt % μ-TiCN showed good microstructure and mechanical properties. Their porosity and volume density were at 4.073% and 4.177 g/cm³, respectively. Their hardness, flexural strength and fracture toughness were at 16.592 GPa, 592.875 MPa and 6.308 MPa/mm². The flexural strength of the ceramics was significantly higher than that of Al₂O₃ ceramics prepared by SLA in document (178.84 ± 17.66 MPa), which had great potential in high-pressure strength structure. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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18 pages, 3565 KiB

Open AccessArticle

Filament Transport Control for Enhancing Mechanical Properties of Parts Realised by Fused Filament Fabrication

by Arianna Rossi, Giulia Morettini, Michele Moretti and Lorenzo Capponi

Materials 2022, 15(10), 3530; https://doi.org/10.3390/ma15103530 - 14 May 2022

Cited by 6 | Viewed by 2284

Abstract

The fused filament fabrication (FFF) process is widely used for producing prototypes and functional parts for diverse applications. While FFF is particularly attractive due to its cost-effectiveness, on the other hand, the fabricated parts have limitations in terms of large manufacturing time and [...] Read more.

The fused filament fabrication (FFF) process is widely used for producing prototypes and functional parts for diverse applications. While FFF is particularly attractive due to its cost-effectiveness, on the other hand, the fabricated parts have limitations in terms of large manufacturing time and reduced mechanical properties. The latter is strongly influenced by the fabrication process parameters, which affect the interlayer bonding and the adhesion between consecutive layers. Several works presented in the literature analysed the correlation between mechanical properties and process parameters. It was demonstrated that an increase in the fabrication feed rate causes slippage between filament and the feeding system, which leads to a decrease in the extruded material flow, and thus in part density. This work aims to investigate how the limitation of the slippage phenomenon affects the mechanical properties of parts fabricated using the FFF process. A prototype machine, equipped with a closed-loop control system on filament transport, was used to fabricate samples for tensile tests and dynamical mechanical analysis. Samples fabricated enabling the filament transport control showed an increase both in ultimate tensile strength and elongation at break for those fabricated with disabled control, whilst a decrease in stiffness was observed. In addition, the results showed that the use of a filament transport control system on a FFF machine increases the possibility of fabricating high value-added parts. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 4621 KiB

Open AccessArticle

Strengthening Effect of Short Carbon Fiber Content and Length on Mechanical Properties of Extrusion-Based Printed Alumina Ceramics

by Haihua Wang, Jian Wu, Hai Zheng, Mingliang Tang and Xiaodong Shen

Materials 2022, 15(9), 3080; https://doi.org/10.3390/ma15093080 - 24 Apr 2022

Cited by 9 | Viewed by 2511

Abstract

Extrusion-based ceramic printing is fast and convenient, but the green body strength is too low, and the application prospect is not high. An extrusion-based printing method of alumina ceramics toughened by short carbon fiber is reported in this paper. The bending strength and [...] Read more.

Extrusion-based ceramic printing is fast and convenient, but the green body strength is too low, and the application prospect is not high. An extrusion-based printing method of alumina ceramics toughened by short carbon fiber is reported in this paper. The bending strength and fracture toughness of 3D-printed alumina ceramics were improved by adding short carbon fiber. The toughening effects of four carbon fiber lengths (100 μm, 300 μm, 700 μm, and 1000 μm) and six carbon fiber contents (1, 2, 3, 4, 5, and 6 wt%) on ceramics were compared. The experimental results show that when the length of carbon fiber is 700 μm, and carbon fiber is 5 wt%, the toughening effect of fiber is the best, and the uniform distribution of fiber is an effective toughening method. Its bending strength reaches 33.426 ± 1.027 MPa, and its fracture toughness reaches 4.53 ± 0.46 MPa·m^1/2. Compared with extrusion-based printed alumina ceramics without fiber, the bending strength and fracture toughness increase by 55.38% and 47.56%, respectively. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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20 pages, 5482 KiB

Open AccessArticle

Comparative Degradation Studies of Carmine Dye by Photocatalysis and Photoelectrochemical Oxidation Processes in the Presence of Graphene/N-Doped ZnO Nanostructures

by Fatma El-Sayed, Mai S. A. Hussien, Thekrayat H. AlAbdulaal, Ahmed Ismail, Heba Y. Zahran, Ibrahim S. Yahia, Mohamed Sh. Abdel-wahab, Yasmin Khairy, Tarik E. Ali and Medhat A. Ibrahim

Crystals 2022, 12(4), 535; https://doi.org/10.3390/cryst12040535 - 11 Apr 2022

Cited by 12 | Viewed by 3175

Abstract

The goal of this study was to synthesize a UV-light-active ZnO photocatalyst by modifying it with nitrogen and graphene, then applying it to the degradation of carmine dye utilizing two promising technologies: photocatalysis and electrochemical oxidation (E.O.). Different techniques were used to analyze [...] Read more.

The goal of this study was to synthesize a UV-light-active ZnO photocatalyst by modifying it with nitrogen and graphene, then applying it to the degradation of carmine dye utilizing two promising technologies: photocatalysis and electrochemical oxidation (E.O.). Different techniques were used to analyze the prepared photocatalysts, such as Fourier transform infrared (FTIR), scanning electron microscopy (SEM), and X-ray diffraction (XRD). According to XRD measurements, the produced nanocomposite possesses a hexagonal wurtzite structure, indicating ZnO and markedly crystalline. For photocatalytic applications, the results revealed that the 0.001 g of G/N-doped ZnO catalyst achieved 66.76% degradation of carmine and kinetic degradation rates of 0.007 min⁻¹ within 185 min by photocatalysis under UV light irradiation. In comparison, the same sample reached 100% degradation of carmine and kinetic degradation rates of 0.202 min⁻¹ within 15 min using the electrochemical oxidation method. The improved photocatalytic activity of as-produced nanocomposites can be attributed to intermediate levels in the prohibited bandgap energy and the enhanced oxygen vacancies caused by nitrogen doping. The electrolyte (NaCl) on the degradation of the carmine dye was tested, and the findings indicated that the dye molecules were photodegraded by the 0.001 g of G/N-doped ZnO nanocomposite after a 15 min time interval. The data presented in this work for the carmine breakdown in water give intriguing contrasts between photocatalytic, indirect electrochemical oxidation, and photoelectrochemical oxidation. The action of chlorinated oxidative species, predominantly HClO, which were electrogenerated at the electrode surface due to the chloride ion’s oxidation in solution, induced indirect electrochemical oxidation degradation. This study also revealed that the modifications made to ZnO were beneficial by improving its photocatalytic activities under UV light, as well as a comparison of photocatalysis and electrochemical oxidation processes to determine which technique is best for treating carmine in effluents with high chloride ions. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 8534 KiB

Open AccessArticle

Foundational Investigation on the Characterization of Porosity and Fiber Orientation Using XCT in Large-Scale Extrusion Additive Manufacturing

by Nevine Tagscherer, Thomas Schromm and Klaus Drechsler

Materials 2022, 15(6), 2290; https://doi.org/10.3390/ma15062290 - 20 Mar 2022

Cited by 9 | Viewed by 2572

Abstract

The great potential of Extrusion Additive Manufacturing (EAM) for structural prototyping in the automotive industry is severely limited by the directional bias in the build direction. The layerwise fabrication leads to reduced mechanical properties at the layer-to-layer interface compared to the bulk of [...] Read more.

The great potential of Extrusion Additive Manufacturing (EAM) for structural prototyping in the automotive industry is severely limited by the directional bias in the build direction. The layerwise fabrication leads to reduced mechanical properties at the layer-to-layer interface compared to the bulk of the strand. Especially for the often-used semi-crystalline thermoplastics, the mechanical properties strongly depend on the processing parameters, even more so if short fibers are used as fillers. Therefore, ideal processing windows in which the mechanical strength and modulus in the z-direction reach their maximum can be identified for these parameters, resulting in a reduced directional bias. The influence of the EAM processing parameters on mechanical strength has already been investigated, correlating strength with thermal conditions during printing. However, these considerations did not distinguish between the thermal effect on the polymer properties, the formation of voids and pores at the layer interface, and the resulting fiber orientation for different strand proportions. Therefore, in this study, the effect of different processing temperatures and layer heights on the pore size and distribution, as well as the fiber orientation in the different regions of the mesostructure was investigated using X-ray Computed Tomography (XCT). Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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13 pages, 12253 KiB

Open AccessArticle

Compression Behaviors and Mechanical Properties of Modified Face-Centered Cubic Lattice Structures under Quasi-Static and High-Speed Loading

by Peng Wang, Fan Yang and Jinfeng Zhao

Materials 2022, 15(5), 1949; https://doi.org/10.3390/ma15051949 - 6 Mar 2022

Cited by 10 | Viewed by 4103

Abstract

Our previous work reported a novel lattice structure composed of modified face-centered cubic (modified FCC) cells with crossing rods introduced at the center of each cell. In this work, the proposed modified FCC lattice is further investigated to ascertain its compression behaviors under [...] Read more.

Our previous work reported a novel lattice structure composed of modified face-centered cubic (modified FCC) cells with crossing rods introduced at the center of each cell. In this work, the proposed modified FCC lattice is further investigated to ascertain its compression behaviors under different loading rates. For this purpose, numerical simulations were carried out for compressing the two-dimensional and three-dimensional modified FCC lattice structures with different loading rates, and to compare their deformation modes and energy absorption capacity under different loading rates. In addition, lattice specimens were fabricated using selective laser melting technology and quasi-static compression experiments were performed to validate the finite element simulations. The results indicate that the proposed modified FCC lattices exhibit better load-bearing capacity and energy absorption than the traditional FCC lattices under different loading rates. Under high-speed loading, the modified FCC structure is less susceptible to buckling, and the length ratio of the central cross-rod corresponding to maximum energy absorption capacity is larger. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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11 pages, 3271 KiB

Open AccessArticle

Additive Manufacturing of Honeycomb Lattice Structure—From Theoretical Models to Polymer and Metal Products

by Tomáš Goldmann, Wei-Chin Huang, Sylwia Rzepa, Jan Džugan, Radek Sedláček and Matej Daniel

Materials 2022, 15(5), 1838; https://doi.org/10.3390/ma15051838 - 1 Mar 2022

Cited by 11 | Viewed by 5141

Abstract

The study aims to compare mechanical properties of polymer and metal honeycomb lattice structures between a computational model and an experiment. Specimens with regular honeycomb lattice structures made of Stratasys Vero PureWhite polymer were produced using PolyJet technology while identical specimens from stainless [...] Read more.

The study aims to compare mechanical properties of polymer and metal honeycomb lattice structures between a computational model and an experiment. Specimens with regular honeycomb lattice structures made of Stratasys Vero PureWhite polymer were produced using PolyJet technology while identical specimens from stainless steel 316L and titanium alloy Ti6Al4V were produced by laser powder bed fusion. These structures were tested in tension at quasi-static rates of strain, and their effective Young’s modulus was determined. Analytical models and finite element models were used to predict effective Young’s modulus of the honeycomb structure from the properties of bulk materials. It was shown, that the stiffness of metal honeycomb lattice structure produced by laser powder bed fusion could be predicted with high accuracy by the finite element model. Analytical models slightly overestimate global stiffness but may be used as the first approximation. However, in the case of polymer material, both analytical and FEM modeling significantly overestimate material stiffness. The results indicate that computer modeling could be used with high accuracy to predict the mechanical properties of lattice structures produced from metal powder by laser melting. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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19 pages, 5040 KiB

Open AccessArticle

Microstructure Evolution and Performance Improvement of Silicon Carbide Ceramics via Impregnation Method

by Wei Li, Conghui Guo, Congcong Cui, Jianxun Bao, Ge Zhang, Yubei Zhang, Shan Li and Gong Wang

Materials 2022, 15(5), 1717; https://doi.org/10.3390/ma15051717 - 24 Feb 2022

Cited by 10 | Viewed by 3441

Abstract

The high topological silicon carbide (SiC) ceramics can be prepared by stereolithography (SLA) combined with liquid silicon infiltration (LSI) techniques. This paper aims to enhance the performance of SiC ceramics prepared by SLA and LSI techniques via the cyclic impregnation/carbonization of the precursor [...] Read more.

The high topological silicon carbide (SiC) ceramics can be prepared by stereolithography (SLA) combined with liquid silicon infiltration (LSI) techniques. This paper aims to enhance the performance of SiC ceramics prepared by SLA and LSI techniques via the cyclic impregnation/carbonization of the precursor of carbon source solution before LSI. The effects of impregnation/carbonization cycles on the microstructure and properties of C/SiC preform and sintered body were analyzed in detail. The results show that, with the increase of impregnation/carbonization cycles, the porosity in the C/SiC preform decreases obviously and the content of secondary SiC in the sintered body increases effectively. Especially, when the impregnation/carbonization cycle was performed twice, the sintered body had the optimal mechanical properties. The value of flexural strength, bulk density and elastic modulus were 258.63 ± 8.33 MPa, 2.95 ± 0.02 g/cm³ and 425.16 ± 14.15 GPa, respectively. In addition, the thermal dimensional stability of sintered body was also improved by this method. This method proves that SiC ceramics prepared by SLA combined with LSI have the potential of applications in space optical mirrors. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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19 pages, 5030 KiB

Open AccessArticle

Influence of Selective Laser Melting Additive Manufacturing Parameters in Inconel 718 Superalloy

by Nikolaos Kladovasilakis, Paschalis Charalampous, Konstantinos Tsongas, Ioannis Kostavelis, Dimitrios Tzovaras and Dimitrios Tzetzis

Materials 2022, 15(4), 1362; https://doi.org/10.3390/ma15041362 - 12 Feb 2022

Cited by 35 | Viewed by 5185

Abstract

Selective laser melting (SLM) is one of the most reliable and efficient procedures for Metal Additive Manufacturing (AM) due to the capability to produce components with high standards in terms of dimensional accuracy, surface finish, and mechanical behavior. In the past years, the [...] Read more.

Selective laser melting (SLM) is one of the most reliable and efficient procedures for Metal Additive Manufacturing (AM) due to the capability to produce components with high standards in terms of dimensional accuracy, surface finish, and mechanical behavior. In the past years, the SLM process has been utilized for direct manufacturing of fully functional mechanical parts in various industries, such as aeronautics and automotive. Hence, it is essential to investigate the SLM procedure for the most commonly used metals and alloys. The current paper focuses on the impact of crucial process-related parameters on the final quality of parts constructed with the Inconel 718 superalloy. Utilizing the SLM process and the Inconel 718 powder, several samples were fabricated using various values on critical AM parameters, and their mechanical behavior as well as their surface finish were examined. The investigated parameters were the laser power, the scan speed, the spot size, and their output Volumetric Energy Density (VED), which were applied on each specimen. The feedstock material was inspected using Scanning Electron Microscopy (SEM), Energy-dispersive X-ray spectroscopy (EDX) analysis, and Particle-size distribution (PSD) measurements in order to classify the quality of the raw material. The surface roughness of each specimen was evaluated via multi-focus imaging, and the mechanical performance was quantified utilizing quasi-static uniaxial tensile and nanoindentation experiments. Finally, regression-based models were developed in order to interpret the behavior of the AM part’s quality depending on the process-related parameters. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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15 pages, 2661 KiB

Open AccessArticle

Natural Porous Carbon Derived from Popped Rice as Anode Materials for Lithium-Ion Batteries

by Ruttapol Boonprachai, Thanapat Autthawong, Orapim Namsar, Chawin Yodbunork, Waewwow Yodying and Thapanee Sarakonsri

Crystals 2022, 12(2), 223; https://doi.org/10.3390/cryst12020223 - 3 Feb 2022

Cited by 22 | Viewed by 5326

Abstract

Popped rice carbons (PC) were derived from popped rice by using a facile and low-cost technique. PC was then activated by different kinds of activating agents, such as potassium hydroxide (KOH), zinc chloride (ZnCl₂), iron (III) chloride (FeCl₃), and [...] Read more.

Popped rice carbons (PC) were derived from popped rice by using a facile and low-cost technique. PC was then activated by different kinds of activating agents, such as potassium hydroxide (KOH), zinc chloride (ZnCl₂), iron (III) chloride (FeCl₃), and magnesium (Mg), in order to increase the number of pores and specific surface area. The phase formation of porous activated carbon (PAC) products after the activation process suggested that all samples showed mainly graphitic, amorphous carbon, or nanocrystalline graphitic carbon. Microstructure observations showed the interconnected macropore in all samples. Moreover, additional micropores and mesopores were also found in all PAC products. The PAC, which was activated by KOH (PAC-KOH), possessed the largest surface area and pore volume. This contributed to excellent electrochemical performance, as evidenced by the highest capacity value (383 mAh g⁻¹ for 150 cycles at a current density of 100 mA g⁻¹). In addition, the preparation used in this work was very simple and cost-effective, as compared to the graphite preparation. Experimental results demonstrated that the PAC architectures from natural popped rice, which were activated by an optimal agent, are promising materials for use as anodes in LIBs. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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14 pages, 4141 KiB

Open AccessArticle

Varying Synthesis Conditions and Comprehensive Characterization of Fluorine-Doped Hydroxyapatite Nanocrystals in a Simulated Body Fluid

by Dinbandhu Thakur, Sheng-Chi Yeh, Ren-Hao Cheng, Song-Seng Loke, Hung-Hsiang Wei, Po-Yu Cheng, Yi-Chun Lai, Hsuan-Ying Chen, Yu-Ren Huang and Shang-Wu Ding

Crystals 2022, 12(2), 139; https://doi.org/10.3390/cryst12020139 - 19 Jan 2022

Cited by 1 | Viewed by 2720

Abstract

Bone supports animal bodies, is the place where blood is produced, and is essential for the immune system, among other important functions. The dominant inorganic component in bone is hydroxyapatite (Hap), the structure and dynamics of which still pose many unsolved puzzles. An [...] Read more.

Bone supports animal bodies, is the place where blood is produced, and is essential for the immune system, among other important functions. The dominant inorganic component in bone is hydroxyapatite (Hap), the structure and dynamics of which still pose many unsolved puzzles. An updated understanding of HAp is of great significance to osteology, dentistry, and the development of artificial bone and other biomaterials. In this work, HAp nanoparticles were synthesized with the wet chemical precipitation method and their structure and morphologies were controlled by varying pH and adding fluoride ions by two different routes: (1) fluoride ions were added during synthesis, and (2) fluoride ions were introduced after the samples were synthesized by soaking the samples in solutions with fluoride ions. XRD and HRTEM were employed to confirm the composition and structure, while various multinuclear (¹H, ¹⁹F, ³¹P) solid-state nuclear magnetic resonance (NMR) methods including 1D single pulse, cross-polarization under magic-angle spinning (CPMAS), and 2D heteronuclear correlation (HETCOR) were used to characterize the structure, morphology, and dynamics, validating the general core-shell morphology in these F-HAp samples. It was found that all hydroxide ions were substituted when the fluoride ion concentration was above 0.005 M. An NMR peak corresponding to water structure emerged and the bulk water peak was shifted upfield, indicating that fluoride substitution modifies both the crystalline core and the amorphous shell of F-HAp nanoparticles. With the second route of fluoride substitution, increases in soaking time or fluoride ion concentration could increase fluoride substitution in HAp, but could not achieve complete substitution. Finally, with ¹H-³¹P CPMAS and HETCOR, it was established that there are two types of phosphorous, one in the crystalline core (PO₄³⁻) and the other in the amorphous shell (HPO₄²⁻). These results are valuable for clarifying the fluoride substitution mechanism in HAp in biomaterials or in organisms, and provide insights for developing next generation replacement materials for bone, tooth, or coating films, drug delivery systems, etc. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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13 pages, 2946 KiB

Open AccessArticle

Influence of Carbon Sorbent Quantity on Breakthrough Time in Absorbent Filters for Antismog Half Mask Application

by Agnieszka Brochocka, Aleksandra Nowak and Paweł Kozikowski

Materials 2022, 15(2), 584; https://doi.org/10.3390/ma15020584 - 13 Jan 2022

Cited by 5 | Viewed by 2152

Abstract

In this article, we present polymer non-woven fabrics with the addition of carbon sorbents being tested to estimate the breakthrough time and efficient protection against vapors present in smog. For this purpose, three substances were selected, which constitute an inhalation hazard and are [...] Read more.

In this article, we present polymer non-woven fabrics with the addition of carbon sorbents being tested to estimate the breakthrough time and efficient protection against vapors present in smog. For this purpose, three substances were selected, which constitute an inhalation hazard and are smog components: cyclohexane, toluene, and sulfur dioxide. It was demonstrated that an increased quantity of carbon sorbent in polymeric filters significantly prolongs the breakthrough time. However, high sorbent quantities may increase the filter surface mass and air flow resistance. To optimize the protective parameters with functionality, a compromise between the two has to be found. By comparing the breakthrough times for different carbon sorbent quantities, the optimal filter composition was elaborated. The analyzed non-woven fabrics were manufactured by the melt-blown process and filled with ball-milled carbon sorbents supplied directly into the fabric blowing nozzle. Both protective performance and textural properties were analyzed for two commercially available carbon sorbents. Furthermore, it was proven that high values of sorbent-specific surface area translates directly into greater filter performance. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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15 pages, 3188 KiB

Open AccessArticle

Effect of Silica Fume on the Rheological Properties of Cement Paste with Ultra-Low Water Binder Ratio

by Juan He, Congmi Cheng, Xiaofen Zhu and Xiaosen Li

Materials 2022, 15(2), 554; https://doi.org/10.3390/ma15020554 - 12 Jan 2022

Cited by 17 | Viewed by 2177

Abstract

The effect of silica fume on the rheological properties of a cement–silica fume–high range water reducer–water mixture with ultra-low water binder ratio (CSHWM) was studied. The results indicate that the W/B ratio and silica fume content have different effects on the rheological parameters, [...] Read more.

The effect of silica fume on the rheological properties of a cement–silica fume–high range water reducer–water mixture with ultra-low water binder ratio (CSHWM) was studied. The results indicate that the W/B ratio and silica fume content have different effects on the rheological parameters, including the yield stress, plastic viscosity, and hysteresis loop area. The shear-thickening influence of CSHWM decreased with the increased silica fume content. When the silica fume content increased from 0% to 35%, the mixture with W/B ratio of 0.19 and 0.23 changed from a dilatant fluid to a Newtonian fluid, and then to a pseudoplastic fluid. When the silica fume content was less than 15%, the yield stress was close to 0. With the increase of silica fume content, the yield stress increased rapidly. The plastic viscosity and hysteresis loop area decreased slightly with the addition of a small amount of silica fume, but increased significantly with the continuous increase of silica fume. Compared with the Bingham and modified Bingham models, the Herschel–Buckley model is more applicable for this CSHWM. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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15 pages, 5568 KiB

Open AccessArticle

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

by Fabian Soffel, Yunong Lin, Dominik Keller, Sergei Egorov and Konrad Wegener

Materials 2022, 15(1), 177; https://doi.org/10.3390/ma15010177 - 27 Dec 2021

Cited by 14 | Viewed by 4356

Abstract

Nickel-based super alloys are popular for applications in the energy and aerospace industries due to their excellent corrosion and high-temperature resistance. Direct metal deposition (DMD) of nickel alloys has reached technology readiness for several applications, especially for the repair of turbomachinery components. However, [...] Read more.

Nickel-based super alloys are popular for applications in the energy and aerospace industries due to their excellent corrosion and high-temperature resistance. Direct metal deposition (DMD) of nickel alloys has reached technology readiness for several applications, especially for the repair of turbomachinery components. However, issues related to part quality and defect formation during the DMD process still persist. Laser remelting can effectively prevent and repair defects during metal additive manufacturing (AM); however, very few studies have focused on numerical modeling and experimental process parameter optimization in this context. Therefore, the aim of this study is to investigate the effect of determining the remelting process parameters via numerical simulation and experimental analyses in order to optimize an industrial process chain for part repair by DMD. A heat conduction model analyzed 360 different process conditions, and the predicted melt geometry was compared with observations from a fluid flow model and experimental single tracks for selected reference conditions. Subsequently, the remelting process was applied to a demonstrator repair case. The results show that the models can well predict the melt pool shape and that the optimized remelting process increases the bonding quality between base and DMD materials. Therefore, DMD part fabrication and repair processes can benefit from the remelting step developed here. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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17 pages, 9553 KiB

Open AccessArticle

A Study on the Mechanical Properties of an Automobile Part Additively Printed through Periodic Layer Rotation Strategies

by Min-Seok Yang, Ji-Heon Kang, Ji-Wook Kim, Kun-Woo Kim, Da-Hye Kim, Ji-Hyun Sung, Dae-Cheol Ko and Jae-Wook Lee

Materials 2022, 15(1), 70; https://doi.org/10.3390/ma15010070 - 22 Dec 2021

Cited by 3 | Viewed by 3171

Abstract

In metal product manufacturing, additive manufacturing (AM) is a method that has the advantage of fabricating complex shapes and customized production, unlike existing machining methods. However, owing to the characteristics of the AM process, anisotropy of macrostructure occurs because of various causes such [...] Read more.

In metal product manufacturing, additive manufacturing (AM) is a method that has the advantage of fabricating complex shapes and customized production, unlike existing machining methods. However, owing to the characteristics of the AM process, anisotropy of macrostructure occurs because of various causes such as the scan direction, melting, fusion, and cooling of the powdered material. The macrostructure anisotropy is realized from the scan direction, and when a single layer is stacked in one direction, it is expressed as orthogonal anisotropy. Here, the classical lamination theory is applied to simply calculate the individual orthotropic layers by superimposing them. Through this, the authors analyzed whether the mechanical properties of the product are isotropically expressed with a periodic layer rotation strategy. To determine if the mechanical properties can be reasonably considered to be isotropic, a shock absorber mount for a vehicle was manufactured by AM. The tensile and vibration test performed on the product was compared with the finite element analysis and experimental results. As a result of the comparison, it was confirmed that the macroscopically of the product was considered isotropic as the load-displacement diagram and the fracture location coincided, as well as the natural frequency and mode shape. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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21 pages, 4658 KiB

Open AccessArticle

Solution-Processable Growth and Characterization of Dandelion-like ZnO:B Microflower Structures

by Selma Erat, Artur Braun, Samed Çetinkaya, Saadet Yildirimcan, Ahmet Emre Kasapoğlu, Emre Gür, Ersan Harputlu and Kasım Ocakoglu

Crystals 2022, 12(1), 11; https://doi.org/10.3390/cryst12010011 - 22 Dec 2021

Cited by 4 | Viewed by 3357

Abstract

Intrinsic and dandelion-like microflower nano-rod structures of boron-doped ZnO thin films were synthesized with an ecofriendly and cost-effective chemical bath deposition technique from an aqueous solution of zinc nitrate hexahdyrate [Zn(NO₃)₂.6H₂O] as a precursor solution and boric [...] Read more.

Intrinsic and dandelion-like microflower nano-rod structures of boron-doped ZnO thin films were synthesized with an ecofriendly and cost-effective chemical bath deposition technique from an aqueous solution of zinc nitrate hexahdyrate [Zn(NO₃)₂.6H₂O] as a precursor solution and boric acid as a doping solution. The boron concentrations were 0.1, 0.3, 0.5, 1.0, 3.0, 5.0, and 7.0 by volume. Scanning electron micrographs showed that doping with boron appears to hinder the vertical alignment of crystallites. Additionally, independent hexagonal nano-rod structures were observed to coalesce together to form dandelion-like structures on the film’s surface. The atomic ratio of the elements was determined via the X-ray photoemission spectrum technique. There were no substantial changes in the vibration structure of the film upon doping in terms of the Raman spectra. The optical band gap of ZnO (3.28 eV) decreased with B doping. The band gap of the ZnO:B film varied between 3.18 and 3.22 eV. The activation energy of the ZnO was calculated as 0.051 eV, whereas that of the ZnO:B film containing 1.0% B was calculated as 0.013 eV at low temperatures (273–348 K), versus 0.072 eV and 0.183 eV at high temperatures (348–523 K), respectively. Consequently, it can be interpreted that the 1% B-doped ZnO, which has the lowest activation energy at both low and high temperatures, may find some application areas such as in sensors for gases and in solar cells. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 3408 KiB

Open AccessArticle

Physics-Based Predictive Model of Lack-of-Fusion Porosity in Laser Powder Bed Fusion Considering Cap Area

by Wenjia Wang and Steven Y. Liang

Crystals 2021, 11(12), 1568; https://doi.org/10.3390/cryst11121568 - 16 Dec 2021

Cited by 5 | Viewed by 2999

Abstract

This work proposed a computationally efficient analytical modeling strategy to calculate the product porosity in laser powder bed fusion (LPBF) induced by a lack-of-fusion defect, with the consideration of cap area in solidified molten pools, influence of powder bed characteristics on material properties, [...] Read more.

This work proposed a computationally efficient analytical modeling strategy to calculate the product porosity in laser powder bed fusion (LPBF) induced by a lack-of-fusion defect, with the consideration of cap area in solidified molten pools, influence of powder bed characteristics on material properties, and un-melted powders in the lack-of-fusion portion. The powder packing pattern and powder bed void fraction were estimated by an advancing front method and the technique of image analysis. The effects of powder bed characteristics on the material properties were considered by analytical models with solid properties and powder bed void fraction as inputs. A physics-based thermal model was utilized to calculate the temperature distribution and molten pool size. The molten pool cross section in transvers direction was assumed to be dual half-elliptical. Based on this assumption and molten pool size, the geometry of the molten pool cross section with cap area was determined. The overlapping pattern of molten pools in adjacent scan tracks and layers was then obtained with given hatch space and layer thickness. The lack-of-fusion area fraction was obtained through image analysis of the overlapping pattern. The lack-of-fusion porosity was the multiplication of the lack-of-fusion area fraction and powder bed void fraction. The predictions of porosity under different process conditions were compared with experimental results of 316L stainless steel and showed a better predictive accuracy than the predictions that did not consider cap area. The proposed analytical modeling method has no numerical calculations, which ensures its low computational cost. Thus, the proposed model can be a convenient tool for the fast computation of lack-of-fusion-induced porosity and can help the quality control in LPBF. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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11 pages, 1935 KiB

Open AccessArticle

Mechanical Properties of Polymer-Based Blanks for Machined Dental Restorations

by Lucian Toma Ciocan, Jana Ghitman, Vlad Gabriel Vasilescu and Horia Iovu

Materials 2021, 14(23), 7293; https://doi.org/10.3390/ma14237293 - 29 Nov 2021

Cited by 17 | Viewed by 2887

Abstract

The tremendous technological and dental material progress led to a progressive advancement of treatment technologies and materials in restorative dentistry and prosthodontics. In this approach, CAD/CAM restorations have proven to be valuable restorative dental materials in both provisional and definitive restoration, owing to [...] Read more.

The tremendous technological and dental material progress led to a progressive advancement of treatment technologies and materials in restorative dentistry and prosthodontics. In this approach, CAD/CAM restorations have proven to be valuable restorative dental materials in both provisional and definitive restoration, owing to multifarious design, improved and highly tunable mechanical, physical and morphological properties. Thus far, the dentistry market offers a wide range of CAD/CAM restorative dental materials with highly sophisticated design and proper characteristics for a particular clinical problem or multiple dentistry purposes. The main goal of this research study was to comparatively investigate the micro-mechanical properties of various CAD/CAM restorations, which are presented on the market and used in clinical dentistry. Among the investigated dental specimens, hybrid ceramic-based CAD/CAM presented the highest micro-mechanical properties, followed by CAD/CAM PMMA-graphene, while the lowest micro-mechanical features were registered for CAD/CAM multilayered PMMA. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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17 pages, 11303 KiB

Open AccessArticle

Microchannel Liquid-Cooled Heat Exchanger Based on a Nonuniform Lattice: Study on Structure Calculation, Formation Process, and Boiling Heat Transfer Performance

by Bo Qian, Hongri Fan, Gang Liu, Jianrui Zhang and Pei Li

Materials 2021, 14(23), 7248; https://doi.org/10.3390/ma14237248 - 27 Nov 2021

Cited by 7 | Viewed by 2577

Abstract

A microchannel radiator is advantageous due to its high efficiency and large boiling heat transfer coefficient of two-phase flow. Based on the research of uniform lattice structures, this study proposed a microchannel heat exchanger with a nonuniform lattice structure. The calculation, optimal formation, [...] Read more.

A microchannel radiator is advantageous due to its high efficiency and large boiling heat transfer coefficient of two-phase flow. Based on the research of uniform lattice structures, this study proposed a microchannel heat exchanger with a nonuniform lattice structure. The calculation, optimal formation, and boiling heat transfer performance of the nonuniform lattice structure based on selective laser melting (SLM) were investigated, and heat exchange samples were successfully prepared using SLM. The porosity and pore morphology of the samples were analysed, and the contrast experiments of boiling heat transfer were conducted with deionised water. The results revealed that the heat flow density of the lattice structure was a minimum of 244% higher than that of the traditional liquid-cooled plate. The critical heat flux density of the lattice structure is 110 W∙cm⁻², and the critical heat flux density of the traditional flat plate is 45 W∙cm⁻². In addition, the effects of cell structures indicated that for frame cells, the heat transfer effect of nonuniform frames was inferior to that of uniform frames; for face-centred cubic (FCC) cells, the nonuniform and uniform frames exhibited the same trend. However, the heat flow density of FCC cells was 25% higher than that of frame structures. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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18 pages, 16848 KiB

Open AccessArticle

Deformation Behaviors and Energy Absorption of Composite Re-Entrant Honeycomb Cylindrical Shells under Axial Load

by Nanfang Ma, Qingtian Deng and Xinbo Li

Materials 2021, 14(23), 7129; https://doi.org/10.3390/ma14237129 - 23 Nov 2021

Cited by 10 | Viewed by 2818

Abstract

Composite materials and re-entrant honeycomb structures have superior mechanical performance in energy absorption capacity. Inspired by laminate composite layers, single-layer re-entrant honeycomb cylindrical shells (RHCSs) with different orientations were established, and composite RHCSs were proposed by combining the single-layer RHCSs with different orientations. [...] Read more.

Composite materials and re-entrant honeycomb structures have superior mechanical performance in energy absorption capacity. Inspired by laminate composite layers, single-layer re-entrant honeycomb cylindrical shells (RHCSs) with different orientations were established, and composite RHCSs were proposed by combining the single-layer RHCSs with different orientations. The deformation behaviors of single layer RHCSs under quasi-static compression were studied by experimentation, and single-layer RHCSs with varying orientations did not show negative Poisson’s ratio effects. The energy absorption capacity of single-layer and composite RHCSs was researched using simulation. To analyze the energy absorption capacity, we determined the plateau stress, the mean force and specific energy absorption of single-layer and multi-layer composite RHCSs under different impact velocities; the following conclusions were obtained: compared with the single-layer RHCSs, the multi-layer composite RHCSs, which had the same size, the energy absorption capacity improved significantly under the same impact velocities. The energy absorption capacity of the multi-layer composite RHCSs improved with increasing number of layers under low velocity. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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18 pages, 12464 KiB

Open AccessArticle

Microstructure and Corrosion Resistance of AA4047/AA7075 Transition Zone Formed Using Electron Beam Wire-Feed Additive Manufacturing

by Andrey Filippov, Veronika Utyaganova, Nikolay Shamarin, Andrey Vorontsov, Nikolay Savchenko, Denis Gurianov, Andrey Chumaevskii, Valery Rubtsov, Evgeny Kolubaev and Sergei Tarasov

Materials 2021, 14(22), 6931; https://doi.org/10.3390/ma14226931 - 16 Nov 2021

Cited by 9 | Viewed by 2812

Abstract

A gradient transition zone was obtained using electron beam deposition from AA4047 wire on AA7075 substrate and characterized for microstructures, tensile strength and corrosion resistance. The microstructure of the transition zone was composed of aluminum alloy grains, Al/Si eutectics and Fe-rich and Si-rich [...] Read more.

A gradient transition zone was obtained using electron beam deposition from AA4047 wire on AA7075 substrate and characterized for microstructures, tensile strength and corrosion resistance. The microstructure of the transition zone was composed of aluminum alloy grains, Al/Si eutectics and Fe-rich and Si-rich particles. Such a microstructure provided strength comparable to that of AA7075-T42 substrate but more intense corrosion due to the higher amount of anodic Mg₂Si particles. The as-deposited AA4047 zone formed above the transition zone was composed of aluminum alloy dendrites and interdendritic Al/Si eutectics with low mechanical strength and high corrosion potential. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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17 pages, 8363 KiB

Open AccessArticle

Microstructural and Mechanical Characterization of Additive Friction Stir-Deposition of Aluminum Alloy 5083 Effect of Lubrication on Material Anisotropy

by Brandon J. Phillips, C. Jacob Williamson, Ryan P. Kinser, J. Brian Jordon, Kevin J. Doherty and Paul G. Allison

Materials 2021, 14(21), 6732; https://doi.org/10.3390/ma14216732 - 8 Nov 2021

Cited by 48 | Viewed by 4555

Abstract

Additive Friction Stir-Deposition (AFS-D) is a transformative, metallic additive manufacturing (AM) process capable of producing near-net shape components with a wide variety of material systems. The solid-state nature of the process permits many of these materials to be successfully deposited without the deleterious [...] Read more.

Additive Friction Stir-Deposition (AFS-D) is a transformative, metallic additive manufacturing (AM) process capable of producing near-net shape components with a wide variety of material systems. The solid-state nature of the process permits many of these materials to be successfully deposited without the deleterious phase and thermally activated defects commonly observed in other metallic AM technologies. This work is the first to investigate the as-deposited microstructure and mechanical performance of a free-standing AA5083 deposition. An initial process parameterization was conducted to down-select optimal parameters for a large deposition to examine build direction properties. Microscopy revealed that constitutive particles were dispersed evenly throughout the matrix when compared to the rolled feedstock. Electron backscatter diffraction revealed a significant grain refinement from the inherent dynamic recrystallization from the AFS-D process. Tensile experiments determined a drop in yield strength, but an improvement in tensile strength in the longitudinal direction. However, a substantial reduction in tensile strength was observed in the build direction of the structure. Subsequent fractographic analysis revealed that the recommended lubrication applied to the feedstock rods, necessary for successful depositions via AFS-D, was ineffectively dispersed into the structure. As a result, lubrication contamination became entrapped at layer boundaries, preventing adequate bonding between layers. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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7 pages, 1611 KiB

Open AccessCommunication

Investigation of Cation Exchange Behaviors of FA_xMA_1−xPbI₃ Films Using Dynamic Spin-Coating

by Hyang Mi Yu, Byeong Geun Jeong, Dae Young Park, Seong Chu Lim, Gon Namkoong and Mun Seok Jeong

Materials 2021, 14(21), 6422; https://doi.org/10.3390/ma14216422 - 26 Oct 2021

Viewed by 2374

Abstract

In this study, we fabricated and characterized uniform multi-cation perovskite FA_xMA_1−xPbI₃ films. We used the dynamic spin-coating method to control the cation ratio of the film by gradually increasing the FA+, which replaced the MA+ in the films. [...] Read more.

In this study, we fabricated and characterized uniform multi-cation perovskite FA_xMA_1−xPbI₃ films. We used the dynamic spin-coating method to control the cation ratio of the film by gradually increasing the FA+, which replaced the MA+ in the films. When the FA+ concentration was lower than xFA ~0.415 in the films, the stability of the multi-cation perovskite improved. Above this concentration, the film exhibited δ-phase FAPbI₃ in the FA_xMA_1−xPbI₃ films. The formation of δ-phase FAPbI₃ disturbed the homogeneity of the photoluminescence spatial distribution and suppressed the absorption spectral bandwidth with the increasing bandgap. The precise control of the cation ratio of multi-cation perovskite films is necessary to optimize the energy-harvesting performance. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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9 pages, 2703 KiB

Open AccessArticle

Development of Low-Shrink Epoxy Putty to Solve Appearance-Quality Defects of Carbon-Fiber-Reinforced Plastic Automotive Exterior Parts

by Manseok Yoon, Kwangsik Yoo, Bongkuk Seo, Seung Hwan Ko and Choong-Sun Lim

Materials 2021, 14(21), 6419; https://doi.org/10.3390/ma14216419 - 26 Oct 2021

Cited by 5 | Viewed by 2569

Abstract

In this study, epoxy putties with novel compositions were developed for the filling of structural voids in carbon-fiber-reinforced plastics (CFRPs), which are used to fabricate automotive parts. Two constituent solutions—one consisting of epoxy resins and the other consisting of a hardener—were formulated, mixed, [...] Read more.

In this study, epoxy putties with novel compositions were developed for the filling of structural voids in carbon-fiber-reinforced plastics (CFRPs), which are used to fabricate automotive parts. Two constituent solutions—one consisting of epoxy resins and the other consisting of a hardener—were formulated, mixed, and then coated on CFRP surfaces, followed by curing. The surfaces were then evaluated to determine the shrinkage rates (calculated based on the liquid densities and cured mixtures), adhesion properties (determined by a peel test), and color differences (measured with a colorimeter) of the synthesized putties. The last two properties were compared with those of the commercially available putties to ascertain the thermal resistance of the developed putties. The results indicated that the synthesized epoxy putties were more strongly adhesive and exhibited less difference in color. Furthermore, after thermal impact, both the adhesive properties and color stabilities of the synthesized epoxy putties were found to be superior to those of the commercial putty. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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28 pages, 56107 KiB

Open AccessArticle

The Low-Cycle Fatigue Behavior, Failure Mechanism and Prediction of SLM Ti-6Al-4V Alloy with Different Heat Treatment Methods

by Jiangjing Xi, Yun Hu, Hui Xing, Yuanfei Han, Haiying Zhang, Jun Jiang and Kamran Nikbin

Materials 2021, 14(21), 6276; https://doi.org/10.3390/ma14216276 - 21 Oct 2021

Cited by 20 | Viewed by 3944

Abstract

Selective laser melting (SLM) is a promising additive manufacturing (AM) process for high-strength or high-manufacturing-cost metals such as Ti-6Al-4V widely applied in aeronautical industry components with high material waste or complex geometry. However, one of the main challenges of AM parts is the [...] Read more.

Selective laser melting (SLM) is a promising additive manufacturing (AM) process for high-strength or high-manufacturing-cost metals such as Ti-6Al-4V widely applied in aeronautical industry components with high material waste or complex geometry. However, one of the main challenges of AM parts is the variability in fatigue properties. In this study, standard cyclic fatigue and monotonic tensile testing specimens were fabricated by SLM and subsequently heat treated using the standard heat treatment (HT) or hot isostatic pressing (HIP) methods. All the specimens were post-treated to relieve the residual stress and subsequently machined to the same surface finishing. These specimens were tested in the low-cycle fatigue (LCF) regime. The effects of post-process methods on the failure mechanisms were observed using scanning electron microscopy (SEM) and optical microscopy (OM) characterization methods. While the tensile test results showed that specimens with different post-process treatment methods have similar tensile strength, the LCF test revealed that no significant difference exists between HT and HIP specimens. Based on the results, critical factors influencing the LCF properties are discussed. Furthermore, a microstructure-based multistage fatigue model was employed to predict the LCF life. The results show good agreement with the experiment. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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16 pages, 3898 KiB

Open AccessArticle

Effect of Fly Ash on Leaching Characteristics of Cement-Stabilized Macadam Base

by Dian Lun, Taiping Yuan, Xiaolong Yang, Hongliu Rong, Junjie Shi and Minqiang Pan

Materials 2021, 14(20), 5935; https://doi.org/10.3390/ma14205935 - 9 Oct 2021

Cited by 9 | Viewed by 2089

Abstract

To study the leaching characteristics of a cement-stabilized macadam base with fly ash, a calcium leaching test, using varying cement and fly ash dosages in an ammonium chloride solution, was designed to obtain the rate of calcium ion leaching, porosity, and permeability coefficient [...] Read more.

To study the leaching characteristics of a cement-stabilized macadam base with fly ash, a calcium leaching test, using varying cement and fly ash dosages in an ammonium chloride solution, was designed to obtain the rate of calcium ion leaching, porosity, and permeability coefficient of cement-stabilized macadam with leaching time. The results showed that the number of leached calcium ions increased with the cement dosage in the leaching of cement-stabilized macadam. With an increase in the cement dosage, the leaching rate of calcium ions decreased, and the leaching process of the material was delayed. The incorporation of fly ash could effectively slow down the degree of calcium ion leaching. The permeability coefficient increased gradually with the extension of leaching time, and the increase in fly ash content had a more significant effect on the improvement of the permeability coefficient than the increase in cement dosage did. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 3727 KiB

Open AccessArticle

Conduction Mechanisms in Au/0.8 nm–GaN/n–GaAs Schottky Contacts in a Wide Temperature Range

by Hicham Helal, Zineb Benamara, Mouhamed Amine Wederni, Sabrine Mourad, Kamel Khirouni, Guillaume Monier, Christine Robert-Goumet, Abdelaziz Rabehi, Arslane Hatem Kacha, Hicham Bakkali, Lionel C. Gontard and Manuel Dominguez

Materials 2021, 14(20), 5909; https://doi.org/10.3390/ma14205909 - 9 Oct 2021

Cited by 3 | Viewed by 3108

Abstract

Au/0.8 nm–GaN/n–GaAs Schottky diodes were manufactured and electrically characterized over a wide temperature range. As a result, the reverse current I_inv increments from 1 × 10⁻⁷ A at 80 K to about 1 × 10⁻⁵ A at 420 K. The [...] Read more.

Au/0.8 nm–GaN/n–GaAs Schottky diodes were manufactured and electrically characterized over a wide temperature range. As a result, the reverse current I_inv increments from 1 × 10⁻⁷ A at 80 K to about 1 × 10⁻⁵ A at 420 K. The ideality factor n shows low values, decreasing from 2 at 80 K to 1.01 at 420 K. The barrier height qϕ_b grows abnormally from 0.46 eV at 80 K to 0.83 eV at 420 K. The tunnel mechanism TFE effect is the responsible for the qϕ_b behavior. The series resistance R_s is very low, decreasing from 13.80 Ω at 80 K to 4.26 Ω at 420 K. These good results are due to the good quality of the interface treated by the nitridation process. However, the disadvantage of the nitridation treatment is the fact that the GaN thin layer causes an inhomogeneous barrier height. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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14 pages, 3251 KiB

Open AccessArticle

Effect of Early Curing Temperature on the Tunnel Fire Resistance of Self-Compacting Concrete Coated with Aerogel Cement Paste

by Kai-Lin Huang, Shu-Jin Li and Ping-Hua Zhu

Materials 2021, 14(19), 5782; https://doi.org/10.3390/ma14195782 - 3 Oct 2021

Cited by 3 | Viewed by 2264

Abstract

In this paper, the effect of early curing temperature on the tunnel fire resistance of self-compacting concrete (SCC) coated with aerogel cement paste (ACP) was studied. The physical properties in terms of the compressive strength, flexural strength, and thermal conductivity of ACP were [...] Read more.

In this paper, the effect of early curing temperature on the tunnel fire resistance of self-compacting concrete (SCC) coated with aerogel cement paste (ACP) was studied. The physical properties in terms of the compressive strength, flexural strength, and thermal conductivity of ACP were tested under different early curing temperatures. The tunnel fire resistance of ACP and SCC coated with ACP was determined, and the microstructure of ACP and SCC after a tunnel fire were characterized by scanning electron microscopy. The results show that the strength of ACP initially increased (by 10–40 °C) and then later decreased (by 40–60 °C) with the increase in early curing temperature. ACP under 40 °C early curing exhibited the minimum number of cracks and mass loss after the tunnel fire. Too high or too low early curing temperature reduced the thermal conductivity of ACP but accelerated the formation and expansion of microcracks during the tunnel fire. The residual compressive strength of SCC coated with ACP under 40 °C early curing after the tunnel fire was the highest, demonstrating the best tunnel fire resistance. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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20 pages, 10472 KiB

Open AccessArticle

Dynamic Properties and Fractal Characteristics of 3D Printed Cement Mortar in SHPB Test

by Yixin Mo, Songlin Yue, Qizhen Zhou, Bowei Feng and Xiao Liu

Materials 2021, 14(19), 5554; https://doi.org/10.3390/ma14195554 - 24 Sep 2021

Cited by 6 | Viewed by 2358

Abstract

Comparing with the traditional construction process, 3D printing technology used in construction offers many advantages due to the elimination of formwork. Currently, 3D printing technology used in the construction field is widely studied, however, limited studies are available on the dynamic properties of [...] Read more.

Comparing with the traditional construction process, 3D printing technology used in construction offers many advantages due to the elimination of formwork. Currently, 3D printing technology used in the construction field is widely studied, however, limited studies are available on the dynamic properties of 3D printed materials. In this study, the effects of sand to binder ratios and printing directions on the fractal characteristics, dynamic compressive strength, and energy dissipation density of 3D printed cement mortar (3DPCM) are explored. The experiment results indicate that the printing direction has a more significant influence on the fractal dimension compared with the sand to binder ratio (S/B). The increasing S/B first causes an increase and then results in a decline in the dynamic compressive strength and energy dissipation of different printing directions. The anisotropic coefficient of 3DPCM first is decreased by 20.67%, then is increased by 10.56% as the S/B increases from 0.8 to 1.4, showing that the anisotropy is first mitigated, then increased. For the same case of S/B, the dynamic compressive strength and energy dissipation are strongly dependent on the printing direction, which are the largest printing in the Y-direction and the smallest printing in the X-direction. Moreover, the fractal dimension has certain relationships with the dynamic compressive strength and energy dissipation density. When the fractal dimension changes from 2.0 to 2.4, it shows a quadratic relationship with the dynamic compressive strength and a logarithmic relationship with the energy dissipation density in different printing directions. Finally, the printing mortar with an S/B = 1.1 is proved to have the best dynamic properties, and is selected for the 3D printing of the designed field barrack model. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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7 pages, 2986 KiB

Open AccessArticle

Lattice-Matched AlInN/GaN/AlGaN/GaN Heterostructured-Double-Channel Metal-Oxide-Semiconductor High-Electron Mobility Transistors with Multiple-Mesa-Fin-Channel Array

by Hsin-Ying Lee, Day-Shan Liu, Jen-Inn Chyi, Edward Yi Chang and Ching-Ting Lee

Materials 2021, 14(19), 5474; https://doi.org/10.3390/ma14195474 - 22 Sep 2021

Cited by 5 | Viewed by 2888

Abstract

Multiple-mesa-fin-channel array patterned by a laser interference photolithography system and gallium oxide (Ga₂O₃) gate oxide layer deposited by a vapor cooling condensation system were employed in double-channel Al_0.83In_0.17N/GaN/Al_0.18Ga_0.82N/GaN heterostructured-metal-oxide-semiconductors (MOSHEMTs). The [...] Read more.

Multiple-mesa-fin-channel array patterned by a laser interference photolithography system and gallium oxide (Ga₂O₃) gate oxide layer deposited by a vapor cooling condensation system were employed in double-channel Al_0.83In_0.17N/GaN/Al_0.18Ga_0.82N/GaN heterostructured-metal-oxide-semiconductors (MOSHEMTs). The double-channel was constructed by the polarized Al_0.18Ga_0.82N/GaN channel 1 and band discontinued lattice-matched Al_0.83In_0.17N/GaN channel 2. Because of the superior gate control capability, the generally induced double-hump transconductance characteristics of double-channel MOSHEMTs were not obtained in the devices. The superior gate control capability was contributed by the side-wall electrical field modulation in the fin-channel. Owing to the high-insulating Ga₂O₃ gate oxide layer and the high-quality interface between the Ga₂O₃ and GaN layers, low noise power density of 8.7 × 10⁻¹⁴ Hz⁻¹ and low Hooge’s coefficient of 6.25 × 10⁻⁶ of flicker noise were obtained. Furthermore, the devices had a unit gain cutoff frequency of 6.5 GHz and a maximal oscillation frequency of 12.6 GHz. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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16 pages, 3919 KiB

Open AccessArticle

Magnetic Properties and SAR for Gadolinium-Doped Iron Oxide Nanoparticles Prepared by Hydrothermal Method

by Heba Kahil, Ahmed Faramawy, Hesham El-Sayed and Adel Abdel-Sattar

Crystals 2021, 11(10), 1153; https://doi.org/10.3390/cryst11101153 - 22 Sep 2021

Cited by 26 | Viewed by 4489

Abstract

This study is an attempt to produce gadolinium-doped iron oxide nanoparticles for the purpose of utilization in magnetic fluid hyperthermia (MFH). Six gadolinium-doped iron oxide samples with varying gadolinium contents ( [...] Read more.

This study is an attempt to produce gadolinium-doped iron oxide nanoparticles for the purpose of utilization in magnetic fluid hyperthermia (MFH). Six gadolinium-doped iron oxide samples with varying gadolinium contents (

G d_{x} F e_{3 - x} O_{4}, x = 0, 0.02, 0.04, 0.06, 0.08, 0.1)

were prepared using the hydrothermal method

at 180 ° C

and high vapor pressure to incorporate gadolinium ions in the iron oxide structure. The samples were indexed as

G d IO / x

, with

x

varying from 0.0 to 0.1. The results reveal that gadolinium ions have a low solubility limit in the iron oxide lattice (x = 0.04). The addition of gadolinium caused distortion in the produced maghemite phase and formation of other phases. Based on X-ray diffraction (XRD) analysis and photoelectron spectroscopy (XPS), it was observed that gadolinium mostly crystalized as gadolinium hydroxide,

G d {(O H)}_{3}

for gadolinium concentrations above the solubility limit. The measured magnetization values are consistent with the formed phases. The saturation magnetization values for all gadolinium-doped samples are lower than the undoped sample. The specific absorption rate (SAR) for the pure iron oxide samples was measured. Sample GdIO/0.04, pure iron oxide doped with gadolinium, showed the highest potential to produce heat at a frequency of 198 kHz. Therefore, the sample is considered to hold great promise as an MFH agent. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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12 pages, 6995 KiB

Open AccessArticle

Microstructure and Mechanical Properties of Carbides Reinforced Nickel Matrix Alloy Prepared by Selective Laser Melting

by Tian Xia, Rui Wang, Zhongnan Bi, Rui Wang, Peng Zhang, Guangbao Sun and Ji Zhang

Materials 2021, 14(17), 4792; https://doi.org/10.3390/ma14174792 - 24 Aug 2021

Cited by 33 | Viewed by 3656

Abstract

Selective laser melting was used to prepare the ceramic particles reinforced nickel alloy owing to its high designability, high working flexibility and high efficiency. In this paper, a carbides particles reinforced Haynes 230 alloy was prepared using SLM technology to further strengthen the [...] Read more.

Selective laser melting was used to prepare the ceramic particles reinforced nickel alloy owing to its high designability, high working flexibility and high efficiency. In this paper, a carbides particles reinforced Haynes 230 alloy was prepared using SLM technology to further strengthen the alloy. Microstructures of the carbide particles reinforced Haynes 230 alloy were investigated using electron microscopy (SEM), electron probe microanalysis (EPMA) and transmission electron microscopy (TEM). Meanwhile, the tensile tests were carried out to determine the strengths of the composite. The results show that the microstructure of the composite consisted of uniformly distributed M₂₃C₆ and M₆C type carbides and the strengths of the alloy were higher than the matrix alloy Haynes 230. The increased strengths of the carbide reinforced Haynes 230 alloy (room temperature yield strength 113 MPa increased, ~ 33.2%) can be attributed to the synergy strengthening including refined grain strengthening, Orowan strengthening and dislocation strengthening. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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13 pages, 5878 KiB

Open AccessArticle

Characteristics of 3D Printable Bronze PLA-Based Filament Composites for Gaskets

by Marcela Sava, Ramona Nagy and Karoly Menyhardt

Materials 2021, 14(16), 4770; https://doi.org/10.3390/ma14164770 - 23 Aug 2021

Cited by 9 | Viewed by 2934

Abstract

Composite materials can be tailored for various properties, but the manufacturing process can be quite lengthy depending on the complexity of the final product. Instead, we focused our attention on the relatively new technology of additive manufacturing (3D printing) that can produce complex [...] Read more.

Composite materials can be tailored for various properties, but the manufacturing process can be quite lengthy depending on the complexity of the final product. Instead, we focused our attention on the relatively new technology of additive manufacturing (3D printing) that can produce complex geometries for a limited number of samples. Due to the weak bond between successive printed layers, these objects will have weaker mechanical properties in relation to cast or sintered materials. Thus, the orientation of the printed layers can make a huge difference in the behavior of the products. In this paper, a 3D printed composite made from bronze-filled PLA is mechanically characterized in order to be used as a substitute for sintered compacted bronze products for compression loads. Thus, cylindrical samples grown with the base horizontally and vertically were subjected to compression loads to determine their stress-strain curves at room temperature as well as in the glass transition region. Due to a lack of published research in this area, this study offers an insight into the usability of bronze-filled PLA for gaskets or other objects subjected to compression loads. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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16 pages, 7844 KiB

Open AccessArticle

Novel Antibacterial Modification of Polycarbonate for Increment Prototyping in Medicine

by Tomasz Flak, Ewa Trejnowska, Szymon Skoczyński, Jadwiga Gabor, Beata Swinarew, Klaudia Grzywnowicz, Hubert Okła, Krzysztof Jasik, Arkadiusz Stanula, Grzegorz Brożek and Andrzej S. Swinarew

Materials 2021, 14(16), 4725; https://doi.org/10.3390/ma14164725 - 21 Aug 2021

Cited by 6 | Viewed by 2797

Abstract

In the era of modern medicine, the number of invasive treatments increases. Artificial devices used in medicine are associated with an increased risk of secondary infections. Bacterial biofilm development observed on the implanted surface is challenging to treat, primarily due to low antibiotics [...] Read more.

In the era of modern medicine, the number of invasive treatments increases. Artificial devices used in medicine are associated with an increased risk of secondary infections. Bacterial biofilm development observed on the implanted surface is challenging to treat, primarily due to low antibiotics penetration. In our study, the preparation of a new polycarbonate composite, filled with nanosilver, nanosilica and rhodamine B derivative, suitable for three-dimensional printing, is described. Polymer materials with antimicrobial properties are known. However, in most cases, protection is limited to the outer layers only. The newly developed materials are protected in their entire volume. Moreover, the antibacterial properties are retained after multiple high-temperature processing were performed, allowing them to be used in 3D printing. Bacterial population reduction was observed, which gives an assumption for those materials to be clinically tested in the production of various medical devices and for the reduction of morbidity and mortality caused by multidrug-resistant bacteria. Full article

(This article belongs to the Topic Structure and Properties Modification in Additive Manufacturing)

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