Ilmenauer Fertigungstechnik TU Ilmenau’s Post

Cracking is a significant issue in 𝐋𝐚𝐬𝐞𝐫 𝐀𝐝𝐝𝐢𝐭𝐢𝐯𝐞 𝐌𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠 for numerous high-strength aluminium alloys, such as AA6061. Researchers at the RMIT Centre for Additive Manufacturing, in collaboration with Technische Universität Ilmenau in Germany and the ESRF - The European Synchrotron Radiation Facility in France have conducted a novel study using a pulsed laser with ramp-down power modulation to improve the cracking resistance by about 50% compared to the use of a rectangular pulsed laser. They implemented synchrotron in situ X-ray imaging at 100,000 images per second, obtaining ground truth data about changes in melt pool geometry, solidification rate, and thermal gradients. The article titled "In situ observation and reduction of hot-cracks in laser additive manufacturing" is out now in the Journal of 𝐂𝐨𝐦𝐦𝐮𝐧𝐢𝐜𝐚𝐭𝐢𝐨𝐧𝐬 𝐌𝐚𝐭𝐞𝐫𝐢𝐚𝐥𝐬. Congratulations to all authors, Yunhui Chen, Duyao Zhang, Patrick O'Toole, Dong Qiu, Marc Seibold, Klaus. Schricker, Jean-Pierre Bergmann, Alexander Rack and Prof. Mark Easton on their wonderful publication. 👏 🌷 Find the paper here: https://lnkd.in/gxxkygsa #additivemanufacturing #3dprinting #RCAM #collabration #research #LB_PBF #rmituniversity

🌟 Insightful Advancements in Additive Manufacturing! 🌟 I'm excited to share another significant publication from our collaboration between EPFL and PSI published in Additive Manufacturing Journal. This paper delves into the innovative use of in-situ Selective Laser Heat Treatment (SLHT) to enhance the microstructure of Ti-6Al-4V fabricated via Laser Powder Bed Fusion (LPBF). 🔬 Our study utilized operando X-ray diffraction and thermal finite element simulations to explore the dynamics of martensite decomposition and the temperature profile during SLHT. The results revealed a gradual formation of the β phase and a narrowing trend of the α/α' peak, highlighting the diffusional nature of α'-martensite decomposition. 🌡️ Interestingly, the controlled temperature evolution during cooling successfully preserved the β phase down to room temperature. Complementary microstructural characterizations further confirmed the presence of a lamellar α+β microstructure post-SLHT. 🎯 The goal of this approach is to integrate it into the LPBF process, thereby bypassing time-consuming post-processing steps and achieving composite-like, architected microstructures. I would like to extend special thanks to my colleagues Reza Esmaeilzadeh (lead researcher), Steven Van Petegem, Lucas Maximilian Schlenger, Charlotte de Formanoir, Cyril Cayron, Roland Loge, Nicola Casati, and Grolimund Daniel for their exceptional contributions. 🙏 We are also grateful for the financial support from the Swiss National Science Foundation and the provision of synchrotron beamtime at the Paul Scherrer Institute. https://lnkd.in/etfJi7my This research marks a significant step forward in our understanding and capabilities in additive manufacturing. Proud to be part of this groundbreaking work! #AdditiveManufacturing #MaterialScience #EPFL #PSI #Innovation #ResearchCollaboration #SLHT #LPBF

Optica [#OPG_Optica] research displays the fabrication of millimeter-sized optical components using tomographic volumetric additive manufacturing: https://bit.ly/3KRnBQk The research team purposefully blurred writing beams by using a large etendue source and eliminated striations to enable the rapid and direct fabrication of smooth surfaces. This approach paves the way for the low-cost, rapid prototyping of freeform optical components. Written by: Daniel Webber, Yujie Zhang, Kathleen L. Sampson, Michel Picard, Thomas Lacelle, Chantal Paquet, Jonathan Boisvert, and Antony Orth #opticalcomponents #scienceandtechnology #optics #physics National Research Council Canada / Conseil national de recherches Canada

We would like to share another fantastic publication by one of our talented PhD candidates, Jordan Noronha. The article titled “Additively Manufactured Functionally Graded Lattices: Design, Mechanical Response, Deformation Behavior, Applications, and Insights is out now in the Journal of the Minerals, Metals & Materials Society (TMS). Functionally graded lattices (FGL) represent an emerging subset of non-uniform lattices characterized by their structural efficiency, employing density gradients for a function-driven mechanical response. These gradients are controlled through stepwise or continuous changes in the geometry or topology of the lattice unit cells. FGLs exhibit multifunctionality, allowing for high compliance and energy absorption or moderate strength and stiffness, depending on the specific gradient. These innovative lattice structures find application in a range of fields, including biomimetic implants, heat dissipation, and impact absorption. The authors have systematically reviewed, classified, and explored the viability of these novel structures for real-world applications. Congrats to all authors, Jordan Noronha, Jason Dash, Prof. Martin Leary, Marcus Watson, Prof. Ma Qian, Elizabeth Kyriakou and Prof, Milan Brandt on their latest published article. 🌷 Read more here: https://lnkd.in/gyETtfHN #additivemanufacturing #3dprinting #lattice #rmituniversity #RCAM

#AMAIZE'ing conclusion of this study: https://lnkd.in/e9XXEYjt "This study demonstrates the potential of the TH (Time Homogenization) scanning strategy, which enables precise control over the local solidification conditions of melt pools. ....... This deposition approach, involving short vector adjustment at the corner of samples, may also be applicable to additive manufacturing of other metallic materials, and especially for thin-walled specimens. In other words, it becomes possible to develop tailor-made laser additive manufacturing techniques by intentionally designing and optimizing the processing parameters. Further research on numerical simulation to quantitatively describe the effect of scanning time intervals on solidification conditions, as well as comprehensive computational analysis of the strengthening mechanism, shows great potential for our future studies." Smart customers of 1000Kelvin in the energy and space industries are already using quantified homogenisation strategies (compared to brut force on every layer) on large and complex parts. I did a quick test it took me less than 2 min to detect the issue and correct them using smart homogenisation using adaptive timing, you can also use an optimised ordering or adapt the power or combine them all. Reach out if you want to start making your #digitalmaterials dreams become a reality !

Lattice metamaterials are a hot topic these days! Post-yield softening (PYS) plays an important role in guiding the design of high-performance energy-absorbing lattice materials. Our researchers at the RMIT Centre for Additive Manufacturing in collaboration with, Shanghai Jiao Tong University have studied #PYS occur in various bending-dominated #Ti-6Al-4V lattices with increasing relative density. The underlying mechanism for this unusual property is elucidated using the Timoshenko beam theory. It is attributed to the increase in stretching and shear deformation with increasing relative density, thereby increasing the tendency towards PYS. The finding of this work extends perspectives on PYS for the design of high-performance energy-absorbing lattice materials. Congrats to H. Z. Zhong, C. W. Lia, Raj Das, J. F. Gu, and Dist Prof Ma Qian on their great work.🌺 The article titled “Post-yield softening of bending-dominated metal metamaterials” are published in the Journal of PNAS Nexus. You can find more here: https://lnkd.in/g_izJ4i6 #additivemanufacturing #3dprinting #researcher #rmituniversity #RCAM #lattice

The Energy I-Corps Program is enabling researchers at DOE’s Fermilab to bring compact electron guns for 3D printing of metals to industry! 🙌 Energy I-Corps program has historically offered an intensive two-month training during which the National Lab researchers explore viable market pathways for their technologies. Under the new Topic 3: Post Energy I-Corps track introduced last year, program alumni applied for additional assistance to aid their next step toward commercialization. OTT and FECM are supporting Fermilab through Topic 3 to ultimately get this cutting-edge technology into use. Metal printing holds significant manufacturing value in the energy and aerospace industries. Learn more: https://bit.ly/3SmZgVL #TechTransfer #NationalLabs

I am excited to announce the publication of my first scientific research paper in Materials & Design. The paper, titled "Evaluating the Adhesion Response of Acrylonitrile-butadiene-styrene (ABS)/Thermoplastic polyurethane (TPU) Fused Interface using Multiscale Simulation and Experiment", provides a comprehensive approach to understanding the interfacial adhesion response of fused ABS and TPU materials. In this paper, we leverage molecular dynamics simulation and finite element analysis to evaluate the adhesion of the ABS and TPU interface. This work showcases how adjusting molecular structures and processing parameters can alter the macroscopic characteristics of a material, which in turn, can inform the design and manufacturing process. Open Access: https://lnkd.in/eSy8mABD I would like to extend my gratitude to my co-authors, Dr. Gideon A Lyngdoh, Rakesh Paswan, Bolaji Oladipo, and my academic advisor, Dr. Sumanta Das. #fusion #interface #moleculardynamics #finiteelementanalysis #additivemanufacturing #3dprinting #polymers

Happy to share our latest publication, "Elucidating the Role of Pulse Shaping on Defect Formation in Aluminum Alloys Fabricated by Powder Bed Fusion," a collaborative effort with colleagues Danilo de Camargo Branco, Licong An, Nikhilesh Chawla, and Gary Cheng In this study, we tackle one of the persistent challenges in Additive Manufacturing - reducing porosity and lack of fusion in Aluminum Alloys. Utilizing techniques such as X-ray microtomography, molecular dynamics, X-ray diffraction, Electron Backscatter Diffraction, and finite element simulations, we've quantified the impact of pulse shaping on the build quality. The findings suggest that laser pulse shaping plays a role in enhancing the quality of PBF-fabricated parts. This opens up a new avenue for research in additive manufacturing processes. Dive into the full paper here: https://lnkd.in/grMGcgYE

📢 I’m thrilled to announce the first paper of my PhD is published in “Advanced Functional Materials” journal (IF=20). 📚In this study we used a non standard free-form beam shaping technology to develope LPBF of a Zr-based BMG. In contrast to Gaussian beam distribution, the shaped beam provides a uniform energy distribution resulting in a larger and shallower melt pool. Thermal history and reheating phenomena can be reduced using higher hatching distances by this technology, revealing inferior atomic-scale relaxation and crystallinity. Further details and the results can be found in the paper: https://lnkd.in/dGmHa4bF 🙏🏻I would like to express my gratitude to my industry partner, Dr. Andreas Burn and Dr. Hossein Ghasemi at Swiss Advanced Manufacturing Center and special thanks are extended to my supervisor, Prof. Jürgen Eckert and my group leader, Dr. Florian Spieckermann at Montanuniversität Leoben, Department of materials science, Chair of materials physics. #lasertechnology #LPBF #additivemanufacturing #BMG #phd