Additive manufacturing(AM)technology has emerged as a viable solution for manufacturing complexshaped WC−Co cemented carbide products,thereby expanding their applications in industries such as resource mining,equipmen...Additive manufacturing(AM)technology has emerged as a viable solution for manufacturing complexshaped WC−Co cemented carbide products,thereby expanding their applications in industries such as resource mining,equipment manufacturing,and electronic information.This review provides a comprehensive summary of the progress of AM technology in WC−Co cemented carbides.The fundamental principles and classification of AM techniques are introduced,followed by a categorization and evaluation of the AM techniques for WC−Co cemented carbides.These techniques are classified as either direct AM technology(DAM)or indirect AM technology(IDAM),depending on their inclusion of post-processes like de-binding and sintering.Through an analysis of microstructure features,the most suitable AM route for WC−Co cemented carbide products with controllable microstructure is identified as the indirect AM technology,such as binder jet printing(BJP),which integrates AM with conventional powder metallurgy.展开更多
Aiming at the problems of insufficient activity and selectivity of Cu-based catalysts in CO_(2)hydrogenation to methanol,Al_(2)O_(3),ZrO_(2)and CeO_(2)modified Cu-ZnO catalysts by the co-precipitation method were prep...Aiming at the problems of insufficient activity and selectivity of Cu-based catalysts in CO_(2)hydrogenation to methanol,Al_(2)O_(3),ZrO_(2)and CeO_(2)modified Cu-ZnO catalysts by the co-precipitation method were prepared,and the influence mechanism of additives on the structure-performance relationship of the catalysts was systematically explored.Through a variety of characterization methods such as XRD,N2 physical adsorption-desorption,TEM,H_(2)-TPR,CO_(2)-TPD and XPS,combined with catalytic performance evaluation experiments,the correlation between the microstructure of catalysts and the reaction performance of CO_(2)hydrogenation to methanol was analyzed in depth.The results show that metal additives significantly improve the performance of catalysts.After the introduction of additives,the specific surface area and pore volume of the catalysts increase,the grain size of Cu decreases,and its dispersion improves.The Ce-modified CZC catalyst exhibited the best performance,with the grain size of CuO as small as 11.41 nm,and the surface oxygen vacancy concentration(OⅡ/OⅠ=3.15)was significantly higher than that of other samples.The reaction performance test shows that under the conditions of 2.8 MPa,8000 h−1 and 280℃,the CO_(2)conversion of the CZC catalyst reached 18.83%,the methanol selectivity was 68.40%,and the methanol yield was 12.88%,all of which are superior to other catalysts.Its excellent performance can be attributed to the fact that CeO_(2)enhances the metal-support interaction,increases the surface basicity,promotes the adsorption and activation of CO_(2),and simultaneously inhibits the reverse water-gas shift side reaction.This study clarifies the structure-activity regulation mechanism of additive modification on Cu-ZnO catalysts,providing a theoretical basis and technical reference for the development of efficient catalysts for CO_(2)hydrogenation to methanol.展开更多
Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing addit...Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing additive-induced defects,and alleviating residual stress and deformation,all of which are critical for enhancing the mechanical performance of the manufactured parts.Integrating interlayer friction stir processing(FSP)into WAAM significantly enhances the quality of deposited materials.However,numerical simulation research focusing on elucidating the associated thermomechanical coupling mechanisms remains insufficient.A comprehensive numerical model was developed to simulate the thermomechanical coupling behavior in friction stir-assisted WAAM.The influence of post-deposition FSP on the coupled thermomechanical response of the WAAM process was analyzed quantitatively.Moreover,the residual stress distribution and deformation behavior under both single-layer and multilayer deposition conditions were investigated.Thermal analysis of different deposition layers in WAAM and friction stir-assisted WAAM was conducted.Results show that subsequent layer deposition induces partial remelting of the previously solidified layer,whereas FSP does not cause such remelting.Furthermore,thermal stress and deformation analysis confirm that interlayer FSP effectively mitigates residual stresses and distortion in WAAM components,thereby improving their structural integrity and mechanical properties.展开更多
Refractory metals,including tungsten(W),tantalum(Ta),molybdenum(Mo),and niobium(Nb),play a vital role in industries,such as nuclear energy and aerospace,owing to their exceptional melting temperatures,thermal durabili...Refractory metals,including tungsten(W),tantalum(Ta),molybdenum(Mo),and niobium(Nb),play a vital role in industries,such as nuclear energy and aerospace,owing to their exceptional melting temperatures,thermal durability,and corrosion resistance.These metals have body-centered cubic crystal structure,characterized by limited slip systems and impeded dislocation motion,resulting in significant low-temperature brittleness,which poses challenges for the conventional processing.Additive manufacturing technique provides an innovative approach,enabling the production of intricate parts without molds,which significantly improves the efficiency of material usage.This review provides a comprehensive overview of the advancements in additive manufacturing techniques for the production of refractory metals,such as W,Ta,Mo,and Nb,particularly the laser powder bed fusion.In this review,the influence mechanisms of key process parameters(laser power,scan strategy,and powder characteristics)on the evolution of material microstructure,the formation of metallurgical defects,and mechanical properties were discussed.Generally,optimizing powder characteristics,such as sphericity,implementing substrate preheating,and formulating alloying strategies can significantly improve the densification and crack resistance of manufactured parts.Meanwhile,strictly controlling the oxygen impurity content and optimizing the energy density input are also the key factors to achieve the simultaneous improvement in strength and ductility of refractory metals.Although additive manufacturing technique provides an innovative solution for processing refractory metals,critical issues,such as residual stress control,microstructure and performance anisotropy,and process stability,still need to be addressed.This review not only provides a theoretical basis for the additive manufacturing of high-performance refractory metals,but also proposes forward-looking directions for their industrial application.展开更多
To deepen understanding of the evolution of coal char microstructural properties of coal char during the co-pyrolysis of coking coal with additives,this study incorporated two typical additives,coal tar pitch(CTP)and ...To deepen understanding of the evolution of coal char microstructural properties of coal char during the co-pyrolysis of coking coal with additives,this study incorporated two typical additives,coal tar pitch(CTP)and waste plastic(HDPE),into a blended coal sample and carried out pyrolysis experiments.The pyrolysis process and the microstructure of char were systematically characterized using various analytical techniques,including thermogravimetric analysis(TGA),X-ray diffraction(XRD)and Raman spectroscopy.Data correlation analysis was performed to reveal the mechanism of carbon structural ordering evolution within the critical temperature range(350−600℃)from colloidal layer formation to semi-coke conversion in coking coal,and to elucidate the regulatory effects of different additives on coal pyrolysis pathways.The results indicate that HDPE releases free radicals during high-temperature pyrolysis,accelerating the pyrolysis reaction and increase the yield of volatile components.Conversely,CTP facilitates pyrolysis at low temperatures through its light components,thereby delaying high-temperature reactions due to the colloidal layer’s effect.XRD results indicate that during the process of pyrolysis,there is a progressive decrease in the interlayer spacing of aromatic layers(d002),while the aromatic ring stacking height(L_(c))and lateral size(L_(a))undergo significant of carbon skeleton ordering.Further comparative reveals that CTP partially suppresses structural ordering at low temperatures,whereas HDPE promotes the condensation and alignment of aromatic clusters via a free radical mechanism.Raman spectroscopy reveals a two-stage reorganization mechanism in the microstructure of the coal char:the decrease in the I_(D)/I_(G)ratio between 350 and 550℃is primarily attributed to the cleavage of aliphatic side chains and cross-linking bonds,leading to a reduction in defective structures;whereas the increase in ID/IG between 550 and 600℃is closely associated with enhanced condensation reactions of aromatic structures.Correlation analysis further demonstrates progressive graphitization during pyrolysis,with a significant positive correlation(R^(2)>0.85)observed between d002 and the full width at half maximum of the G-band(FWHM-G).展开更多
Two-dimensional MXene Ti_(3)C_(2)T_(x)demonstrates great promise in perovskite solar cells(PSCs).Herein,sulfur-terminated Ti_(3)C_(2)T_(x)(S-Ti_(3)C_(2)T_(x))is developed by modifying Ti_(3)C_(2)T_(x)via a facile hydr...Two-dimensional MXene Ti_(3)C_(2)T_(x)demonstrates great promise in perovskite solar cells(PSCs).Herein,sulfur-terminated Ti_(3)C_(2)T_(x)(S-Ti_(3)C_(2)T_(x))is developed by modifying Ti_(3)C_(2)T_(x)via a facile hydrothermal method using thioacetamide.As a perovskite additive,S-Ti_(3)C_(2)T_(x)outperforms pristine Ti_(3)C_(2)T_(x)by(1)significantly promoting grain growth,enhancing carrier mobility,and reducing defect density;(2)optimizing energy level alignment to lower interfacial energy barriers and minimize interface non-radiative recombination;(3)stabilizing uncoordinated Pb2+and[PbI6]4-octahedra via Pb-S bonds while alleviating bulk lattice strain,as this Pb-S interaction exerts a“tape-like”effect.Based on this synergistic mechanism,PSCs with S-Ti_(3)C_(2)T_(x)achieve a champion efficiency of 25.51%—outperforming control(23.46%)and pristine Ti_(3)C_(2)T_(x)-based devices(24.54%)—with enhanced stability.This work highlights terminal group engineering as a critical strategy for advancing high-performance PSCs and their potential for emerging photovoltaic technologies.展开更多
Additive manufacturing(AM),with its high flexibility,cost-effectiveness,and customization,significantly accelerates the advancement of nanogenerators,contributing to sustainable energy solutions and the Internet of Th...Additive manufacturing(AM),with its high flexibility,cost-effectiveness,and customization,significantly accelerates the advancement of nanogenerators,contributing to sustainable energy solutions and the Internet of Things.In this review,an in-depth analysis of AM for piezoelectric and triboelectric nanogenerators is presented from the perspectives of fundamental mechanisms,recent advancements,and future prospects.It highlights AM-enabled advantages of versatility across materials,structural topology optimization,microstructure design,and integrated printing,which enhance critical performance indicators of nanogenerators,such as surface charge density and piezoelectric constant,thereby improving device performance compared to conventional fabrication.Common AM techniques for nanogenerators,including fused deposition modeling,direct ink writing,stereolithography,and digital light processing,are systematically examined in terms of their working principles,improved metrics(output voltage/current,power density),theoretical explanation,and application scopes.Hierarchical relationships connecting AM technologies with performance optimization and applications of nanogenerators are elucidated,providing a solid foundation for advancements in energy harvesting,self-powered sensors,wearable devices,and human-machine interaction.Furthermore,the challenges related to fabrication quality,cross-scale manufacturing,processing efficiency,and industrial deployment are critically discussed.Finally,the future prospects of AM for nanogenerators are explored,aiming to foster continuous progress and innovation in this field.展开更多
Achieving high energy and power densities is currently a core challenge in the fabrication of energy storage materials.Although numerous high-capacity materials have been developed,conventional planar electrodes canno...Achieving high energy and power densities is currently a core challenge in the fabrication of energy storage materials.Although numerous high-capacity materials have been developed,conventional planar electrodes cannot achieve high active material loading and efficient ion/electron transport simultaneously.By contrast,three-dimensional(3D)structures have attracted increasing interest because of their capacity to enhance active material utilization,shorten ion and electron transport pathways,reduce interfacial impedance,and provide spatial accommodation for volume expansion.Additive manufacturing(AM)technology effectively fabricates energy-storage materials with 3D structures by accurately constructing complex 3D structures via layer-by-layer deposition.Recent studies have employed AM to construct ordered 3D electrodes that can optimize ion/electron transport,regulate electric field distribution,or improve the electrode-electrolyte interface,thereby contributing to enhanced kinetic performance and cycling stability.This review systematically summarizes the applications of several AM technologies in the fabrication of energy storage materials and analyzes their respective advantages and limitations.Subsequently,the advantages of AM technology in the fabrication of energy storage materials and several major optimization strategies are comprehensively discussed.Finally,the major challenges and potential applications of AM technology in energy storage material optimization are discussed.展开更多
Low-velocity impact tests are carried out to explore the energy absorption characteristics of bio-inspired lattices,mimicking the architecture of the marine sponge organism Euplectella aspergillum.These sea sponge-ins...Low-velocity impact tests are carried out to explore the energy absorption characteristics of bio-inspired lattices,mimicking the architecture of the marine sponge organism Euplectella aspergillum.These sea sponge-inspired lattice structures feature a square-grid 2D lattice with double diagonal bracings and are additively manufactured via digital light processing(DLP).The collapse strength and energy absorption capacity of sea sponge lattice structures are evaluated under various impact conditions and are compared to those of their constituent square-grid and double diagonal lattices.This study demonstrates that sea sponge lattices can achieve an 11-fold increase in energy absorption compared to the square-grid lattice,due to the stabilizing effect of the double diagonal bracings prompting the structure to collapse layer-bylayer under impact.By adjusting the thickness ratio in the sea sponge lattice,up to 76.7%increment in energy absorption is attained.It is also shown that sea-sponge lattices outperform well-established energy-absorbing materials of equal weight,such as hexagonal honeycombs,confirming their significant potential for impact mitigation.Additionally,this research highlights the enhancements in energy absorption achieved by adding a small amount(0.015 phr)of Multi-Walled Carbon Nanotubes(MWCNTs)to the photocurable resin,thus unlocking new possibilities for the design of innovative lightweight structures with multifunctional attributes.展开更多
The high voltage of Li||LiCoO_(2) battery can increase the energy density.However,the cycling performance associated with cathode structural stability remains challenging.To address this question,we proposed an electr...The high voltage of Li||LiCoO_(2) battery can increase the energy density.However,the cycling performance associated with cathode structural stability remains challenging.To address this question,we proposed an electrolyte strategy for improving the performance of 4.6 V Li||LiCoO_(2) battery by using trimethylsilyl isocyanate(TMIS)as electrolyte additive.The trimethylsilyl group of TMIS can trap HF while the isocyanate group brings polyamide components to the CEI and the SEI.By the synergistic action,the Co3+dissolution problem of the LiCoO_(2) cathode was effectively curbed.Furthermore,TMIS regulates the construction of anion-dominated LiF-rich SEI by influencing the solvation structure of Li+.As expected,the 4.6 V Li||LiCoO_(2) battery with TMIS retains 77.9% initial capacity after 200 cycles at 0.5 C.展开更多
Functionally graded cellular structures(FGCSs)have a multitude of applications to a wide range of industries.Utilising the ever-progressing technology of additive manufacturing(AM),FGCSs can be applied to control mate...Functionally graded cellular structures(FGCSs)have a multitude of applications to a wide range of industries.Utilising the ever-progressing technology of additive manufacturing(AM),FGCSs can be applied to control material grading and achieve the desired mechanical properties.The current study explores the design and optimisation of FGCSs for AM,with a focus on improving the compression and impact performance of below knee(BK)prosthetic limbs made of thermoplastic polyurethane(TPU).A multiscale research methodology integrating topology optimization(TO),finite element analysis(FEA),and design of experiments(Do E)was adopted to optimise lattice structures in terms of stiffness and lightweight properties.Two-unit cell designs were considered in the study:Schwarz P gyroid and body-centered cubic(BCC).Response surface methodology(RSM)was implemented to analyse the effect of minimum and maximum cell wall thickness,cell size,and unit cell type on the mechanical performance of TPU FGCS structures.The results indicated that a Schwarz P FGCS structure with cell size,minimum and maximum cell wall thickness of 6,0.9 and 2.8 mm,respectively,could be optimal for a compromise between performance and weight.In this optimized case,stiffness and volume fraction values of 684 N/mm and 0.64 were obtained,respectively.The study also presents a proof-of-concept design for a BK prosthetic damper,highlighting the potential of FGCSs to enhance patient comfort,reduce manufacturing costs,and enable personalised designs through 3D scanning and AM.The obtained results could be a step forward towards the incorporation of AM technologies in prosthetics,offering a pathway to lightweight,cost-effective,and functionally tailored solutions.展开更多
Achieving simultaneous enhancement of crystallinity and optimal domain size remains a fundamental challenge in organic photovoltaics(OPVs),where conventional crystallization strategies often trigger excessive aggregat...Achieving simultaneous enhancement of crystallinity and optimal domain size remains a fundamental challenge in organic photovoltaics(OPVs),where conventional crystallization strategies often trigger excessive aggregation of small-molecule acceptors.This work pioneers a kinetic paradigm for resolving the crystallinity-domain size trade-off in organic photovoltaics through dual-additive-guided stepwise crystallization.By strategically pairing 1,2-dichlorobenzene(o-DCB,low binding energy to Y6)and 1-fluoronaphthalene(FN,high binding energy),we achieve temporally decoupled crystallization control:o-DCB first mediates donor-acceptor co-crystallization during film formation,constructing a metastable network,whereupon FN induces confined Y6 crystallization within this framework during thermal annealing,refining nanostructure without over-aggregation.Morphology studies reveal that this synergy enhances crystallinity of(100)diffraction peaks by 21%–10%versus single-additive controls(o-DCB/FN alone),while maintaining optimal domain size.These morphological advantages yield balanced carrier transport(μh/μe=1.23),near-unity exciton dissociation(98.53%),and a champion power conversion efficiency(PCE)of 18.08%for PM6:Y6,significantly surpassing single-additive devices(o-DCB:17.20%;FN:17.53%).Crucially,the dual-additive strategy demonstrates universal applicability across diverse active layer systems,achieving an outstanding PCE of 19.27%in PM6:L8-BO-based devices,thereby establishing a general framework for morphology control in high-efficiency OPVs.展开更多
Additive Manufacturing(AM)has significantly impacted the development of high-performance materials and structures,offering new possibilities for industries ranging from aerospace to biomedicine.This special issue feat...Additive Manufacturing(AM)has significantly impacted the development of high-performance materials and structures,offering new possibilities for industries ranging from aerospace to biomedicine.This special issue features pioneering research that integrates AI-driven methods with AM,enabling the design and fabrication of complex,optimized structures with enhanced properties.展开更多
Additive manufacturing of aluminum(Al)alloys has attracted significant attention in the aerospace industry.However,achieving ultrahigh-strength(>500 MPa)Al alloys remains challenging due to their intrinsic poor pri...Additive manufacturing of aluminum(Al)alloys has attracted significant attention in the aerospace industry.However,achieving ultrahigh-strength(>500 MPa)Al alloys remains challenging due to their intrinsic poor printability.Here,we report a novel hybrid additive manufacturing(HAM)approach to process ultrahigh-strength AlMgSc alloy,which combines laser powder bed fusion(LPBF)with interlayer ultrasonic shot peening(USP).The results show that the interlayer ultrasonic shot peening depth reached∼700μm,leading to almost full density and residual stress convection from tension to compression.The HAM method promotes equiaxed grain formation and refines grain due to grain recrystallizations.Interestingly,the HAM followed by aging treatment tailors the hierarchically multi-gradient structures,inhibits Mg element intragranular segregation,and promotes the multi-nanoprecipitates(e.g.Al_(3)(Sc,Zr)and Al_(6)Mn)precipitation.Remarkably,the HAM followed by aging treatment achieves yield strength of 609 MPa and breaks elongation of 7.5%,demonstrating ultrahigh strength and good ductility compared with other Al alloys manufactured by AM and forging as reported in the literature.The strength enhancement mechanisms in this AlMgSc alloy are discussed.The high-density Al_(3)(Sc,Zr)precipitates are the main strengthening contributor,and unique hetero-deformation induced(HDI)strengthening(originates from the heterogeneous microstructures)further enhances the strength of the material.This work highlights a novel approach for processing complex-structured ultrahigh strength Al alloy components by hybrid additive manufacturing.展开更多
Additive manufacturing(AM)has emerged as one of the most utilized processes in manufacturing due to its ability to produce complex geometries with minimal material waste and greater design freedom.Laser-based AM(LAM)t...Additive manufacturing(AM)has emerged as one of the most utilized processes in manufacturing due to its ability to produce complex geometries with minimal material waste and greater design freedom.Laser-based AM(LAM)technologies use high-power lasers to melt metallic materials,which then solidify to form parts.However,it inherently induces self-equilibrating residual stress during fabrication due to thermal loads and plastic deformation.These residual stresses can cause defects such as delamination,cracking,and distortion,as well as premature failure under service conditions,necessitating mitigation.While post-treatment methods can reduce residual stresses,they are often costly and time-consuming.Therefore,tuning the fabrication process parameters presents a more feasible approach.Accordingly,in addition to providing a comprehensive view of residual stress by their classification,formation mechanisms,measurement methods,and common post-treatment,this paper reviews and compares the studies conducted on the effect of key parameters of the LAM process on the resulting residual stresses.This review focuses on proactively adjusting LAM process parameters as a strategic approach to mitigate residual stress formation.It provides a result of the various parameters influencing residual stress outcomes,such as laser power,scanning speed,beam diameter,hatch spacing,and scanning strategies.Finally,the paper identifies existing research gaps and proposes future studies needed to deepen understanding of the relationship between process parameters and residual stress mitigation in LAM.展开更多
1.Introduction As one of the most widely used additive manufacturing(AM)techniques,selective laser melting(SLM)is a laser-based layer-by-layer manufacturing process,which has relatively high fabrication resolution and...1.Introduction As one of the most widely used additive manufacturing(AM)techniques,selective laser melting(SLM)is a laser-based layer-by-layer manufacturing process,which has relatively high fabrication resolution and can directly form complex metal parts.During SLM,the interaction of laser with metal powder forms a tiny melt pool.Following the rapid movement of the laser,the cooling rate of the melt pool can be as high as 105-106 K s−1[1].Such a fast cool-ing rate inhibits grain growth and element segregation in the alloy,leading to a notable enhancement in strength and toughness[2].Therefore,SLM enables unlimited possibilities in the fabrication of complex parts with high performance.To date,the most extensively researched Al alloys for SLM are Al-Si alloys,such as AlSi10Mg,Al-12Si,and AlSi7Mg[2-5].展开更多
An approach called hybrid heat-source solid-state additive manufacturing (HHSAM) for fabricating multilayer AA6061 deposition with superior properties is proposed in this paper. As compared with the traditional additi...An approach called hybrid heat-source solid-state additive manufacturing (HHSAM) for fabricating multilayer AA6061 deposition with superior properties is proposed in this paper. As compared with the traditional additive friction stir deposition (AFSD), the auxiliary induction heat-source in HHSAM effectively improves the temperature and fluidity of plastic flow, which facilitates the formation and enrichment of residual Mg_(2)Si phases besides Al(Fe,Mn)Si, promotes the dynamic recrystallization and increases the bonding strength between layers during the deposition process. Therefore, the HHSAM depositions possess a more uniform structure, superior integral mechanical properties and corrosion resistance after heat treatment process. Moreover, HHSAMed specimens avoid abnormal grain growth (AGG) in heat treatment process, which is regularly encountered in the traditional AFSD. HHSAM method is proved to be a new solid-state additive manufacturing method with good developing prospects for fabricating alloy production with excellent properties in a high-efficiency manner.展开更多
At present,the emerging solid-phase friction-based additive manufacturing technology,including friction rolling additive man-ufacturing(FRAM),can only manufacture simple single-pass components.In this study,multi-laye...At present,the emerging solid-phase friction-based additive manufacturing technology,including friction rolling additive man-ufacturing(FRAM),can only manufacture simple single-pass components.In this study,multi-layer multi-pass FRAM-deposited alumin-um alloy samples were successfully prepared using a non-shoulder tool head.The material flow behavior and microstructure of the over-lapped zone between adjacent layers and passes during multi-layer multi-pass FRAM deposition were studied using the hybrid 6061 and 5052 aluminum alloys.The results showed that a mechanical interlocking structure was formed between the adjacent layers and the adja-cent passes in the overlapped center area.Repeated friction and rolling of the tool head led to different degrees of lateral flow and plastic deformation of the materials in the overlapped zone,which made the recrystallization degree in the left and right edge zones of the over-lapped zone the highest,followed by the overlapped center zone and the non-overlapped zone.The tensile strength of the overlapped zone exceeded 90%of that of the single-pass deposition sample.It is proved that although there are uneven grooves on the surface of the over-lapping area during multi-layer and multi-pass deposition,they can be filled by the flow of materials during the deposition of the next lay-er,thus ensuring the dense microstructure and excellent mechanical properties of the overlapping area.The multi-layer multi-pass FRAM deposition overcomes the limitation of deposition width and lays the foundation for the future deposition of large-scale high-performance components.展开更多
Laser additive manufacturing(LAM)has been widely used in high-end manufacturing fields such as aerospace,nuclear power,and shipbuilding.However,it is a grand challenge for direct and continuous observation of complex ...Laser additive manufacturing(LAM)has been widely used in high-end manufacturing fields such as aerospace,nuclear power,and shipbuilding.However,it is a grand challenge for direct and continuous observation of complex laser-matter interaction,melt flow,and defect formation during LAM due to extremely large temperature gradient,fast cooling rate,and small time(millisecond)and space(micron)scales.The emergence of synchrotron radiation provides a feasible approach for in situ observation of the LAM process.This paper outlines the current development in real-time characterization of LAM by synchrotron radiation,including laser-matter interaction,molten pool evolution,solidification structure evolution,and defects formation and elimination.Furthermore,the future development direction and application-oriented research are also discussed.展开更多
AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries.Despite its popularity,the utilization of additively manufactured AA6061 through the laser powder bed fus...AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries.Despite its popularity,the utilization of additively manufactured AA6061 through the laser powder bed fusion(LPBF)process has been hindered by the pronounced formation of pores and cracks during rapid solidification.This study quantitatively investigated defects,including pores and cracks,and microstructures,including texture,grain size,subgrain structure,and precipitates,of LPBF-manufactured AA6061 across a broad spectrum of laser power and speed combinations.A high relative density of more than 99%was achieved with a low-power and low-speed condition,specifically 200 W and 100 mm s−1,with minimal cracks.Large pores,akin to or exceeding melt pool dimensions,emerged under either low or high energy densities,driven by the lack of fusion and vaporization/denudation mechanisms,re-spectively.Solidification cracks,confirmed by the fractography,were propagated along grain boundaries and are highly dependent on laser scanning speed.Elevated power and speed exhibited finer grain size with refined subgrain cellular structures and increased precipitates at interdendritic regions.The cooling rate and thermal gradient estimated from thermal analytical solutions explain the microstructures’char-acteristics.Nano-sized Si-Fe-Mg enriched precipitates are confirmed in both as-built and heat-treated conditions,whereas T6 heat treatment promotes a uniform distribution with coarsening of those precipi-tates.The low-power and low-speed conditions demonstrated the highest yield strength,consistent with defect levels.A minimum of 102.3%increase in yield strength with reduced ductility was observed after heat treatment for all examined conditions.This work sheds light on printing parameters to mitigate the formation of pores and cracks in additively manufactured AA6061,proposing a process window for op-timized fabrication and highlighting the potential for enhanced material properties and reduced defects through process control.展开更多
基金supported by Major Science and Technology Projects in Fujian Province,China(No.2023HZ021005)State Key Laboratory of Powder Metallurgy,Central South University,ChinaFujian Key Laboratory of Rare-earth Functional Materials,China。
文摘Additive manufacturing(AM)technology has emerged as a viable solution for manufacturing complexshaped WC−Co cemented carbide products,thereby expanding their applications in industries such as resource mining,equipment manufacturing,and electronic information.This review provides a comprehensive summary of the progress of AM technology in WC−Co cemented carbides.The fundamental principles and classification of AM techniques are introduced,followed by a categorization and evaluation of the AM techniques for WC−Co cemented carbides.These techniques are classified as either direct AM technology(DAM)or indirect AM technology(IDAM),depending on their inclusion of post-processes like de-binding and sintering.Through an analysis of microstructure features,the most suitable AM route for WC−Co cemented carbide products with controllable microstructure is identified as the indirect AM technology,such as binder jet printing(BJP),which integrates AM with conventional powder metallurgy.
基金Supported by National Key R&D Program of China(2022YFA1503400)。
文摘Aiming at the problems of insufficient activity and selectivity of Cu-based catalysts in CO_(2)hydrogenation to methanol,Al_(2)O_(3),ZrO_(2)and CeO_(2)modified Cu-ZnO catalysts by the co-precipitation method were prepared,and the influence mechanism of additives on the structure-performance relationship of the catalysts was systematically explored.Through a variety of characterization methods such as XRD,N2 physical adsorption-desorption,TEM,H_(2)-TPR,CO_(2)-TPD and XPS,combined with catalytic performance evaluation experiments,the correlation between the microstructure of catalysts and the reaction performance of CO_(2)hydrogenation to methanol was analyzed in depth.The results show that metal additives significantly improve the performance of catalysts.After the introduction of additives,the specific surface area and pore volume of the catalysts increase,the grain size of Cu decreases,and its dispersion improves.The Ce-modified CZC catalyst exhibited the best performance,with the grain size of CuO as small as 11.41 nm,and the surface oxygen vacancy concentration(OⅡ/OⅠ=3.15)was significantly higher than that of other samples.The reaction performance test shows that under the conditions of 2.8 MPa,8000 h−1 and 280℃,the CO_(2)conversion of the CZC catalyst reached 18.83%,the methanol selectivity was 68.40%,and the methanol yield was 12.88%,all of which are superior to other catalysts.Its excellent performance can be attributed to the fact that CeO_(2)enhances the metal-support interaction,increases the surface basicity,promotes the adsorption and activation of CO_(2),and simultaneously inhibits the reverse water-gas shift side reaction.This study clarifies the structure-activity regulation mechanism of additive modification on Cu-ZnO catalysts,providing a theoretical basis and technical reference for the development of efficient catalysts for CO_(2)hydrogenation to methanol.
基金National Key Research and Development Program of China(2022YFB4600902)Shandong Provincial Science Foundation for Outstanding Young Scholars(ZR2024YQ020)。
文摘Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing additive-induced defects,and alleviating residual stress and deformation,all of which are critical for enhancing the mechanical performance of the manufactured parts.Integrating interlayer friction stir processing(FSP)into WAAM significantly enhances the quality of deposited materials.However,numerical simulation research focusing on elucidating the associated thermomechanical coupling mechanisms remains insufficient.A comprehensive numerical model was developed to simulate the thermomechanical coupling behavior in friction stir-assisted WAAM.The influence of post-deposition FSP on the coupled thermomechanical response of the WAAM process was analyzed quantitatively.Moreover,the residual stress distribution and deformation behavior under both single-layer and multilayer deposition conditions were investigated.Thermal analysis of different deposition layers in WAAM and friction stir-assisted WAAM was conducted.Results show that subsequent layer deposition induces partial remelting of the previously solidified layer,whereas FSP does not cause such remelting.Furthermore,thermal stress and deformation analysis confirm that interlayer FSP effectively mitigates residual stresses and distortion in WAAM components,thereby improving their structural integrity and mechanical properties.
基金National MCF Energy R&D Program(2024YFE03260300)。
文摘Refractory metals,including tungsten(W),tantalum(Ta),molybdenum(Mo),and niobium(Nb),play a vital role in industries,such as nuclear energy and aerospace,owing to their exceptional melting temperatures,thermal durability,and corrosion resistance.These metals have body-centered cubic crystal structure,characterized by limited slip systems and impeded dislocation motion,resulting in significant low-temperature brittleness,which poses challenges for the conventional processing.Additive manufacturing technique provides an innovative approach,enabling the production of intricate parts without molds,which significantly improves the efficiency of material usage.This review provides a comprehensive overview of the advancements in additive manufacturing techniques for the production of refractory metals,such as W,Ta,Mo,and Nb,particularly the laser powder bed fusion.In this review,the influence mechanisms of key process parameters(laser power,scan strategy,and powder characteristics)on the evolution of material microstructure,the formation of metallurgical defects,and mechanical properties were discussed.Generally,optimizing powder characteristics,such as sphericity,implementing substrate preheating,and formulating alloying strategies can significantly improve the densification and crack resistance of manufactured parts.Meanwhile,strictly controlling the oxygen impurity content and optimizing the energy density input are also the key factors to achieve the simultaneous improvement in strength and ductility of refractory metals.Although additive manufacturing technique provides an innovative solution for processing refractory metals,critical issues,such as residual stress control,microstructure and performance anisotropy,and process stability,still need to be addressed.This review not only provides a theoretical basis for the additive manufacturing of high-performance refractory metals,but also proposes forward-looking directions for their industrial application.
基金Supported by National Natural Science Foundation of China(22378180,22078141)Education Department Foundation of Liaoning Province(JYTMS20230960)。
文摘To deepen understanding of the evolution of coal char microstructural properties of coal char during the co-pyrolysis of coking coal with additives,this study incorporated two typical additives,coal tar pitch(CTP)and waste plastic(HDPE),into a blended coal sample and carried out pyrolysis experiments.The pyrolysis process and the microstructure of char were systematically characterized using various analytical techniques,including thermogravimetric analysis(TGA),X-ray diffraction(XRD)and Raman spectroscopy.Data correlation analysis was performed to reveal the mechanism of carbon structural ordering evolution within the critical temperature range(350−600℃)from colloidal layer formation to semi-coke conversion in coking coal,and to elucidate the regulatory effects of different additives on coal pyrolysis pathways.The results indicate that HDPE releases free radicals during high-temperature pyrolysis,accelerating the pyrolysis reaction and increase the yield of volatile components.Conversely,CTP facilitates pyrolysis at low temperatures through its light components,thereby delaying high-temperature reactions due to the colloidal layer’s effect.XRD results indicate that during the process of pyrolysis,there is a progressive decrease in the interlayer spacing of aromatic layers(d002),while the aromatic ring stacking height(L_(c))and lateral size(L_(a))undergo significant of carbon skeleton ordering.Further comparative reveals that CTP partially suppresses structural ordering at low temperatures,whereas HDPE promotes the condensation and alignment of aromatic clusters via a free radical mechanism.Raman spectroscopy reveals a two-stage reorganization mechanism in the microstructure of the coal char:the decrease in the I_(D)/I_(G)ratio between 350 and 550℃is primarily attributed to the cleavage of aliphatic side chains and cross-linking bonds,leading to a reduction in defective structures;whereas the increase in ID/IG between 550 and 600℃is closely associated with enhanced condensation reactions of aromatic structures.Correlation analysis further demonstrates progressive graphitization during pyrolysis,with a significant positive correlation(R^(2)>0.85)observed between d002 and the full width at half maximum of the G-band(FWHM-G).
基金supported by the National Natural Science Foundation of China(51872145 and 12004192)Natural Science Foundation of Nanjing University of Posts and Telecommunications(NY224170)。
文摘Two-dimensional MXene Ti_(3)C_(2)T_(x)demonstrates great promise in perovskite solar cells(PSCs).Herein,sulfur-terminated Ti_(3)C_(2)T_(x)(S-Ti_(3)C_(2)T_(x))is developed by modifying Ti_(3)C_(2)T_(x)via a facile hydrothermal method using thioacetamide.As a perovskite additive,S-Ti_(3)C_(2)T_(x)outperforms pristine Ti_(3)C_(2)T_(x)by(1)significantly promoting grain growth,enhancing carrier mobility,and reducing defect density;(2)optimizing energy level alignment to lower interfacial energy barriers and minimize interface non-radiative recombination;(3)stabilizing uncoordinated Pb2+and[PbI6]4-octahedra via Pb-S bonds while alleviating bulk lattice strain,as this Pb-S interaction exerts a“tape-like”effect.Based on this synergistic mechanism,PSCs with S-Ti_(3)C_(2)T_(x)achieve a champion efficiency of 25.51%—outperforming control(23.46%)and pristine Ti_(3)C_(2)T_(x)-based devices(24.54%)—with enhanced stability.This work highlights terminal group engineering as a critical strategy for advancing high-performance PSCs and their potential for emerging photovoltaic technologies.
基金support from the Research Committee of The Hong Kong Polytechnic University(Project codes:RMJK and 4-ZZSJ)supported by a grant from the Research Grants Council of the Hong Kong Special Administrative Region,China(Project No.PolyU15212523).
文摘Additive manufacturing(AM),with its high flexibility,cost-effectiveness,and customization,significantly accelerates the advancement of nanogenerators,contributing to sustainable energy solutions and the Internet of Things.In this review,an in-depth analysis of AM for piezoelectric and triboelectric nanogenerators is presented from the perspectives of fundamental mechanisms,recent advancements,and future prospects.It highlights AM-enabled advantages of versatility across materials,structural topology optimization,microstructure design,and integrated printing,which enhance critical performance indicators of nanogenerators,such as surface charge density and piezoelectric constant,thereby improving device performance compared to conventional fabrication.Common AM techniques for nanogenerators,including fused deposition modeling,direct ink writing,stereolithography,and digital light processing,are systematically examined in terms of their working principles,improved metrics(output voltage/current,power density),theoretical explanation,and application scopes.Hierarchical relationships connecting AM technologies with performance optimization and applications of nanogenerators are elucidated,providing a solid foundation for advancements in energy harvesting,self-powered sensors,wearable devices,and human-machine interaction.Furthermore,the challenges related to fabrication quality,cross-scale manufacturing,processing efficiency,and industrial deployment are critically discussed.Finally,the future prospects of AM for nanogenerators are explored,aiming to foster continuous progress and innovation in this field.
基金support of the National Natural Science Foundation of China(No.52574411)Beijing Natural Science Foundation(No.2242043).
文摘Achieving high energy and power densities is currently a core challenge in the fabrication of energy storage materials.Although numerous high-capacity materials have been developed,conventional planar electrodes cannot achieve high active material loading and efficient ion/electron transport simultaneously.By contrast,three-dimensional(3D)structures have attracted increasing interest because of their capacity to enhance active material utilization,shorten ion and electron transport pathways,reduce interfacial impedance,and provide spatial accommodation for volume expansion.Additive manufacturing(AM)technology effectively fabricates energy-storage materials with 3D structures by accurately constructing complex 3D structures via layer-by-layer deposition.Recent studies have employed AM to construct ordered 3D electrodes that can optimize ion/electron transport,regulate electric field distribution,or improve the electrode-electrolyte interface,thereby contributing to enhanced kinetic performance and cycling stability.This review systematically summarizes the applications of several AM technologies in the fabrication of energy storage materials and analyzes their respective advantages and limitations.Subsequently,the advantages of AM technology in the fabrication of energy storage materials and several major optimization strategies are comprehensively discussed.Finally,the major challenges and potential applications of AM technology in energy storage material optimization are discussed.
基金supported by the Khalifa University of Science and Technology internal grants(Nos.2021-CIRA-109,2020-CIRA-007,and 2020-CIRA-024).
文摘Low-velocity impact tests are carried out to explore the energy absorption characteristics of bio-inspired lattices,mimicking the architecture of the marine sponge organism Euplectella aspergillum.These sea sponge-inspired lattice structures feature a square-grid 2D lattice with double diagonal bracings and are additively manufactured via digital light processing(DLP).The collapse strength and energy absorption capacity of sea sponge lattice structures are evaluated under various impact conditions and are compared to those of their constituent square-grid and double diagonal lattices.This study demonstrates that sea sponge lattices can achieve an 11-fold increase in energy absorption compared to the square-grid lattice,due to the stabilizing effect of the double diagonal bracings prompting the structure to collapse layer-bylayer under impact.By adjusting the thickness ratio in the sea sponge lattice,up to 76.7%increment in energy absorption is attained.It is also shown that sea-sponge lattices outperform well-established energy-absorbing materials of equal weight,such as hexagonal honeycombs,confirming their significant potential for impact mitigation.Additionally,this research highlights the enhancements in energy absorption achieved by adding a small amount(0.015 phr)of Multi-Walled Carbon Nanotubes(MWCNTs)to the photocurable resin,thus unlocking new possibilities for the design of innovative lightweight structures with multifunctional attributes.
基金supported by the National Natural Science Foundation of China(Nos.U21A20311 and 52400163).
文摘The high voltage of Li||LiCoO_(2) battery can increase the energy density.However,the cycling performance associated with cathode structural stability remains challenging.To address this question,we proposed an electrolyte strategy for improving the performance of 4.6 V Li||LiCoO_(2) battery by using trimethylsilyl isocyanate(TMIS)as electrolyte additive.The trimethylsilyl group of TMIS can trap HF while the isocyanate group brings polyamide components to the CEI and the SEI.By the synergistic action,the Co3+dissolution problem of the LiCoO_(2) cathode was effectively curbed.Furthermore,TMIS regulates the construction of anion-dominated LiF-rich SEI by influencing the solvation structure of Li+.As expected,the 4.6 V Li||LiCoO_(2) battery with TMIS retains 77.9% initial capacity after 200 cycles at 0.5 C.
基金financially supported and funded by the Deanship of Scientific Research at Imam Mohammad Ibn Saud Islamic University(IMSIU)(No.IMSIU-DDRSP2503)。
文摘Functionally graded cellular structures(FGCSs)have a multitude of applications to a wide range of industries.Utilising the ever-progressing technology of additive manufacturing(AM),FGCSs can be applied to control material grading and achieve the desired mechanical properties.The current study explores the design and optimisation of FGCSs for AM,with a focus on improving the compression and impact performance of below knee(BK)prosthetic limbs made of thermoplastic polyurethane(TPU).A multiscale research methodology integrating topology optimization(TO),finite element analysis(FEA),and design of experiments(Do E)was adopted to optimise lattice structures in terms of stiffness and lightweight properties.Two-unit cell designs were considered in the study:Schwarz P gyroid and body-centered cubic(BCC).Response surface methodology(RSM)was implemented to analyse the effect of minimum and maximum cell wall thickness,cell size,and unit cell type on the mechanical performance of TPU FGCS structures.The results indicated that a Schwarz P FGCS structure with cell size,minimum and maximum cell wall thickness of 6,0.9 and 2.8 mm,respectively,could be optimal for a compromise between performance and weight.In this optimized case,stiffness and volume fraction values of 684 N/mm and 0.64 were obtained,respectively.The study also presents a proof-of-concept design for a BK prosthetic damper,highlighting the potential of FGCSs to enhance patient comfort,reduce manufacturing costs,and enable personalised designs through 3D scanning and AM.The obtained results could be a step forward towards the incorporation of AM technologies in prosthetics,offering a pathway to lightweight,cost-effective,and functionally tailored solutions.
基金supported by the Shaanxi Provincial High level Talent Introduction Project(5113220044)the Shaanxi Outstanding Youth Project(2023-JC-JQ-33)+8 种基金the Youth Science and Technology Talent Promotion Project of Jiangsu Association for Science and Technology(TJ-2022-088)the Project funded by China Postdoctoral Science Foundation(2023TQ0273,2023TQ0274,2023M742833)the NationalNatural Science Foundation of China(62304181)the Natural Science Basic Research Program of Shaanxi(2023-JC-QN-0726,2025JC-YBQN-469)the GuangdongBasic and Applied Basic Research Foundation(2022A1515110286,2024A1515012538)the Basic Research Programs of Taicang(TC2024JC04)the Suzhou Science and Technology Development Plan Innovation Leading Talent Project(ZXL2023183)the Fundamental Research Funds for the Central Universities(G2022KY05108,G2024KY0605,G2023KY0601)and the Aeronautical Science Foundation of China(2018ZD53047).
文摘Achieving simultaneous enhancement of crystallinity and optimal domain size remains a fundamental challenge in organic photovoltaics(OPVs),where conventional crystallization strategies often trigger excessive aggregation of small-molecule acceptors.This work pioneers a kinetic paradigm for resolving the crystallinity-domain size trade-off in organic photovoltaics through dual-additive-guided stepwise crystallization.By strategically pairing 1,2-dichlorobenzene(o-DCB,low binding energy to Y6)and 1-fluoronaphthalene(FN,high binding energy),we achieve temporally decoupled crystallization control:o-DCB first mediates donor-acceptor co-crystallization during film formation,constructing a metastable network,whereupon FN induces confined Y6 crystallization within this framework during thermal annealing,refining nanostructure without over-aggregation.Morphology studies reveal that this synergy enhances crystallinity of(100)diffraction peaks by 21%–10%versus single-additive controls(o-DCB/FN alone),while maintaining optimal domain size.These morphological advantages yield balanced carrier transport(μh/μe=1.23),near-unity exciton dissociation(98.53%),and a champion power conversion efficiency(PCE)of 18.08%for PM6:Y6,significantly surpassing single-additive devices(o-DCB:17.20%;FN:17.53%).Crucially,the dual-additive strategy demonstrates universal applicability across diverse active layer systems,achieving an outstanding PCE of 19.27%in PM6:L8-BO-based devices,thereby establishing a general framework for morphology control in high-efficiency OPVs.
文摘Additive Manufacturing(AM)has significantly impacted the development of high-performance materials and structures,offering new possibilities for industries ranging from aerospace to biomedicine.This special issue features pioneering research that integrates AI-driven methods with AM,enabling the design and fabrication of complex,optimized structures with enhanced properties.
基金supported by the National Natural Science Foundation of China(Grant No:52475484)National Key R&D Program of China(Grant No:2022YFB4600800)the 2022 MTC Young Individual Research Grants(Grant No:M22K3c0097)under the Singapore RIE 2025 Plan.
文摘Additive manufacturing of aluminum(Al)alloys has attracted significant attention in the aerospace industry.However,achieving ultrahigh-strength(>500 MPa)Al alloys remains challenging due to their intrinsic poor printability.Here,we report a novel hybrid additive manufacturing(HAM)approach to process ultrahigh-strength AlMgSc alloy,which combines laser powder bed fusion(LPBF)with interlayer ultrasonic shot peening(USP).The results show that the interlayer ultrasonic shot peening depth reached∼700μm,leading to almost full density and residual stress convection from tension to compression.The HAM method promotes equiaxed grain formation and refines grain due to grain recrystallizations.Interestingly,the HAM followed by aging treatment tailors the hierarchically multi-gradient structures,inhibits Mg element intragranular segregation,and promotes the multi-nanoprecipitates(e.g.Al_(3)(Sc,Zr)and Al_(6)Mn)precipitation.Remarkably,the HAM followed by aging treatment achieves yield strength of 609 MPa and breaks elongation of 7.5%,demonstrating ultrahigh strength and good ductility compared with other Al alloys manufactured by AM and forging as reported in the literature.The strength enhancement mechanisms in this AlMgSc alloy are discussed.The high-density Al_(3)(Sc,Zr)precipitates are the main strengthening contributor,and unique hetero-deformation induced(HDI)strengthening(originates from the heterogeneous microstructures)further enhances the strength of the material.This work highlights a novel approach for processing complex-structured ultrahigh strength Al alloy components by hybrid additive manufacturing.
文摘Additive manufacturing(AM)has emerged as one of the most utilized processes in manufacturing due to its ability to produce complex geometries with minimal material waste and greater design freedom.Laser-based AM(LAM)technologies use high-power lasers to melt metallic materials,which then solidify to form parts.However,it inherently induces self-equilibrating residual stress during fabrication due to thermal loads and plastic deformation.These residual stresses can cause defects such as delamination,cracking,and distortion,as well as premature failure under service conditions,necessitating mitigation.While post-treatment methods can reduce residual stresses,they are often costly and time-consuming.Therefore,tuning the fabrication process parameters presents a more feasible approach.Accordingly,in addition to providing a comprehensive view of residual stress by their classification,formation mechanisms,measurement methods,and common post-treatment,this paper reviews and compares the studies conducted on the effect of key parameters of the LAM process on the resulting residual stresses.This review focuses on proactively adjusting LAM process parameters as a strategic approach to mitigate residual stress formation.It provides a result of the various parameters influencing residual stress outcomes,such as laser power,scanning speed,beam diameter,hatch spacing,and scanning strategies.Finally,the paper identifies existing research gaps and proposes future studies needed to deepen understanding of the relationship between process parameters and residual stress mitigation in LAM.
基金supported by the National Natu-ral Science Foundation of China(Nos.52071262,52301197,and 52234009)the National Key Research and Development Program(No.2022YFB3404203)+3 种基金the Natural Science Basic Research Pro-gram of Shaanxi Province,China(No.2023-JC-QN-0421)the Re-search Fund of the State Key Laboratory of Solidification Processing(NPU),China(Nos.2024-ZD-06 and 2024-TS-06)the Fundamental Research Funds for the Central Universities(No.D5000240144)the Young Talent Fund of Xi’an Association for Science and Tech-nology(No.959202413014).
文摘1.Introduction As one of the most widely used additive manufacturing(AM)techniques,selective laser melting(SLM)is a laser-based layer-by-layer manufacturing process,which has relatively high fabrication resolution and can directly form complex metal parts.During SLM,the interaction of laser with metal powder forms a tiny melt pool.Following the rapid movement of the laser,the cooling rate of the melt pool can be as high as 105-106 K s−1[1].Such a fast cool-ing rate inhibits grain growth and element segregation in the alloy,leading to a notable enhancement in strength and toughness[2].Therefore,SLM enables unlimited possibilities in the fabrication of complex parts with high performance.To date,the most extensively researched Al alloys for SLM are Al-Si alloys,such as AlSi10Mg,Al-12Si,and AlSi7Mg[2-5].
基金supported by the Science and Technology Development Fund(FDCT)of Macao SAR(No.0110/2023/AMJ)Innovation Support Plan,Hong Kong,Macao and Taiwan Science and Technology Cooperation Project of Jiangsu Province(No.BZ2022047)+1 种基金National Key Research and Development Program of China(2023YFE0205300)the Joint Fund of Ba-sic and Applied Basic Research Fund of Guangdong Province(No.2021B1515130009).
文摘An approach called hybrid heat-source solid-state additive manufacturing (HHSAM) for fabricating multilayer AA6061 deposition with superior properties is proposed in this paper. As compared with the traditional additive friction stir deposition (AFSD), the auxiliary induction heat-source in HHSAM effectively improves the temperature and fluidity of plastic flow, which facilitates the formation and enrichment of residual Mg_(2)Si phases besides Al(Fe,Mn)Si, promotes the dynamic recrystallization and increases the bonding strength between layers during the deposition process. Therefore, the HHSAM depositions possess a more uniform structure, superior integral mechanical properties and corrosion resistance after heat treatment process. Moreover, HHSAMed specimens avoid abnormal grain growth (AGG) in heat treatment process, which is regularly encountered in the traditional AFSD. HHSAM method is proved to be a new solid-state additive manufacturing method with good developing prospects for fabricating alloy production with excellent properties in a high-efficiency manner.
基金supported by the National Key Research and Development Program of China(No.2022YFB3404700)the National Natural Science Foundation of China(Nos.52105313 and 52275299)+2 种基金the Research and Development Program of Beijing Municipal Education Commission,China(No.KM202210005036)the Natural Science Foundation of Chongqing,China(No.CSTB2023NSCQ-MSX0701)the National Defense Basic Research Projects of China(No.JCKY2022405C002).
文摘At present,the emerging solid-phase friction-based additive manufacturing technology,including friction rolling additive man-ufacturing(FRAM),can only manufacture simple single-pass components.In this study,multi-layer multi-pass FRAM-deposited alumin-um alloy samples were successfully prepared using a non-shoulder tool head.The material flow behavior and microstructure of the over-lapped zone between adjacent layers and passes during multi-layer multi-pass FRAM deposition were studied using the hybrid 6061 and 5052 aluminum alloys.The results showed that a mechanical interlocking structure was formed between the adjacent layers and the adja-cent passes in the overlapped center area.Repeated friction and rolling of the tool head led to different degrees of lateral flow and plastic deformation of the materials in the overlapped zone,which made the recrystallization degree in the left and right edge zones of the over-lapped zone the highest,followed by the overlapped center zone and the non-overlapped zone.The tensile strength of the overlapped zone exceeded 90%of that of the single-pass deposition sample.It is proved that although there are uneven grooves on the surface of the over-lapping area during multi-layer and multi-pass deposition,they can be filled by the flow of materials during the deposition of the next lay-er,thus ensuring the dense microstructure and excellent mechanical properties of the overlapping area.The multi-layer multi-pass FRAM deposition overcomes the limitation of deposition width and lays the foundation for the future deposition of large-scale high-performance components.
基金supported by the National Natural Science Foundation of China-Distinguished Young Scholars(No.52325407)the National Natural Science Foundation of China-Key Program(No.52234010)the Open Research Fund of the State Key Laboratory of Rolling and Automation,Northeastern University(No.2022RALKFKT004).
文摘Laser additive manufacturing(LAM)has been widely used in high-end manufacturing fields such as aerospace,nuclear power,and shipbuilding.However,it is a grand challenge for direct and continuous observation of complex laser-matter interaction,melt flow,and defect formation during LAM due to extremely large temperature gradient,fast cooling rate,and small time(millisecond)and space(micron)scales.The emergence of synchrotron radiation provides a feasible approach for in situ observation of the LAM process.This paper outlines the current development in real-time characterization of LAM by synchrotron radiation,including laser-matter interaction,molten pool evolution,solidification structure evolution,and defects formation and elimination.Furthermore,the future development direction and application-oriented research are also discussed.
基金Savannah River National Laboratory(SRNL).SRNL is operated by Battelle Savannah River Alliance,LLC under Contract No 89303321CEM000080 for the US Department of Energy.
文摘AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries.Despite its popularity,the utilization of additively manufactured AA6061 through the laser powder bed fusion(LPBF)process has been hindered by the pronounced formation of pores and cracks during rapid solidification.This study quantitatively investigated defects,including pores and cracks,and microstructures,including texture,grain size,subgrain structure,and precipitates,of LPBF-manufactured AA6061 across a broad spectrum of laser power and speed combinations.A high relative density of more than 99%was achieved with a low-power and low-speed condition,specifically 200 W and 100 mm s−1,with minimal cracks.Large pores,akin to or exceeding melt pool dimensions,emerged under either low or high energy densities,driven by the lack of fusion and vaporization/denudation mechanisms,re-spectively.Solidification cracks,confirmed by the fractography,were propagated along grain boundaries and are highly dependent on laser scanning speed.Elevated power and speed exhibited finer grain size with refined subgrain cellular structures and increased precipitates at interdendritic regions.The cooling rate and thermal gradient estimated from thermal analytical solutions explain the microstructures’char-acteristics.Nano-sized Si-Fe-Mg enriched precipitates are confirmed in both as-built and heat-treated conditions,whereas T6 heat treatment promotes a uniform distribution with coarsening of those precipi-tates.The low-power and low-speed conditions demonstrated the highest yield strength,consistent with defect levels.A minimum of 102.3%increase in yield strength with reduced ductility was observed after heat treatment for all examined conditions.This work sheds light on printing parameters to mitigate the formation of pores and cracks in additively manufactured AA6061,proposing a process window for op-timized fabrication and highlighting the potential for enhanced material properties and reduced defects through process control.
