New materials and manufacturing technologies require applicable non-destructive techniques for quality assurance so as to achieve better performance.This study comprehensively investigated the effect of influencing fa...New materials and manufacturing technologies require applicable non-destructive techniques for quality assurance so as to achieve better performance.This study comprehensively investigated the effect of influencing factors includ-ing excitation frequency,lift-off distance,defect depth and size,residual heat,and surface roughness on the defect EC signals of an Inconel 738LC alloy produced by selective laser melting(SLM).The experimental investigations recorded the impedance amplitude and phase angle of EC signals for each defect to explore the feasibility of detecting sub-surface defects by merely analyzing these two key indicators.Overall,this study revealed preliminary qualitative and roughly quantitative relationships between influencing factors and corresponding EC signals,which provided a prac-tical reference on how to quantitively inspect subsurface defects using eddy current testing(ECT)on SLMed parts,and also made solid progress toward on-line ECT in additive/subtractive hybrid manufacturing(ASHM)for fabricating SLMed parts with enhanced quality and better performance.展开更多
Additive manufacturing(AM)processes are reliable techniques to build highly complex metallic parts.Direct energy deposition(DED)is one of the most common technologies to 3D print metal alloys.Despite a wide range of l...Additive manufacturing(AM)processes are reliable techniques to build highly complex metallic parts.Direct energy deposition(DED)is one of the most common technologies to 3D print metal alloys.Despite a wide range of literature that has discussed the ability of DED in metal printing,weak binding,poor accuracy,and rough surface still exist in final products.Thus,limitations in 3D printing of metal powder and wire indicate post-processing techniques required to achieve high quality in both mechanical properties and surface quality.Therefore,hybrid manufacturing(HM),specifically additive/subtractive hybrid manufacturing(ASHM)of DED has been proposed to enhance product quality.ASHM is a capable process that combines two technologies with 3-axis or multi-axis machines.Different methods have been suggested to increase the accuracy of machines to find better quality and microstructure.In contrast,drawbacks in ASHM still exist such as limitations in existing reliable materials and poor accuracy in machine coordination to avoid collision in the multi-axes machine.It should be noted that there is no review work with focuses on both DED and hybridization of DED processes.Thus,in this review work,a unique study of DED in comparison to ASHM as well as novel techniques are discussed with the objective of showing the capabilities of each process and the benefits of using them for different applications.Finally,new gaps are discussed in ASHM to enhance the layer bonding and surface quality with the processes'effects on microstructures and performance.展开更多
A reasonable process plan is an important basis for implementing wire arc additive and subtractive hybrid manufacturing(ASHM),and a new optimization method is proposed.Firstly,the target parts and machining tools are ...A reasonable process plan is an important basis for implementing wire arc additive and subtractive hybrid manufacturing(ASHM),and a new optimization method is proposed.Firstly,the target parts and machining tools are modeled by level set functions.Secondly,the mathematical model of the additive direction optimization problem is established,and an improved particle swarm optimization algorithm is designed to decide the best additive direction.Then,the two-step strategy is used to plan the hybrid manufacturing alternating sequence.The target parts are directly divided into various processing regions;each processing region is optimized based on manufacturability and manufacturing efficiency,and the optimal hybrid manufacturing alternating sequence is obtained by merging some processing regions.Finally,the method is used to outline the process plan of the designed example model and applied to the actual hybrid manufacturing process of the model.The manufacturing result shows that the method can meet the main considerations in hybrid manufacturing.In addition,the degree of automation of process planning is high,and the dependence on manual intervention is low.展开更多
Black wings of butterfly Ornithoptera goliath and infrared-band radiative cooling function of Rapala dioetas butterfly wings are associated with black pigment(e.g.,melanin)and unique hierarchical micro/nanostructures,...Black wings of butterfly Ornithoptera goliath and infrared-band radiative cooling function of Rapala dioetas butterfly wings are associated with black pigment(e.g.,melanin)and unique hierarchical micro/nanostructures,greatly stimulating biomimetic fabrication of functional photonic structures but mainly targeted to one prototype.Targeted at two-prototype integrated biomimetic fabrication from fully compositional/structural/functional aspects,femtosecond(fs)laser subtractive/additive-integrated hierarchical micro/nano-manufacturing technique is proposed in this work.This technique can one-step transfer refractory metals(e.g.,W,Mo,Nb,Ta)into black non-stoichiometric oxide nanomaterials with abundant oxygen vacancies and simultaneously enable the realization of in situ quasi-controllable micro/nanoscale hierarchical aggregation and assembly,all displaying black color but with tunable infrared emission.Adjusting the scan interval for biomimetic manufacturing can tailor the structural oxidation degree,the emission in the long-wave infrared(LWIR)band while keeping the blackness of hierarchical aggregates,and the confined height between the covering quartz plate and the ablated sample.The blackening efficiency of this technique can reach∼11.25 cm^(2)·min^(−1),opening opportunities for high-throughput optical/thermal applications.Selectively patterned Chinese characters,Arabic numbers,and English letters are easily fabricable,which are intrinsically invisible-infrared dual-band encrypted but decryptable via static/dynamic environment stimuli(e.g.,sample heating/cooling,introducing external hot/cold sources including human hands).The self-evolution from‘orderless’structuring to‘ordered’functionalization is validated for the proposed fs laser subtractive/additive-integrated biomimetic manufacturing,specifically from the synthesis of diverse black nanomaterials and the seemingly disordered micro/nano-aggregates to the ordered optical/thermal regulation capacities for a delicate modulation of information encryption and decryption,unveiling a new concept for future exploration and extension.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
As the demand for high voltage, high power inverters are increasing and there is a problem of connecting a power semiconductor switch directly to a high voltage network. As a part of this the multilevel inverters had ...As the demand for high voltage, high power inverters are increasing and there is a problem of connecting a power semiconductor switch directly to a high voltage network. As a part of this the multilevel inverters had been introduced. As a part of this, several researches had been done for the development of multilevel inverters. The commercially available and extensively studied topologies for multilevel voltage output are Neutral Point Clamped (NPC), Cascaded Half Bridge (CHB) and Flying Capacitor (FC) converters. However, with these existing topologies, there is a significant increase in the number of power switches and passive components. Thus it leads to more complex control circuitry and overall cost of the system increase with increase in the output levels. In this paper, a novel multilevel inverter is proposed in which it employs additive and subtractive topology to get higher output levels. This approach significantly reduces the number of power switches needed as compared to existing topology. The present developed multilevel inverter can generate only five voltage levels. With this proposed topology the multilevel inverter can be modified to nine-level inverter. Moreover modified hybrid multicarrier Pulse Width Modulation (PWM) technique can be implemented in the proposed multilevel inverter in order to obtain uniform switch utilization and lower THD. An appropriate modulation scheme is presented and also the proposed concept is analyzed through simulation studies.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
SiC is a wave-absorbing material with good dielectric properties,high-temperature resistance,and corrosion resistance,which has great potential for development in the field of high-temperature wave-absorbing.However,S...SiC is a wave-absorbing material with good dielectric properties,high-temperature resistance,and corrosion resistance,which has great potential for development in the field of high-temperature wave-absorbing.However,SiC is limited by its low impedance-matching performance and single wave-absorbing mechanism.Therefore,compatible metamaterial technologies are required to enhance its wave-absorbing performance further.The electromagnetic wave(EMW)absorbing metamaterials can realize perfect absorption of EMWs in specific frequency bands and precise regulation of EMW phase,propagation mode,and absorption frequency bands through structural changes.However,the traditional molding methods for manufacturing complex geometric shapes require expensive molds,involve process complexity,and have poor molding accuracy and other limitations.Therefore,additive manufacturing(AM)technology,through material layered stacking to achieve the processing of materials,is a comprehensive multidisciplinary advanced manufacturing technology and has become the core technology for manufacturing metamaterials.This review introduces the principles and applications of different AM technologies for SiC and related materials,discusses the current status and development trends of various AM technologies for fabricating silicon-carbon-based wave-absorbing metamaterials,summarizes the limitations and technological shortcomings of existing AM technologies for fabricating silicon-carbon-based wave-absorbing metamaterials,and provides an outlook for the future development of related AM technologies.展开更多
In this review,we propose a comprehensive overview of additive manufacturing(AM)technologies and design possibilities in manufacturing metamaterials for various applications in the biomedical field,of which many are i...In this review,we propose a comprehensive overview of additive manufacturing(AM)technologies and design possibilities in manufacturing metamaterials for various applications in the biomedical field,of which many are inspired by nature itself.It describes how new AM technologies(e.g.continuous liquid interface production and multiphoton polymerization,etc)and recent developments in more mature AM technologies(e.g.powder bed fusion,stereolithography,and extrusion-based bioprinting(EBB),etc)lead to more precise,efficient,and personalized biomedical components.EBB is a revolutionary topic creating intricate models with remarkable mechanical compatibility of metamaterials,for instance,stress elimination for tissue engineering and regenerative medicine,negative or zero Poisson’s ratio.By exploiting the designs of porous structures(e.g.truss,triply periodic minimal surface,plant/animal-inspired,and functionally graded lattices,etc),AM-made bioactive bone implants,artificial tissues,and organs are made for tissue replacement.The material palette of the AM metamaterials has high diversity nowadays,ranging from alloys and metals(e.g.cobalt-chromium alloys and titanium,etc)to polymers(e.g.biodegradable polycaprolactone and polymethyl methacrylate,etc),which could be even integrated within bioactive ceramics.These advancements are driving the progress of the biomedical field,improving human health and quality of life.展开更多
1.Introduction.Cold Spray(CS)is a highly advanced solid-state metal depo-sition process that was first developed in the 1980s.This innovative technique involves the high-speed(300-1200 m/s)impact deposition of micron-...1.Introduction.Cold Spray(CS)is a highly advanced solid-state metal depo-sition process that was first developed in the 1980s.This innovative technique involves the high-speed(300-1200 m/s)impact deposition of micron-sized particles(5-50μm)to fabricate coatings[1-3].CS has been extensively used in a variety of coating applications,such as aerospace,automotive,energy,medical,marine,and others,to provide protection against high temperatures,corrosion,erosion,oxidation,and chemicals[4,5].Nowadays,the technical interest in CS is twofold:(i)as a repair process for damaged components,and(ii)as a solid-state additive manufacturing process.Compared to other fusion-based additive manufacturing(AM)technologies,Cold Spray Additive Manufacturing(CSAM)is a new member of the AM family that can enable the fabrication of deposits without undergoing melting.The chemical composition has been largely preserved from the powder to the deposit due to the minimal oxidation.The significant advantages of CSAM over other additive manufacturing processes include a high production rate,unlimited deposition size,high flexibility,and suitability for repairing damaged parts.展开更多
Gas quenching and vacuum quenching process are widely applied to accelerate solvent volatilization to induce nucleation of perovskites in blade-coating method.In this work,we found these two pre-crystallization proces...Gas quenching and vacuum quenching process are widely applied to accelerate solvent volatilization to induce nucleation of perovskites in blade-coating method.In this work,we found these two pre-crystallization processes lead to different order of crystallization dynamics within the perovskite thin film,resulting in the differences of additive distribution.We then tailor-designed an additive molecule named 1,3-bis(4-methoxyphenyl)thiourea to obtain films with fewer defects and holes at the buried interface,and prepared perovskite solar cells with a certified efficiency of 23.75%.Furthermore,this work also demonstrates an efficiency of 20.18%for the large-area perovskite solar module(PSM)with an aperture area of 60.84 cm^(2).The PSM possesses remarkable continuous operation stability for maximum power point tracking of T_(90)>1000 h in ambient air.展开更多
Friction rolling additive manufacturing(FRAM)is a solid-state additive manufacturing technology that plasticizes the feed and deposits a material using frictional heat generated by the tool head.The thermal efficiency...Friction rolling additive manufacturing(FRAM)is a solid-state additive manufacturing technology that plasticizes the feed and deposits a material using frictional heat generated by the tool head.The thermal efficiency of FRAM,which depends only on friction to generate heat,is low,and the thermal-accumulation effect of the deposition process must be addressed.An FRAM heat-balance-control method that combines plasma-arc preheating and instant water cooling(PC-FRAM)is devised in this study,and a temperature field featuring rapidly increasing and decreasing temperature is constructed around the tool head.Additionally,2195-T87 Al-Li alloy is used as the feed material,and the effects of heating and cooling rates on the microstructure and mechanical properties are investigated.The results show that water cooling significantly improves heat accumulation during the deposition process.The cooling rate increases by 11.7 times,and the high-temperature residence time decreases by more than 50%.The grain size of the PC-FRAM sample is the smallest,i.e.,3.77±1.03μm,its dislocation density is the highest,and the number density of precipitates is the highest,the size of precipitates is the smallest,which shows the best precipitation-strengthening effect.The hardness test results are consistent with the precipitation distribution.The ultimate tensile strength,yield strength and elongation of the PC-FRAM samples are the highest(351±15.6 MPa,251.3±15.8 MPa and 16.25%±1.25%,respectively)among the samples investigated.The preheating and water-cooling-assisted deposition simultaneously increases the tensile strength and elongation of the deposited samples.The combination of preheating and instant cooling improves the deposition efficiency of FRAM and weakens the thermal-softening effect.展开更多
The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully ci...The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully circumvent defects in Ti-6Al-4V deposits for LAAM_(p) and LAAM_(w),respectively.With the optimized process parameters,robust interfaces were achieved between powder/wire deposits and the forged substrate,as well as between powder and wire deposits.Microstructure characterization results revealed the epitaxial prior β grains in the deposited Ti-6Al-4V,wherein the powder deposit was dominated by a finerα′microstructure and the wire deposit was characterized by lamellar α phases.The mechanisms of microstructure formation and correlation with mechanical behavior were analyzed and discussed.The mechanical properties of the interfacial samples can meet the requirements of the relevant Aerospace Material Specifications(AMS 6932)even without post heat treatment.No fracture occurred within the interfacial area,further suggesting the robust interface.The findings of this study highlighted the feasibility of combining LAAM_(p) and LAAM_(w) in the direct manufacturing of Ti-6Al-4V parts in accordance with the required dimensional resolution and deposition rate,together with sound strength and ductility balance in the as-built condition.展开更多
To tackle the common issue of green defects in material extrusion(MEX)additive manufacturing(AM)cemented carbides,warm isostatic pressing(WIP)was introduced to eliminate defects of MEX WC-9Co cemented carbide greens,t...To tackle the common issue of green defects in material extrusion(MEX)additive manufacturing(AM)cemented carbides,warm isostatic pressing(WIP)was introduced to eliminate defects of MEX WC-9Co cemented carbide greens,thereby improving both microstructure uniformity and mechanical properties of sintered bodies.The results indicate that WIP reduces defects in MEX greens,thus decreasing the dimensions and numbers of defects,modifying shapes of pores within sintered bodies,while preserving surface quality and shape characteristics.Compared with WC-9Co prepared via MEX followed by debinding and sintering(DS),the hardness of WC-9Co prepared using MEX-WIP-DS does not change significantly,ranging HV_(30)1494-1508,the transverse rupture strength increases by up to 49.3%,reaching 2998-3514 MPa,and the fracture toughness remains high,ranging 14.8-17.0 MPa·m^(1/2).The mechanical properties surpass comparable cemented carbides fabricated through other AM methods and are comparable to those produced by powder metallurgy.The integration of green WIP into MEX-DS broadens the MEX processing window,and improves the overall mechanical properties of MEX AM WC-Co cemented carbides.展开更多
Metal Additive Manufacturing(MAM) technology has become an important means of rapid prototyping precision manufacturing of special high dynamic heterogeneous complex parts. In response to the micromechanical defects s...Metal Additive Manufacturing(MAM) technology has become an important means of rapid prototyping precision manufacturing of special high dynamic heterogeneous complex parts. In response to the micromechanical defects such as porosity issues, significant deformation, surface cracks, and challenging control of surface morphology encountered during the selective laser melting(SLM) additive manufacturing(AM) process of specialized Micro Electromechanical System(MEMS) components, multiparameter optimization and micro powder melt pool/macro-scale mechanical properties control simulation of specialized components are conducted. The optimal parameters obtained through highprecision preparation and machining of components and static/high dynamic verification are: laser power of 110 W, laser speed of 600 mm/s, laser diameter of 75 μm, and scanning spacing of 50 μm. The density of the subordinate components under this reference can reach 99.15%, the surface hardness can reach 51.9 HRA, the yield strength can reach 550 MPa, the maximum machining error of the components is 4.73%, and the average surface roughness is 0.45 μm. Through dynamic hammering and high dynamic firing verification, SLM components meet the requirements for overload resistance. The results have proven that MEM technology can provide a new means for the processing of MEMS components applied in high dynamic environments. The parameters obtained in the conclusion can provide a design basis for the additive preparation of MEMS components.展开更多
Increasing environmental concerns about limiting harmful emissions has necessitated sulfur-and phosphorus-free green lubricant additives.Although boron-containing compounds have been widely investigated as green lubri...Increasing environmental concerns about limiting harmful emissions has necessitated sulfur-and phosphorus-free green lubricant additives.Although boron-containing compounds have been widely investigated as green lubricant additives,their macromolecular analogs have been rarely considered yet to develop environmentally friendly lubricant additives.In this work,a series of boron-containing copolymers have been synthesized by free-radical copolymerization of stearyl methacrylate and isopropenyl boronic acid pinacol ester with different feeding ratios(S_(n)-r-B_(m),n=1,m=1/3,1,2,3,5,9).The resulting copolymers of S_(n)-r-B_(m)(n=1,m=1/3,1,2,3,5)are readily dispersed in the PAO-10 base oil and form micelle-like aggregates with hydrodynamic diameters ranging from 9.7 to 52 nm.SRV-IV oscillating reciprocating tribological tests on ball-on-flat steel pairs show that compared with the base oil of PAO-10,the friction coefficients and wear volumes of the base oil solutions of S_(n)-r-B_(m)decrease considerably up to 62%and 97%,respectively.Moreover,the base oil solution of S_(1)-r-B_(1)exhibits an excellent load-bearing capacity of(850±100)N.These superior lubricating properties are due to the formation of protective tribofilms comprising S_(n)-r-B_(m),boron oxide,and iron oxide compounds on the lubricated steel surface.Therefore,the boron-containing copolymers can be regarded as a novel class of environmentally friendly lubricating oil macroadditives for efficient friction and wear reduction without sulfur and phosphorus elements.展开更多
The functionally graded materials(FGMs)are obtained by various processes.Although a few FGMs are obtained naturally,such as oyster,pearl,and bamboo,additive manufacturing(AM),known as 3D printing,is a net-shaped manuf...The functionally graded materials(FGMs)are obtained by various processes.Although a few FGMs are obtained naturally,such as oyster,pearl,and bamboo,additive manufacturing(AM),known as 3D printing,is a net-shaped manufacturing process employed to manufacture complex 3D objects without tools,molds,assembly,and joining.Currently,commercial AM techniques mostly use homogeneous composition with simplified geometric descriptions,employing a single material across the entire component to achieve functional graded additive manufacturing(FGAM),in contrast to multi-material FGAM with heterogeneous structures.FGMs are widely used in various fields due to their mechanical property advantages.Because FGM plays a significant role in the industrial production,the characteristics and mechanical behaviour of FGMs prepared by AM were reviewed.In this review,the research on FGMs and AM over the past 30 years was reviewed,suggesting that future researchers should focus on the application of artificial intelligence and machine learning technologies in industry to optimize the process parameters of different gradient systems.展开更多
To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and l...To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.展开更多
Fiber-reinforced composites are an ideal material for the lightweight design of aerospace structures. Especially in recent years, with the rapid development of composite additive manufacturing technology, the design o...Fiber-reinforced composites are an ideal material for the lightweight design of aerospace structures. Especially in recent years, with the rapid development of composite additive manufacturing technology, the design optimization of variable stiffness of fiber-reinforced composite laminates has attracted widespread attention from scholars and industry. In these aerospace composite structures, numerous cutout panels and shells serve as access points for maintaining electrical, fuel, and hydraulic systems. The traditional fiber-reinforced composite laminate subtractive drilling manufacturing inevitably faces the problems of interlayer delamination, fiber fracture, and burr of the laminate. Continuous fiber additive manufacturing technology offers the potential for integrated design optimization and manufacturing with high structural performance. Considering the integration of design and manufacturability in continuous fiber additive manufacturing, the paper proposes linear and nonlinear filtering strategies based on the Normal Distribution Fiber Optimization (NDFO) material interpolation scheme to overcome the challenge of discrete fiber optimization results, which are difficult to apply directly to continuous fiber additive manufacturing. With minimizing structural compliance as the objective function, the proposed approach provides a strategy to achieve continuity of discrete fiber paths in the variable stiffness design optimization of composite laminates with regular and irregular holes. In the variable stiffness design optimization model, the number of candidate fiber laying angles in the NDFO material interpolation scheme is considered as design variable. The sensitivity information of structural compliance with respect to the number of candidate fiber laying angles is obtained using the analytical sensitivity analysis method. Based on the proposed variable stiffness design optimization method for complex perforated composite laminates, the numerical examples consider the variable stiffness design optimization of typical non-perforated and perforated composite laminates with circular, square, and irregular holes, and systematically discuss the number of candidate discrete fiber laying angles, discrete fiber continuous filtering strategies, and filter radius on structural compliance, continuity, and manufacturability. The optimized discrete fiber angles of variable stiffness laminates are converted into continuous fiber laying paths using a streamlined process for continuous fiber additive manufacturing. Meanwhile, the optimized non-perforated and perforated MBB beams after discrete fiber continuous treatment, are manufactured using continuous fiber co-extrusion additive manufacturing technology to verify the effectiveness of the variable stiffness fiber optimization framework proposed in this paper.展开更多
基金Supported by Basic Research Project of Science and Technology Plan of Shenzhen(Grant No.JCYJ20170817111811303).
文摘New materials and manufacturing technologies require applicable non-destructive techniques for quality assurance so as to achieve better performance.This study comprehensively investigated the effect of influencing factors includ-ing excitation frequency,lift-off distance,defect depth and size,residual heat,and surface roughness on the defect EC signals of an Inconel 738LC alloy produced by selective laser melting(SLM).The experimental investigations recorded the impedance amplitude and phase angle of EC signals for each defect to explore the feasibility of detecting sub-surface defects by merely analyzing these two key indicators.Overall,this study revealed preliminary qualitative and roughly quantitative relationships between influencing factors and corresponding EC signals,which provided a prac-tical reference on how to quantitively inspect subsurface defects using eddy current testing(ECT)on SLMed parts,and also made solid progress toward on-line ECT in additive/subtractive hybrid manufacturing(ASHM)for fabricating SLMed parts with enhanced quality and better performance.
文摘Additive manufacturing(AM)processes are reliable techniques to build highly complex metallic parts.Direct energy deposition(DED)is one of the most common technologies to 3D print metal alloys.Despite a wide range of literature that has discussed the ability of DED in metal printing,weak binding,poor accuracy,and rough surface still exist in final products.Thus,limitations in 3D printing of metal powder and wire indicate post-processing techniques required to achieve high quality in both mechanical properties and surface quality.Therefore,hybrid manufacturing(HM),specifically additive/subtractive hybrid manufacturing(ASHM)of DED has been proposed to enhance product quality.ASHM is a capable process that combines two technologies with 3-axis or multi-axis machines.Different methods have been suggested to increase the accuracy of machines to find better quality and microstructure.In contrast,drawbacks in ASHM still exist such as limitations in existing reliable materials and poor accuracy in machine coordination to avoid collision in the multi-axes machine.It should be noted that there is no review work with focuses on both DED and hybridization of DED processes.Thus,in this review work,a unique study of DED in comparison to ASHM as well as novel techniques are discussed with the objective of showing the capabilities of each process and the benefits of using them for different applications.Finally,new gaps are discussed in ASHM to enhance the layer bonding and surface quality with the processes'effects on microstructures and performance.
基金The National Natural Science Foundation of China(No.52305381)the Natural Science Foundation of Jiangsu Province(No.BK20210351)the Fundamental Research Funds for the Central Universities(No.30923011008).
文摘A reasonable process plan is an important basis for implementing wire arc additive and subtractive hybrid manufacturing(ASHM),and a new optimization method is proposed.Firstly,the target parts and machining tools are modeled by level set functions.Secondly,the mathematical model of the additive direction optimization problem is established,and an improved particle swarm optimization algorithm is designed to decide the best additive direction.Then,the two-step strategy is used to plan the hybrid manufacturing alternating sequence.The target parts are directly divided into various processing regions;each processing region is optimized based on manufacturability and manufacturing efficiency,and the optimal hybrid manufacturing alternating sequence is obtained by merging some processing regions.Finally,the method is used to outline the process plan of the designed example model and applied to the actual hybrid manufacturing process of the model.The manufacturing result shows that the method can meet the main considerations in hybrid manufacturing.In addition,the degree of automation of process planning is high,and the dependence on manual intervention is low.
基金financially supported by Shanghai Pujiang Program 23PJ1406500.
文摘Black wings of butterfly Ornithoptera goliath and infrared-band radiative cooling function of Rapala dioetas butterfly wings are associated with black pigment(e.g.,melanin)and unique hierarchical micro/nanostructures,greatly stimulating biomimetic fabrication of functional photonic structures but mainly targeted to one prototype.Targeted at two-prototype integrated biomimetic fabrication from fully compositional/structural/functional aspects,femtosecond(fs)laser subtractive/additive-integrated hierarchical micro/nano-manufacturing technique is proposed in this work.This technique can one-step transfer refractory metals(e.g.,W,Mo,Nb,Ta)into black non-stoichiometric oxide nanomaterials with abundant oxygen vacancies and simultaneously enable the realization of in situ quasi-controllable micro/nanoscale hierarchical aggregation and assembly,all displaying black color but with tunable infrared emission.Adjusting the scan interval for biomimetic manufacturing can tailor the structural oxidation degree,the emission in the long-wave infrared(LWIR)band while keeping the blackness of hierarchical aggregates,and the confined height between the covering quartz plate and the ablated sample.The blackening efficiency of this technique can reach∼11.25 cm^(2)·min^(−1),opening opportunities for high-throughput optical/thermal applications.Selectively patterned Chinese characters,Arabic numbers,and English letters are easily fabricable,which are intrinsically invisible-infrared dual-band encrypted but decryptable via static/dynamic environment stimuli(e.g.,sample heating/cooling,introducing external hot/cold sources including human hands).The self-evolution from‘orderless’structuring to‘ordered’functionalization is validated for the proposed fs laser subtractive/additive-integrated biomimetic manufacturing,specifically from the synthesis of diverse black nanomaterials and the seemingly disordered micro/nano-aggregates to the ordered optical/thermal regulation capacities for a delicate modulation of information encryption and decryption,unveiling a new concept for future exploration and extension.
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.
文摘As the demand for high voltage, high power inverters are increasing and there is a problem of connecting a power semiconductor switch directly to a high voltage network. As a part of this the multilevel inverters had been introduced. As a part of this, several researches had been done for the development of multilevel inverters. The commercially available and extensively studied topologies for multilevel voltage output are Neutral Point Clamped (NPC), Cascaded Half Bridge (CHB) and Flying Capacitor (FC) converters. However, with these existing topologies, there is a significant increase in the number of power switches and passive components. Thus it leads to more complex control circuitry and overall cost of the system increase with increase in the output levels. In this paper, a novel multilevel inverter is proposed in which it employs additive and subtractive topology to get higher output levels. This approach significantly reduces the number of power switches needed as compared to existing topology. The present developed multilevel inverter can generate only five voltage levels. With this proposed topology the multilevel inverter can be modified to nine-level inverter. Moreover modified hybrid multicarrier Pulse Width Modulation (PWM) technique can be implemented in the proposed multilevel inverter in order to obtain uniform switch utilization and lower THD. An appropriate modulation scheme is presented and also the proposed concept is analyzed through simulation studies.
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supported by National Natural Science Foundation of China(Grant No.U2006218)Project of Construction and Support for High-Level Innovative Teams of Beijing Municipal Institutions(Grant No.BPHR20220124).
文摘SiC is a wave-absorbing material with good dielectric properties,high-temperature resistance,and corrosion resistance,which has great potential for development in the field of high-temperature wave-absorbing.However,SiC is limited by its low impedance-matching performance and single wave-absorbing mechanism.Therefore,compatible metamaterial technologies are required to enhance its wave-absorbing performance further.The electromagnetic wave(EMW)absorbing metamaterials can realize perfect absorption of EMWs in specific frequency bands and precise regulation of EMW phase,propagation mode,and absorption frequency bands through structural changes.However,the traditional molding methods for manufacturing complex geometric shapes require expensive molds,involve process complexity,and have poor molding accuracy and other limitations.Therefore,additive manufacturing(AM)technology,through material layered stacking to achieve the processing of materials,is a comprehensive multidisciplinary advanced manufacturing technology and has become the core technology for manufacturing metamaterials.This review introduces the principles and applications of different AM technologies for SiC and related materials,discusses the current status and development trends of various AM technologies for fabricating silicon-carbon-based wave-absorbing metamaterials,summarizes the limitations and technological shortcomings of existing AM technologies for fabricating silicon-carbon-based wave-absorbing metamaterials,and provides an outlook for the future development of related AM technologies.
基金sponsored by the Science and Technology Program of Hubei Province,China(2022EHB020,2023BBB096)support provided by Centre of the Excellence in Production Research(XPRES)at KTH。
文摘In this review,we propose a comprehensive overview of additive manufacturing(AM)technologies and design possibilities in manufacturing metamaterials for various applications in the biomedical field,of which many are inspired by nature itself.It describes how new AM technologies(e.g.continuous liquid interface production and multiphoton polymerization,etc)and recent developments in more mature AM technologies(e.g.powder bed fusion,stereolithography,and extrusion-based bioprinting(EBB),etc)lead to more precise,efficient,and personalized biomedical components.EBB is a revolutionary topic creating intricate models with remarkable mechanical compatibility of metamaterials,for instance,stress elimination for tissue engineering and regenerative medicine,negative or zero Poisson’s ratio.By exploiting the designs of porous structures(e.g.truss,triply periodic minimal surface,plant/animal-inspired,and functionally graded lattices,etc),AM-made bioactive bone implants,artificial tissues,and organs are made for tissue replacement.The material palette of the AM metamaterials has high diversity nowadays,ranging from alloys and metals(e.g.cobalt-chromium alloys and titanium,etc)to polymers(e.g.biodegradable polycaprolactone and polymethyl methacrylate,etc),which could be even integrated within bioactive ceramics.These advancements are driving the progress of the biomedical field,improving human health and quality of life.
基金supported by the National Natural Science Foundation of China(No.52061135101 and 52001078)the German Research Foundation(DFG,No.448318292)+3 种基金the Technology Innovation Guidance Special Foundation of Shaanxi Province(No.2023GXLH-085)the Fundamental Research Funds for the Central Universities(No.D5000240161)the Project of Key areas of innovation team in Shaanxi Province(No.2024RS-CXTD-20)The author Yingchun Xie thanks the support from the National Key R&D Program(No.2023YFE0108000).
文摘1.Introduction.Cold Spray(CS)is a highly advanced solid-state metal depo-sition process that was first developed in the 1980s.This innovative technique involves the high-speed(300-1200 m/s)impact deposition of micron-sized particles(5-50μm)to fabricate coatings[1-3].CS has been extensively used in a variety of coating applications,such as aerospace,automotive,energy,medical,marine,and others,to provide protection against high temperatures,corrosion,erosion,oxidation,and chemicals[4,5].Nowadays,the technical interest in CS is twofold:(i)as a repair process for damaged components,and(ii)as a solid-state additive manufacturing process.Compared to other fusion-based additive manufacturing(AM)technologies,Cold Spray Additive Manufacturing(CSAM)is a new member of the AM family that can enable the fabrication of deposits without undergoing melting.The chemical composition has been largely preserved from the powder to the deposit due to the minimal oxidation.The significant advantages of CSAM over other additive manufacturing processes include a high production rate,unlimited deposition size,high flexibility,and suitability for repairing damaged parts.
基金supported by National Natural Science Foundation of China(62104082)Guangdong Basic and Applied Basic Research Foundation(2022A1515010746,2022A1515011228,and 2022B1515120006)the Science and Technology Program of Guangzhou(202201010458).
文摘Gas quenching and vacuum quenching process are widely applied to accelerate solvent volatilization to induce nucleation of perovskites in blade-coating method.In this work,we found these two pre-crystallization processes lead to different order of crystallization dynamics within the perovskite thin film,resulting in the differences of additive distribution.We then tailor-designed an additive molecule named 1,3-bis(4-methoxyphenyl)thiourea to obtain films with fewer defects and holes at the buried interface,and prepared perovskite solar cells with a certified efficiency of 23.75%.Furthermore,this work also demonstrates an efficiency of 20.18%for the large-area perovskite solar module(PSM)with an aperture area of 60.84 cm^(2).The PSM possesses remarkable continuous operation stability for maximum power point tracking of T_(90)>1000 h in ambient air.
基金supported by the National Natural Science Foundation of China(Nos.52275299,52105313)R&D Program of Beijing Municipal Education Commission(No.KM202210005036)+1 种基金Natural Science Foundation of Chongqing,China(No.CSTB2023NSCQ-MSX0701)National Defense Basic Research Projects of China(No.JCKY2022405C002).
文摘Friction rolling additive manufacturing(FRAM)is a solid-state additive manufacturing technology that plasticizes the feed and deposits a material using frictional heat generated by the tool head.The thermal efficiency of FRAM,which depends only on friction to generate heat,is low,and the thermal-accumulation effect of the deposition process must be addressed.An FRAM heat-balance-control method that combines plasma-arc preheating and instant water cooling(PC-FRAM)is devised in this study,and a temperature field featuring rapidly increasing and decreasing temperature is constructed around the tool head.Additionally,2195-T87 Al-Li alloy is used as the feed material,and the effects of heating and cooling rates on the microstructure and mechanical properties are investigated.The results show that water cooling significantly improves heat accumulation during the deposition process.The cooling rate increases by 11.7 times,and the high-temperature residence time decreases by more than 50%.The grain size of the PC-FRAM sample is the smallest,i.e.,3.77±1.03μm,its dislocation density is the highest,and the number density of precipitates is the highest,the size of precipitates is the smallest,which shows the best precipitation-strengthening effect.The hardness test results are consistent with the precipitation distribution.The ultimate tensile strength,yield strength and elongation of the PC-FRAM samples are the highest(351±15.6 MPa,251.3±15.8 MPa and 16.25%±1.25%,respectively)among the samples investigated.The preheating and water-cooling-assisted deposition simultaneously increases the tensile strength and elongation of the deposited samples.The combination of preheating and instant cooling improves the deposition efficiency of FRAM and weakens the thermal-softening effect.
基金financially supported by the Agency for Science,Technology and Research(A*Star),Republic of Singapore,under the Aerospace Consortium Cycle 12“Characterization of the Effect of Wire and Powder Deposited Materials”(No.A1815a0078)。
文摘The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully circumvent defects in Ti-6Al-4V deposits for LAAM_(p) and LAAM_(w),respectively.With the optimized process parameters,robust interfaces were achieved between powder/wire deposits and the forged substrate,as well as between powder and wire deposits.Microstructure characterization results revealed the epitaxial prior β grains in the deposited Ti-6Al-4V,wherein the powder deposit was dominated by a finerα′microstructure and the wire deposit was characterized by lamellar α phases.The mechanisms of microstructure formation and correlation with mechanical behavior were analyzed and discussed.The mechanical properties of the interfacial samples can meet the requirements of the relevant Aerospace Material Specifications(AMS 6932)even without post heat treatment.No fracture occurred within the interfacial area,further suggesting the robust interface.The findings of this study highlighted the feasibility of combining LAAM_(p) and LAAM_(w) in the direct manufacturing of Ti-6Al-4V parts in accordance with the required dimensional resolution and deposition rate,together with sound strength and ductility balance in the as-built condition.
基金supported by the Key Project of Chinese Academy of Engineering(No.2019-XZ-11)the General Project of Chinese Academy of Engineering(No.2023-XY-18)+1 种基金the Open Fund of National Joint Engineering Research Center for Abrasion Control and Molding of Metal Materials of China(No.HKDNM201907)the Independent Project of State Key Laboratory of Powder Metallurgy,China。
文摘To tackle the common issue of green defects in material extrusion(MEX)additive manufacturing(AM)cemented carbides,warm isostatic pressing(WIP)was introduced to eliminate defects of MEX WC-9Co cemented carbide greens,thereby improving both microstructure uniformity and mechanical properties of sintered bodies.The results indicate that WIP reduces defects in MEX greens,thus decreasing the dimensions and numbers of defects,modifying shapes of pores within sintered bodies,while preserving surface quality and shape characteristics.Compared with WC-9Co prepared via MEX followed by debinding and sintering(DS),the hardness of WC-9Co prepared using MEX-WIP-DS does not change significantly,ranging HV_(30)1494-1508,the transverse rupture strength increases by up to 49.3%,reaching 2998-3514 MPa,and the fracture toughness remains high,ranging 14.8-17.0 MPa·m^(1/2).The mechanical properties surpass comparable cemented carbides fabricated through other AM methods and are comparable to those produced by powder metallurgy.The integration of green WIP into MEX-DS broadens the MEX processing window,and improves the overall mechanical properties of MEX AM WC-Co cemented carbides.
基金funded by the National Natural Science Foundation of China Youth Fund(Grant No.62304022)Science and Technology on Electromechanical Dynamic Control Laboratory(China,Grant No.6142601012304)the 2022e2024 China Association for Science and Technology Innovation Integration Association Youth Talent Support Project(Grant No.2022QNRC001).
文摘Metal Additive Manufacturing(MAM) technology has become an important means of rapid prototyping precision manufacturing of special high dynamic heterogeneous complex parts. In response to the micromechanical defects such as porosity issues, significant deformation, surface cracks, and challenging control of surface morphology encountered during the selective laser melting(SLM) additive manufacturing(AM) process of specialized Micro Electromechanical System(MEMS) components, multiparameter optimization and micro powder melt pool/macro-scale mechanical properties control simulation of specialized components are conducted. The optimal parameters obtained through highprecision preparation and machining of components and static/high dynamic verification are: laser power of 110 W, laser speed of 600 mm/s, laser diameter of 75 μm, and scanning spacing of 50 μm. The density of the subordinate components under this reference can reach 99.15%, the surface hardness can reach 51.9 HRA, the yield strength can reach 550 MPa, the maximum machining error of the components is 4.73%, and the average surface roughness is 0.45 μm. Through dynamic hammering and high dynamic firing verification, SLM components meet the requirements for overload resistance. The results have proven that MEM technology can provide a new means for the processing of MEMS components applied in high dynamic environments. The parameters obtained in the conclusion can provide a design basis for the additive preparation of MEMS components.
文摘Increasing environmental concerns about limiting harmful emissions has necessitated sulfur-and phosphorus-free green lubricant additives.Although boron-containing compounds have been widely investigated as green lubricant additives,their macromolecular analogs have been rarely considered yet to develop environmentally friendly lubricant additives.In this work,a series of boron-containing copolymers have been synthesized by free-radical copolymerization of stearyl methacrylate and isopropenyl boronic acid pinacol ester with different feeding ratios(S_(n)-r-B_(m),n=1,m=1/3,1,2,3,5,9).The resulting copolymers of S_(n)-r-B_(m)(n=1,m=1/3,1,2,3,5)are readily dispersed in the PAO-10 base oil and form micelle-like aggregates with hydrodynamic diameters ranging from 9.7 to 52 nm.SRV-IV oscillating reciprocating tribological tests on ball-on-flat steel pairs show that compared with the base oil of PAO-10,the friction coefficients and wear volumes of the base oil solutions of S_(n)-r-B_(m)decrease considerably up to 62%and 97%,respectively.Moreover,the base oil solution of S_(1)-r-B_(1)exhibits an excellent load-bearing capacity of(850±100)N.These superior lubricating properties are due to the formation of protective tribofilms comprising S_(n)-r-B_(m),boron oxide,and iron oxide compounds on the lubricated steel surface.Therefore,the boron-containing copolymers can be regarded as a novel class of environmentally friendly lubricating oil macroadditives for efficient friction and wear reduction without sulfur and phosphorus elements.
文摘The functionally graded materials(FGMs)are obtained by various processes.Although a few FGMs are obtained naturally,such as oyster,pearl,and bamboo,additive manufacturing(AM),known as 3D printing,is a net-shaped manufacturing process employed to manufacture complex 3D objects without tools,molds,assembly,and joining.Currently,commercial AM techniques mostly use homogeneous composition with simplified geometric descriptions,employing a single material across the entire component to achieve functional graded additive manufacturing(FGAM),in contrast to multi-material FGAM with heterogeneous structures.FGMs are widely used in various fields due to their mechanical property advantages.Because FGM plays a significant role in the industrial production,the characteristics and mechanical behaviour of FGMs prepared by AM were reviewed.In this review,the research on FGMs and AM over the past 30 years was reviewed,suggesting that future researchers should focus on the application of artificial intelligence and machine learning technologies in industry to optimize the process parameters of different gradient systems.
基金Shaanxi Province Qin Chuangyuan“Scientist+Engineer”Team Construction Project(2022KXJ-071)2022 Qin Chuangyuan Achievement Transformation Incubation Capacity Improvement Project(2022JH-ZHFHTS-0012)+1 种基金Shaanxi Province Key Research and Development Plan-“Two Chains”Integration Key Project-Qin Chuangyuan General Window Industrial Cluster Project(2023QCY-LL-02)Xixian New Area Science and Technology Plan(2022-YXYJ-003,2022-XXCY-010)。
文摘To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.
基金supports for this research were provided by the National Natural Science Foundation of China(No.12272301,12002278,U1906233)the Guangdong Basic and Applied Basic Research Foundation,China(Nos.2023A1515011970,2024A1515010256)+1 种基金the Dalian City Supports Innovation and Entrepreneurship Projects for High-Level Talents,China(2021RD16)the Key R&D Project of CSCEC,China(No.CSCEC-2020-Z-4).
文摘Fiber-reinforced composites are an ideal material for the lightweight design of aerospace structures. Especially in recent years, with the rapid development of composite additive manufacturing technology, the design optimization of variable stiffness of fiber-reinforced composite laminates has attracted widespread attention from scholars and industry. In these aerospace composite structures, numerous cutout panels and shells serve as access points for maintaining electrical, fuel, and hydraulic systems. The traditional fiber-reinforced composite laminate subtractive drilling manufacturing inevitably faces the problems of interlayer delamination, fiber fracture, and burr of the laminate. Continuous fiber additive manufacturing technology offers the potential for integrated design optimization and manufacturing with high structural performance. Considering the integration of design and manufacturability in continuous fiber additive manufacturing, the paper proposes linear and nonlinear filtering strategies based on the Normal Distribution Fiber Optimization (NDFO) material interpolation scheme to overcome the challenge of discrete fiber optimization results, which are difficult to apply directly to continuous fiber additive manufacturing. With minimizing structural compliance as the objective function, the proposed approach provides a strategy to achieve continuity of discrete fiber paths in the variable stiffness design optimization of composite laminates with regular and irregular holes. In the variable stiffness design optimization model, the number of candidate fiber laying angles in the NDFO material interpolation scheme is considered as design variable. The sensitivity information of structural compliance with respect to the number of candidate fiber laying angles is obtained using the analytical sensitivity analysis method. Based on the proposed variable stiffness design optimization method for complex perforated composite laminates, the numerical examples consider the variable stiffness design optimization of typical non-perforated and perforated composite laminates with circular, square, and irregular holes, and systematically discuss the number of candidate discrete fiber laying angles, discrete fiber continuous filtering strategies, and filter radius on structural compliance, continuity, and manufacturability. The optimized discrete fiber angles of variable stiffness laminates are converted into continuous fiber laying paths using a streamlined process for continuous fiber additive manufacturing. Meanwhile, the optimized non-perforated and perforated MBB beams after discrete fiber continuous treatment, are manufactured using continuous fiber co-extrusion additive manufacturing technology to verify the effectiveness of the variable stiffness fiber optimization framework proposed in this paper.
