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
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
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
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
Due to the safety,high energy density,and rapid charging feature,aqueous zinc-ion batteries(AZIBs)have attracted great attention in large-scale energy storage systems.Although excellent electrochemical performances ha...Due to the safety,high energy density,and rapid charging feature,aqueous zinc-ion batteries(AZIBs)have attracted great attention in large-scale energy storage systems.Although excellent electrochemical performances have been achieved,the cycling stabilities of AZIBs are still unsatisfactory,especially at low current densities,because the cathode materials are prone to being dissolved into electrolytes.Here we develop a unique zincophilic and hydrophobic amorphous additive of ZnSnO_(3)(ZSO),which effectively prevents the irreversible dissolution and deamination of NH_(4)V_(4)O_(10)(NVO)cathode.Benefiting from the ingenious design,NVO@ZSO cathode delivers the best cycling stability at a low current density(0.1 A·g^(-1)),with an ultrahigh capacity retention of 98.8% after 300 cycles.Besides,at a high current density of 5 A·g^(-1),the NVO@ZSO cathode still possesses excellent cycling performance,and a reversible capacity of 284.6 mAh·g^(-1)is achieved even after 7000 cycles.The mechanism is clarified with the aid of density function theory calculations and molecular dynamics simulations.These findings provide a new paradigm for designing stable cathodes by introducing amorphous additive,which should promote further application exploration of AZIBs at low current densities.展开更多
Although their cost-effectiveness and intrinsic safety,aqueous zinc-ion batteries suffer from notorious side reactions including hydrogen evolution reaction,Zn corrosion and passivation,and Zn dendrite formation on th...Although their cost-effectiveness and intrinsic safety,aqueous zinc-ion batteries suffer from notorious side reactions including hydrogen evolution reaction,Zn corrosion and passivation,and Zn dendrite formation on the anode.Despite numerous strategies to alleviate these side reactions have been demonstrated,they can only provide limited performance improvement from a single aspect.Herein,a triple-functional additive with trace amounts,ammonium hydroxide,was demonstrated to comprehensively protect zinc anodes.The results show that the shift of electrolyte pH from 4.1 to 5.2 lowers the HER potential and encourages the in situ formation of a uniform ZHS-based solid electrolyte interphase on Zn anodes.Moreover,cationic NH^(4+)can preferentially adsorb on the Zn anode surface to shield the“tip effect”and homogenize the electric field.Benefitting from this comprehensive protection,dendrite-free Zn deposition and highly reversible Zn plating/stripping behaviors were realized.Besides,improved electrochemical performances can also be achieved in Zn//MnO_(2)full cells by taking the advantages of this triple-functional additive.This work provides a new strategy for stabilizing Zn anodes from a comprehensive perspective.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
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
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
Many strategies have been proposed to produce arenes from lignin as liquid fuel additives.However,the development of these methods is limited by the low yield of products,low atom utilization,and inefficient lignin de...Many strategies have been proposed to produce arenes from lignin as liquid fuel additives.However,the development of these methods is limited by the low yield of products,low atom utilization,and inefficient lignin depolymerization.Herein,we develop an energy-efficient synthetic method for the production of high-carbon-number arenes from sustainable lignin with a total yield of 23.1 wt%.Particularly,high carbon number arenes are obtained by fully utilizing the formaldehyde stabilizing additive and the methoxy group in lignin.The process begins with the reductive depolymerization of formaldehyde-stabilized lignin,followed by transmethylation between lignin monomers over Au/Nb_(2)O_(5) catalyst,and the Ru/Nb2O5-catalyzed hydrodeoxygenation.This work demonstrates the potential of value-added arenes production directly from lignin.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
Co-precipitation strengthening of the L1_(2)nano-particles along with hard intermetallic phases,including L2_(1),B2,σandη,demonstrates significant potential for the development of advanced CoCrFeNi high-entropy allo...Co-precipitation strengthening of the L1_(2)nano-particles along with hard intermetallic phases,including L2_(1),B2,σandη,demonstrates significant potential for the development of advanced CoCrFeNi high-entropy alloys(HEAs)with favorable strength-ductility balances.Understanding the alloying effect of Al and Ti on the formation and stability of these intermetallic phases in the CoCrFeNi HEAs is crucial for efficiently exploring the multi-component space for future alloy designs.In the present work,stepwise compositionally graded CoCrFeNi-AlTi HEAs comprising 35 different compositions were fabricated using high-throughput additive manufacturing(AM)and analyzed through a suite of localized characterization techniques.Our analysis confirmed the existence of two primary solid solution phases,face-centered cubic(FCC)and body-centered cubic(BCC),as well as four distinct intermetallic phases,which include L1_(2),L2_(1),σandη.By overlapping the zero phase fraction(ZPF)lines of these phases,the pseudo-ternary phase diagram of the multi-component CoCrFeNi-AlTi system at 800℃was determined,demonstrating good agreement with the literature results.Furthermore,the composition-dependent microstructural evolution and Vickers hardness(HV)were also established,providing numerous opportunities to design CoCrFeNi-AlTi HEAs with superior microstructure stability and balanced strength-ductility properties for structural applications at elevated temperatures.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
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
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
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
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
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
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
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.U24A2055 and 92164103)the National Key R&D Program of China(No.2021YFA1200800)+2 种基金the Natural Science Foundation of Hubei Province(No.2024AFA052)Wuhan Science and Technology Bureau(Knowledge Innovation Program of Wuhan-Basic Research,No.2023010201010067)the Fundamental Research Funds for the Central Universities(No.2042023kf0187).
文摘Due to the safety,high energy density,and rapid charging feature,aqueous zinc-ion batteries(AZIBs)have attracted great attention in large-scale energy storage systems.Although excellent electrochemical performances have been achieved,the cycling stabilities of AZIBs are still unsatisfactory,especially at low current densities,because the cathode materials are prone to being dissolved into electrolytes.Here we develop a unique zincophilic and hydrophobic amorphous additive of ZnSnO_(3)(ZSO),which effectively prevents the irreversible dissolution and deamination of NH_(4)V_(4)O_(10)(NVO)cathode.Benefiting from the ingenious design,NVO@ZSO cathode delivers the best cycling stability at a low current density(0.1 A·g^(-1)),with an ultrahigh capacity retention of 98.8% after 300 cycles.Besides,at a high current density of 5 A·g^(-1),the NVO@ZSO cathode still possesses excellent cycling performance,and a reversible capacity of 284.6 mAh·g^(-1)is achieved even after 7000 cycles.The mechanism is clarified with the aid of density function theory calculations and molecular dynamics simulations.These findings provide a new paradigm for designing stable cathodes by introducing amorphous additive,which should promote further application exploration of AZIBs at low current densities.
基金supported by the National Key Research and Development Program of China(2019YFE0114400)the Guangdong Basic and Applied Basic Research Foundation(2021B1515120005)+7 种基金the National Natural Science Foundation of China(32171721)the Guangdong Basic and Applied Basic Research Foundation(2021B151512000)the Guangzhou Science and Technology Plan Project(202102020262)the State Key Laboratory of Pulp&Paper Engineering(2022C01),the State Key Laboratory of Pulp&Paper Engineering(202208)the Engineering and Physical Sciences Research Council(EPSRCEP/V027433/1EP/V027433/2EP/Y008707/1)。
文摘Although their cost-effectiveness and intrinsic safety,aqueous zinc-ion batteries suffer from notorious side reactions including hydrogen evolution reaction,Zn corrosion and passivation,and Zn dendrite formation on the anode.Despite numerous strategies to alleviate these side reactions have been demonstrated,they can only provide limited performance improvement from a single aspect.Herein,a triple-functional additive with trace amounts,ammonium hydroxide,was demonstrated to comprehensively protect zinc anodes.The results show that the shift of electrolyte pH from 4.1 to 5.2 lowers the HER potential and encourages the in situ formation of a uniform ZHS-based solid electrolyte interphase on Zn anodes.Moreover,cationic NH^(4+)can preferentially adsorb on the Zn anode surface to shield the“tip effect”and homogenize the electric field.Benefitting from this comprehensive protection,dendrite-free Zn deposition and highly reversible Zn plating/stripping behaviors were realized.Besides,improved electrochemical performances can also be achieved in Zn//MnO_(2)full cells by taking the advantages of this triple-functional additive.This work provides a new strategy for stabilizing Zn anodes from a comprehensive perspective.
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.
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.
文摘Many strategies have been proposed to produce arenes from lignin as liquid fuel additives.However,the development of these methods is limited by the low yield of products,low atom utilization,and inefficient lignin depolymerization.Herein,we develop an energy-efficient synthetic method for the production of high-carbon-number arenes from sustainable lignin with a total yield of 23.1 wt%.Particularly,high carbon number arenes are obtained by fully utilizing the formaldehyde stabilizing additive and the methoxy group in lignin.The process begins with the reductive depolymerization of formaldehyde-stabilized lignin,followed by transmethylation between lignin monomers over Au/Nb_(2)O_(5) catalyst,and the Ru/Nb2O5-catalyzed hydrodeoxygenation.This work demonstrates the potential of value-added arenes production directly from lignin.
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 Taishan Scholars Program of Shandong Province(Nos.tsqn201909081,tsqn202211115,and tsqn202306162)Shandong Natural Science Foundation of China(Nos.ZR2021QE102,ZR2020ZD05,and ZR2022ME067)+1 种基金the Science Foundation Program for Distinguished Young Scholars(Overseas)of Shandong Province(No.2022HWYQ-084)the Talent Training Program for Shandong Province Higher Educational Youth Innovative Teams(2021).
文摘Co-precipitation strengthening of the L1_(2)nano-particles along with hard intermetallic phases,including L2_(1),B2,σandη,demonstrates significant potential for the development of advanced CoCrFeNi high-entropy alloys(HEAs)with favorable strength-ductility balances.Understanding the alloying effect of Al and Ti on the formation and stability of these intermetallic phases in the CoCrFeNi HEAs is crucial for efficiently exploring the multi-component space for future alloy designs.In the present work,stepwise compositionally graded CoCrFeNi-AlTi HEAs comprising 35 different compositions were fabricated using high-throughput additive manufacturing(AM)and analyzed through a suite of localized characterization techniques.Our analysis confirmed the existence of two primary solid solution phases,face-centered cubic(FCC)and body-centered cubic(BCC),as well as four distinct intermetallic phases,which include L1_(2),L2_(1),σandη.By overlapping the zero phase fraction(ZPF)lines of these phases,the pseudo-ternary phase diagram of the multi-component CoCrFeNi-AlTi system at 800℃was determined,demonstrating good agreement with the literature results.Furthermore,the composition-dependent microstructural evolution and Vickers hardness(HV)were also established,providing numerous opportunities to design CoCrFeNi-AlTi HEAs with superior microstructure stability and balanced strength-ductility properties for structural applications at elevated temperatures.
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.
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.
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.
