Metal 3D Printing Research Articles

3D printing of continuous metal fiber-reinforced recycled ABS with varying fiber loading

PurposeThe current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique.Design/methodology/approachRecycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed.FindingsUpon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (Lmax), flexural stress at maximum load (sfmax), flex modulus (Ef) and work of fracture (WOF), compression modulus (Ec) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively.Originality/valueLimited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

Analytical realization of complex thermal meta-devices

Fourier’s law dictates that heat flows from warm to cold. Nevertheless, devices can be tailored to cloak obstacles or even reverse the heat flow. Mathematical transformation yields closed-form equations for graded, highly anisotropic thermal metamaterial distributions needed for obtaining such functionalities. For simple geometries, devices can be realized by regular conductor distributions; however, for complex geometries, physical realizations have so far been challenging, and sub-optimal solutions have been obtained by expensive numerical approaches. Here we suggest a straightforward and highly efficient analytical de-homogenization approach that uses optimal multi-rank laminates to provide closed-form solutions for any imaginable thermal manipulation device. We create thermal cloaks, rotators, and concentrators in complex domains with close-to-optimal performance and esthetic elegance. The devices are fabricated using metal 3D printing, and their omnidirectional thermal functionalities are investigated numerically and validated experimentally. The analytical approach enables next-generation free-form thermal meta-devices with efficient synthesis, near-optimal performance, and concise patterns.

Volume-Metallization 3D-Printed Polymer Composites.

3D printing polymer or metal can achieve complicated structures while lacking multifunctional performance. Combined printing of polymer and metal is desirable and challenging due to their insurmountable mismatch in melting-point temperatures. Here, a novel volume-metallization 3D-printed polymer composite (VMPC) with bicontinuous phases for enabling coupled structure and function, which are prepared by infilling low-melting-point metal (LM) to controllable porous configuration is reported. Based on vacuum-assisted low-pressure conditions, LM is guided by atmospheric pressure action and overcomes surface tension to spread along the printed polymer pore channel, enabling the complete filling saturation of porous structures for enhanced tensile strength (up to 35.41MPa), thermal (up to 25.29Wm-1K-1) and electrical (>106Sm-1) conductivities. The designed 3D-printed microstructure-oriented can achieve synergistic anisotropy in mechanics (1.67), thermal (27.2), and electrical (>1012) conductivities. VMPC multifunction is demonstrated, including customized 3D electronics with elevated strength, electromagnetic wave-guided transport and signal amplification, heat dissipation device for chip temperature control, and storage components for thermoelectric generator energy conversion with light-heat-electricity.

Microstructure and corrosion behaviour of structural steel fabricated by wire arc additive manufacturing (WAAM)

Wire arc additive manufacturing (WAAM) is a metal 3D printing technique that allows large-scale elements to be built in a relatively timely and cost-effective manner, well suited to the cost-sensitive construction sector. Despite the potential of this novel technology, the basic properties of WAAM materials remain elusive. This paper presents a comparative study on the microstructure and corrosion behaviour of WAAM steel plates and the conventionally rolled Q345 steel. The WAAM steel exhibited comparable corrosion performance to the conventionally-produced steel within twelve days exposure in 3.5 wt% NaCl solution, including the corrosion current density, and the characteristics of steel/concrete interface, determined through electrochemical impedance spectroscopy (EIS) analysis. Post-corrosion observations revealed that preferential dissolution occurred at (Si, Mn)-rich oxide inclusions, in addition to the general corrosion of surrounding steel matrix. The much higher content of Si and Mn element in the feedstock material WAAM steel resulted in slightly higher susceptibility to localised corrosion, compared to the Q345 rolled steel.

Numerical investigation and design methods of the local buckling of WAAM stainless steel circular hollow section stub columns

3D printing is an advanced technology that has been used in biomedical and automotive engineering, and has raised a significant response in civil engineering. Wire and arc additive manufacturing (WAAM), a metal 3D printing technology, has prospective applications in steel construction because it can fabricate large-scale structural members at an acceptable cost and manufacturing efficiency. Fundamental studies are still urgently needed to realize its engineering application. However, due to the irregular geometric features, limited studies on the structural performance of WAAM components, particularly the numerical studies, have been carried out. To this end, a numerical investigation on the local buckling of WAAM stainless steel circular hollow section (CHS) stub columns under axial compression has been conducted and presented herein. The finite element (FE) models were established and validated against the existing experimental research. Parametric studies were subsequently carried out to broaden the cross-sectional resistance data pool using the developed FE models. The applicability of the cross-section design provisions specified in EN 1993-1-4:2006 + A2:2020, ANSI/AISC 370-21 and the continuous strength method (CSM) for the design of WAAM CHS was evaluated according to the experimental and FE results. Furthermore, a modified design method with improved accuracy was suggested.

Spectral Behavior of Fiber Bragg Gratings during Embedding in 3D-Printed Metal Tensile Coupons and Cyclic Loading.

Additive manufacturing (AM) enables the spatially configurable 3D integration of sensors in metal components to realize smart materials and structures. Outstanding sensing capabilities and size compatibility have made fiber optic sensors excellent candidates for integration in AM components. In this study, fiber Bragg grating (FBG) sensors were embedded in Inconel 718 tensile coupons printed using laser powder bed fusion AM. On-axis (fiber runs through the coupon's center of axis) and off-axis (fiber is at 5° and 10° to the coupon's center of axis) sensors were buried in epoxy resin inside narrow channels that run through the coupons. FBGs' spectral evolutions during embedment in the coupons were examined and cyclic loading experiments were conducted to analyze and evaluate the sensor integration process, complex strain loading, process flaws, and sensing performance. This study also demonstrates that the AM process-born deficiencies such as poor surface finish and staircase effects can be detrimental to the embedded sensors and their sensing performance.

A Simple Method to Manufacture a Force Sensor Array Based on a Single-Material 3D-Printed Piezoresistive Foam and Metal Coating.

Nowadays, 3D printing is becoming an increasingly common option for the manufacturing of sensors, primarily due to its capacity to produce intricate geometric shapes. However, a significant challenge persists in integrating multiple materials during printing, for various reasons. In this study, we propose a straightforward approach that combines 3D printing with metal coating to create an array of resistive force sensors from a single material. The core concept involves printing a sensing element using a conductive material and subsequently separating it into distinct parts using metal-coated lines connected to the electrical ground. This post-printing separation process involves manual intervention utilizing a stencil and metallic spray. The primary obstacle lies in establishing a sufficient contact surface between the sprayed metal and the structure, to ensure effective isolation among different zones. To address this challenge, we suggest employing a lattice structure to augment the contact surface area. Through experimental validation, we demonstrate the feasibility of fabricating two sensing elements from a single-material 3D-printed structure, with a maximum electrical isolation ratio between the sensors of above 30. These findings hold promise for the development of a new generation of low-tech 3D-printed force/displacement sensor arrays.

Properties Enhancement of Metal Additive Manufactured Part via Cold Deformation Process

Wire-arc additive manufacturing is a method of 3D printing metal using welding techniques. However, due to heat, the mechanical properties of the deposited material may be affected. Various methods have been proposed to mechanically improve the properties. In this study, cold deformation was introduced to enhance the properties. The effects of a few parameters, including welding speed, wire feed rate, heat input, thickness ratio, and types of material, were studied. Based on the result, the hardness, tensile, and wear properties of the manufactured part improved, while other properties, like impact toughness, had a lower value. Based on the preliminary result, cold deformation shows potential alternatives for part repair or reconstruction of worn or broken parts.

An in vitro evaluation of bond strength and failure behavior between 3D-printed cobalt-chromium alloy and different types of denture base resins

ObjectivesThis study aimed to evaluate the shear bond strength and failure behavior between cobalt-chromium (Co-Cr) alloy and different types of denture base resins (DBRs) over time. MethodsSeventy-two disk-shaped specimens (8 mm in diameter and 2 mm in thickness) were manufactured using a selective laser melting technology-based metal 3D printer. Three types of DBRs were used: heat-cure (HEA group), cold-cure (COL group), and 3D-printable (TDP group) DBRs (n = 12 per group). Each DBR specimen was fabricated as a 5 mm × 5 mm × 5 mm cube model. The specimens of the TDP group were manufactured using a digital light processing technology-based 3D printer. Half of the DBRs were stored in distilled water at 37 °C for 24 h, whereas the remaining half underwent thermocycling for 10,000 cycles. Shear bond strength was measured using a universal testing machine; failure modes were observed, and metal surfaces were evaluated using energy dispersive spectrometry. ResultsThe shear bond strength did not differ between the DBR types within the non-thermocycled groups. Contrarily, the TDP group exhibited inferior strength compared to the HEA group (P = 0.008) after thermocycling. All three types of DBRs exhibited a significant decrease in the shear bond strength and an increased tendency toward adhesive failure after thermocycling. ConclusionsThe bond strength between 3D-printable DBRs and Co-Cr alloy was comparable to that of heat-and cold-cure DBRs before thermocycling. However, it exhibited a considerable weakening in comparison to heat-cure DBRs after simulated short-term use. Clinical SignificanceThe application of 3D-printable DBR in metal framework-incorporated removable partial dentures may be feasible during the early phase of the treatment. However, its application is currently limited because the bond strength between the 3D-printable DBR and metal may weaken after short-term use. Further studies on methods to increase the bond strength between these heterogeneous materials are required.

A microchip gas chromatography column assembly with a 3D metal printing micro column oven and a flexible stainless-steel column

In this work, a microchip gas chromatography (GC) column assembly utilizing a three-dimensional (3D) printed micro oven and a flexible stainless steel capillary column was developed. The assembly's performance and separation capabilities were characterized. The key components include a 3D printed aluminum plate (7.50 × 7.50 × 0.16 cm) with a 3-meter-long circular spiral channel, serving as the oven, and the column coiled on the channel with an inner diameter of 320 μm and a stationary phase of OV-1. A heating ceramic plate was affixed on the opposite side of the plate. The assembly weighed 40.3 g. The design allows for easy disassembly, or stacking of heating devices and columns, enabling flexibility in adjusting column length. When using n-C13 as the test analyte at 140 °C, a retention factor (k) was 8.5, and 7797 plates (2599 plates/m) were obtained. The assembly, employing resistance heating, demonstrated effective separation performance for samples containing alkanes, aromatics, alcohols and ketones, with good reproducibility. The reduction in theoretical plates compared to oven heating was only 2.95 %. In the boiling point range of C6 to C18, rapid temperature programming (120 °C/min) was achieved with a power consumption of 119.512 W. The assembly was successfully employed to separate benzene series compounds, gasoline and volatile organic compounds (VOCs), demonstrating excellent separation performance. This innovative design addresses the challenges of the complexity and low repeatability of the fabrication process and the high cost associated with microchip columns. Furthermore, its versatility makes it suitable for outdoor analysis applications.

Colloidal carbon soot templated TiO2/Ag surface functionalized 3D printed metal brushes as new generation surface enhanced Raman scattering substrates

This present work demonstrated the functional transformation of 3D printed metal substrates into a new family of Surface-enhanced Raman Scattering substrates, a promising approach in developing SERS-based Point-of-care (PoC) analytical platforms. l-Powder Bed Fusion (l-PBF, Additive manufacturing or 3D printing technique) printed metal substrates have rough surfaces, and exhibit high thermal stability and intrinsic chemical inertness, necessitating a suitable surface functionalization approach. This present work demonstrated a unique multi-stage approach to transform l-PBF printed metal structures as recyclable SERS substrates by colloidal carbon templating, chemical vapor deposition, and electroless plating methods sequentially. The surface of the printed metal structures was functionalized using the colloidal carbon soot particles, that were formed by the eucalyptus oil flame deposition method. These carbon particles were shown to interact with the metals present in the printed structures by forming metal carbides and function as an adlayer on the surface. Subsequent deposition of TiO2 onto these templates led to strong grafting of TiO2 and retaining the fractal structure of the soot template onto the metal surface. Electroless deposition of silver nanoparticles resulted in the formation of fractally structured TiO2/Ag nanostructures and these functionalized printed metal structures were shown as excellent SERS substrates in enhancing the vibrational spectral features of Rhodamine B (RhB). The presence of TiO2 photocatalyst on the surface was shown to remove the RhB analyte from the surface under photochemical conditions, which enables the regeneration of SERS activity, and the substrate can be recycled. The migration of metals from the printed metal structures into the fractally ordered TiO2/Ag nanostructures was found to enhance the photocatalytic activity and increase the recyclability of these substrates. This study demonstrates the potential of 3D-printed Inconel metal substrates as next-generation recyclable SERS platforms, offering a substantial advancement over traditional colloidal, thin-film, flexible, and hard SERS substrates.

Comparison of Novel 3D-printed Stepped Porous Metal Cones and Metaphyseal Sleeves for Reconstruction of Severe Knee Bone Defects: Short-term Clinical Outcomes.

Both porous metal cones and metaphyseal sleeves are excellent implants for reconstructing severe bone defects in the knee joint, but they both exhibit design limitations. The porous metal cone, especially, has significant room for improvement in its shape design. The existing porous metal cones often feature a conical external surface with a relatively small taper, potentially compromising both rotational and axial stability. To improve both axial and rotational stability in porous metal cones, we developed a 3D-printed stepped porous metal cone. This study aimed to assess the short-term clinical outcome of the 3D-printed stepped porous metal cone and to compare it with the clinical outcome of patients who underwent revision total knee arthroplasty (rTKA) with the metaphyseal sleeves during the same period. Patients who underwent total knee arthroplasty revision with metaphyseal bone defect reconstruction from 2019 to 2021 were retrospectively analyzed. A total of 61 patients were enrolled in the study, including 15 patients using 3D-printed stepped porous metal cones and 46 patients using metaphyseal metal sleeves. Thirty patients using metaphyseal sleeves were screened by propensity score matching method and compared with those using stepped cones. Analysis included the American Knee Society Score, the Hospital for Special Surgery knee score, the Western Ontario and McMaster Universities Arthritis index, the Short Form 12 (SF-12) health survey, and radiographic assessment with a mean follow-up of 28.5 ± 8.3 months. To conduct comparative analyses, unpaired Student's t-tests were employed for continuous variables, while categorical variables were analyzed using the appropriate Fisher exact or chi-squared test. In this study, the survival rates of both the stepped cone and metaphyseal sleeve were 100%. There was no statistically significant difference in postoperative knee function scores between the two groups (p > 0.05). However, patients in the cone group had significantly higher mental component summary scores on the SF-12 scale (p < 0.05) and higher increases in mean postoperative physical component summary scores than patients in the sleeve group (p < 0.05). In addition, patients in the cone group experienced fewer intraoperative and postoperative complications compared to the sleeve group. The 3D-printed stepped porous metal cone can effectively reconstruct bone defects in complex rTKA and provide satisfactory early clinical and radiographic results. The 3D-printed stepped cone provides a more stable structure similar to the sleeve while maintaining the original benefits of the cone making it a promising choice for rTKA.

CdTe XG-Cam: A new high-resolution x-ray and gamma-ray camera for studies of the pharmacokinetics of radiopharmaceuticals in small animals.

The recent emergence of targeted radionuclide therapy has increased the demand for imagers capable of visualizing pharmacokinetics in developing radiopharmaceuticals in the preclinical phase. Some radionuclides emit hard x-rays and gamma-rays below 100 keV, in which energy range the performance of conventional NaI scintillators is poor. Multipinhole collimators are also used for small animal imaging with a good spatial resolution but have a limited field of view (FOV). In this study, a new imager with high sensitivity over a wide FOV in the low-energy band ( 100 keV) was developed for the pharmacokineticstudy. We developed an x-ray and gamma-ray camera for high-resolution spectroscopy, named "CdTe XG-Cam," equipped with a cadmium telluride semiconductor detector and a parallel-hole collimator using a metal 3D printer. To evaluate the camera-system performance, phantom measurements with single and dual nuclides ( , , and were performed. The performance for in vivo imaging was evaluated using tumor-bearing mice to which a nuclide ( or administered. We simultaneously obtained information on and , which emit emission lines in the low-energy band with peak energies close to each other (23-26 keV for and 27-31 keV for , and applied an analytical method based on spectral model fitting to determine the individual radioactivities accurately. In the small animal imaging, the distributions of the nuclide in tumors were accurately quantified and time-activity curves in tumors areobtained. The demonstrated capability of our system to perform in vivo imaging suggests that the camera can be used for applications of pharmacokineticsresearch.

Optimization of the lost PLA production process for the manufacturing of Al-alloy porous structures: Recent developments, macrostructural and microstructural analysis

The main task of this work is the optimization of the manufacturing process of Al-alloy lattice cellular structures with rhombic cell, obtained with lost-PLA technique. It is an easy, environment sustainable and economical technique (both for infrastructure and operating costs) for the manufacturing of Al porous structure based on the 3D printing of PLA and replication process alternative to that based on expensive metal 3D printers. Plaster processing, PLA burnout and AA 6082 alloy casting conditions and parameters have been suitably tuned in order to get final samples with geometry and surface finishing conditions identical to the starting ones made in PLA. A good replication process has been implemented with a high repeatability rate and accurate surface finishing, comparable with that of the PLA printed objects. Morphological analysis on PLA and Al 6082 was conducted as well microstructural analysis and Vickers microhardness tests on Al alloy samples in the as-cast conditions. Metallography reveals the presence of AlFeSi and AlFeMnSi intermetallic phases at the cell boundaries and some coarse precipitates Mg2Si in the AA 6082 alloy. Microstructures and HV measured values are aligned with literature data for this alloy in the same (as-cast) conditions.

"Fabrication of cutting inserts with chromium-molybdenum steel for turning operations using material extrusion technology"

In this study, cutting inserts for turning were produced using metal 3D printing's material extrusion technology. The primary focus was on optimizing cutting parameters. An experimental plan was devised involving rounds of cutting tests based on a design of experiments and analysis of variance. Inserts were manufactured by printing bound metal powder filament, a combination of chromium-molybdenum tool steel with a polymeric binder. After printing, green parts underwent debinding to eliminate the binder, eventually resulting in full metal parts via sintering. These inserts underwent machining tests on aluminum-copper EN AW-2030 alloy specimens. Results indicated that the inserts could function within cutting speeds (Vc) ranging from 40 to 260 m/min, feed rates (f) from 0.05 to 0.25 mm/r, and radial pass depths (ap) from 0.1 to 2.4 mm. Optimal technological conditions were determined as Vc = 160–200 m/min, f = 0.20–0.25 mm/r, and ap = 1.2 mm. Analysis revealed that cutting speed was less significant than feed rate or depth of cut on tool wear. Feed rate minimized wear within the 0.15–0.25 mm/r range, while pass depth proved most influential on wear, with optimal values between 0.8 and 1.2 mm. Surface finish, assessed through mean roughness Ra, showed high dependence on pass depth, improving for low ap values and relatively high Vc values. These findings demonstrate that inserts fabricated via material extrusion can operate within a technological range like commercial inserts, presenting an advanced approach for customizing design and manufacturing while surpassing conventional insert limitations.

Evaluation of Additive Manufacturing for Wireless Power Transfer Applications

Additive Manufacturing (AM) has emerged as an economical and feasible technology for creating industrial components. This paper evaluates the use of AM for inductive Wireless Power Transfer (WPT) systems. In particular, the innovative use of metal 3D printing is proposed as a manufacturing process for the coils. For this reason, the recent improvement of metal AM is proposed as a suitable solution to increase design opportunities, reduce costs and production time while improving transmission efficiency. In fact, the WPT coil current distribution can be preliminarily studied through Finite Element Analysis (FEA) to optimize its cross-section and geometry. In this work, a general design procedure for WPT coils using metal AM is presented and this technology is compared with traditional solutions (i.e. hollow and litz wire) through extensive experimental measurements. The analysis shows that AM allows to reduce the parasitic resistance, costs and weight while increasing the transmission efficiency. Thus, the obtained results confirm the potential of AM for producing WPT coils, nominating this technology as a flexible, sustainable, and rapid solution for custom WPT coils production.

Strengthening complex concentrated alloy without ductility loss by 3D printed high-density coherent nanoparticles

Metallic 3D printing enables fast fabrication of net-shaped components for broad engineering applications, yet it restrains the use of most mechanical processing methods for strengthening alloys, e.g. forging, rolling, etc. Here, we proposed a new strategy for enhancing the strength of 3D printed complex concentrated alloys without losing ductility. This strategy relies on the rapid cooling of 3D printing to achieve a supersaturation state that is beyond conventional casting. Then, spinodal decomposition via aging is exploited to introduce high-density coherent nanoparticles for strengthening. The proposed strategy is demonstrated in a 3D printed Cu-based complex concentrated alloy. The rapid solidification during printing strongly inhibits elemental diffusion, leading to a high supersaturation state. High-density nanoparticles with coherent interface and size of ∼7 nm are introduced into the 3D printed samples through spinodal decomposition via simple aging treatment. The strength of the 3D printed alloy is increased by 30 % after aging with no ductility loss, leading to a strength-ductility combination superior to other Cu alloys. This strategy is readily applicable to other spinodal alloys fabricated by 3D printing for circumventing the strength-ductility trade-off dilemma.

EARLY RESULTS OF SHOULDER ARTHRODESIS WITH 3D-TITANIUM IMPLANTS FOR TREATMENT OF SEVERE GUNSHOT WOUNDS OF THE SHOULDER GIRDLE

As a result of large-scale war in Ukraine, the frequency of gunshot wounds of the upper extremities has increased dramatically, accompanied by massive damage to soft tissue, neurovascular plexuses, and significant bone deficiency, so their treatment with traditional methods is risky. This leads to the development of new treatment methods, in particular, techniques for shoulder arthrodesis. Objective. To investigate the effectiveness of shoulder arthrodesis using an individual 3D-titanium implant and or a locked compression plate (LCP) with bone autoplasty for the treatment of severe combat trauma of the upper extremity. Methods. In 2022–2023, 19 men aged 36.2 (24–52) years with severe combat trauma of the upper extremity underwent shoulder arthrodesis using individual 3D-titanium implants (n = 9) or LCP with bone autoplasty (n = 10). The follow-up period was 18 months. Individual 3D-implants were created in the CAD program Autodesk Fusion 360 and made of Ti6AI4V alloy by three- dimensional metal 3D-printing. The functional status of the shoulder joint was assessed by the Oxford Shoulder Score, VAS at 6 and 12 months after surgery. Fusion was checked radiographically at 1, 3, 6 and 12 months. Results. The average follow-up period was 12 months. Ankylosis of the shoulder joint was formed in 18 (95 %) patients, and clinical consolidation without final restructuring with a positive tendency to bone fusion was detected in one patient (5 %). Radiologically confirmed fusion in 8.5 months (6–12). After 12 months, a decrease in pain (VAS: 5 to 1 points; p &lt; 0.001) and improvement in the condition of the shoulder (Oxford Shoulder Score: 25 to 40 points, p &lt; 0.001) were found compared with 6 months. Conclusions. Treatment of severe combat trauma of the upper extremity by shoulder arthrodesis allows to eliminate pain and restore sufficient function to perform daily tasks one year after surgery. The combination of shoulder arthrodesis with individual 3D-implants resulted in the restoration of upper limb function in all 9 patients with massive bone and muscle defects.

Additively manufactured steel reinforcement for small scale reinforced concrete modeling: Tensile and bond behavior

Small scale (∼1:30–1:40) Reinforced Concrete is useful for centrifuge testing. However, manufacturing the reinforcing cages by hand at this scale is practically difficult. This paper suggests that small scale reinforcement can be manufactured using a metal 3D printer. Mechanical properties of 3D printed submillimeter rebars are discussed and compared to properties of typical prototype rebars. Different model concrete mix designs are tested to identify optimal mixes. Pullout tests of rebars with different surface rib configurations embedded in different concrete mixes are discussed.Based on the test results, by modulating the printing parameters it seems feasible to obtain 3D printed submillimeter bars that can be used as physical models of prototype rebars. A gypsum-based model concrete was more similar to prototype concrete than cement-based mixes. Most importantly, bond slip behavior that is comparable to full-scale concrete could be achieved, something that is vital and has never been reported before.

Characteristics of 3D Printed Functionally Graded Material for Replacement of Dissimilar Metal Weld in Nuclear Reactor

The dissimilar metal welds in the most of the reactors are connections between low alloy steel parts and stainless steel piping. There is a high possibility of primary water stress corrosion cracking (PWSCC) damage attributed to residual stress caused by the difference in material properties in the dissimilar metal weld joints. A number of accidents such as leakage of radioactive coolant due to PWSCC have been reported around the world, posing a great threat to nuclear safety. The objective of this study is to develop a technology that can fundamentally remove dissimilar metal welds by replacing the existing dissimilar metal parts with the functionally graded material (FGM) manufactured by metal 3D printing consisting of low alloy steel and austenitic stainless steel. A powder production, mixing ratio calculation, and metal 3D printing were performed to fabricate the low alloy steel-stainless steel FGM, and microstructure analysis, mechanical properties, and coefficient of thermal expansion (CTE) measurement of the FGM were performed. As a result, it is observed that CTE tended to increase as the austenite content increased in FGM. The gradual change of coefficient of thermal expansion in a FGM showed that the additive manufacturing using 3D printing was effective for preventing an abrupt change in thermal expansion properties throughout their layers.