Advanced Manufacturing Technology Research Articles

Investigation into the role of Si and SiC phases in RB-SiC ceramics surface modified ultra-precision grinding

RB-SiC ceramic has greater specific stiffness and thermal stability as space optical materials in the field of deep space exploration. To ultra-precision grinding advanced manufacturing technology drawbacks, a fabrication of highly shape accuracy and surface quality and surface modification assisted processing at room temperature. The RB-SiC ceramics are modified by plasma torches to produce compounds with lower hardness values, an exceptional surface quality (Sa surface roughness of [0.481, 0.959]), and has excellent thermal and chemical stability after surface modification process via 100 °C plasma torch at room temperature environment, which makes it an ideal suitable for the deep space exploration conditions such as space optical materials. In addition, oxygen(O2) plasma surface modification and finite element simulation force-heat conduction of RB-SiC ceramic hard-brittle materials surface grinding force were compared with advanced manufacturing experiments of the precision grinding, revealing the formation mechanism and influence mechanism of surface micro-morphology during micro-cutting of precision grinding finish surface. The advanced manufacturing precision grinding difficulties of RB-SiC ceramic oxygen plasma torch reducing subsurface damage and removing space optical hard-brittle materials via ultra-precision grinding process of resin-funded corundum grinding wheel were solved. Subsurface damage (SSD) was effectively inhibited and its formation mechanism model.

Optimization Algorithms and Their Applications and Prospects in Manufacturing Engineering.

In modern manufacturing, optimization algorithms have become a key tool for improving the efficiency and quality of machining technology. As computing technology advances and artificial intelligence evolves, these algorithms are assuming an increasingly vital role in the parameter optimization of machining processes. Currently, the development of the response surface method, genetic algorithm, Taguchi method, and particle swarm optimization algorithm is relatively mature, and their applications in process parameter optimization are quite extensive. They are increasingly used as optimization objectives for surface roughness, subsurface damage, cutting forces, and mechanical properties, both for machining and special machining. This article provides a systematic review of the application and developmental trends of optimization algorithms within the realm of practical engineering production. It delves into the classification, definition, and current state of research concerning process parameter optimization algorithms in engineering manufacturing processes, both domestically and internationally. Furthermore, it offers a detailed exploration of the specific applications of these optimization algorithms in real-world scenarios. The evolution of optimization algorithms is geared towards bolstering the competitiveness of the future manufacturing industry and fostering the advancement of manufacturing technology towards greater efficiency, sustainability, and customization.

(Invited) Battery Manufacturing Needs from the Perspective of DOE's Advanced Materials and Manufacturing Technologies Office

The Department of Energy’s Advanced Materials and Manufacturing Technologies Office (AMMTO) continues to invest in energy storage research, development, and demonstration (RD&D) to help stakeholders improve efficiency, cut costs, and make materials, components, and systems with superior performance. Despite recent promising advances, manufacturing capabilities are still necessary to meet the expected demand for batteries as we move toward a clean energy economy. Strengthening the domestic manufacturing supply chains is also another important task to pursue in parallel. A multi-pronged approach is required to strengthen domestic battery manufacturing and reduce time to commercialization and deployment of transformative technologies. AMMTO recognizes a number of unmet needs that need to be addressed including development of manufacturing processes and equipment that take advantage of the most recent technical advances as well as effective utilization of data-driven analysis and experimentation to assist in manufacturing optimization.In this talk, AMMTO’s perspective on energy storage technology development and manufacturing will be discussed, highlighting current gaps and challenges that need to be addressed. In addition, there will be a robust discussion of a wide variety of DOE’s efforts in the context of technical and manufacturing challenges regarding scale-up and performance that still prevent the electrochemical energy storage community from achieving cost targets and commercial viability.

(Invited) Structured Electrode Manufacturing for Next-Generation Lithium-Ion Batteries

Achieving high-energy and high-power density Lithium-ion batteries (LIBs) with fast charging capabilities is critical to advancing electric vehicle (EV) and portable electronic technologies. Long-range, fast charge EVs and more compact portable electronics require significant advances in battery performance, lifetime, and cost. Conventional LIBs are composed of flat anode and cathode electrode stacks that can be optimized for energy or power, but not both concurrently. This is due to ion transport limitations that persist with increases in electrode thickness. Several research efforts have focused on optimizing LIB performance through material innovations with lithium metal and silicon anodes or new cathode materials, to name a few. Structured Electrode (SE) designs1 have been investigated over the last couple of decades as an alternate solution to address these challenges. SEs engineer electrode materials into different three-dimensional (3D) architectures on a scale ranging from tens to hundreds of microns to facilitate rapid ion-transport in thicker electrodes. While a promising concept, reliable and scalable manufacturing methods for fabricating SEs over the large and complex areas needed for EV and portable electronic applications remains limited.This talk covers manufacturing approaches investigated by our research group to fabricate SEs rapidly and efficiently. Both computational design and experimental approaches are employed to facilitate the development of new hardware, software, and processing techniques for SEs. Specifically, we highlight Additive Manufacturing (AM) tools for portable electronic applications and the use of acoustophoresis for manufacturing EV SEs. First, we have developed new computational fabrication tools2 and material formulations to push the bounds of AM for SE fabrication. Through this work, we investigate the impact of electrode design and fabrication on the rate capability and charge performance of Li4Ti5O12 and LiFePO4 cells. Next, taking AM towards larger area fabrication, we have combined acoustophoresis with AM principles to facilitate large-area printing and patterning of SEs for LIBs.3 Acoustophoresis utilizes acoustic standing wavesto drive particles into predefined patterns, with micron-scale control at time scales < 1 second. Our initial results with LiNi0.6Mn0.2Co0.2O2 and graphite have defined process conditions that enable acoustophoretic fabrication of SEs with improved rate capability over conventional, flat LIB electrodes. Our work highlights the material and processing considerations that must be given when developing new manufacturing processes for SEs. References C.-H. Hung, P. Huynh, K. Teo, and C.L. Cobb, “Are Three-dimensional Batteries Beneficial? Analyzing Historical Data to Elucidate Performance Advantages,” ACS Energy Letters, 8 (1), pp. 296–305, 2023.F. Fossdal, V. Nguyen, R. Heldal, C.L. Cobb, and N. Peek, “Vespidae: A Programming Framework for Developing Digital Fabrication Workflows,” In Proc. of 2023 Designing Interactive Systems Conference, ACM, New York, NY, USA.K.E. Johnson, D.S. Melchert, E.N. Armstrong, Daniel S. Gianola, C.L. Cobb, M.R. Begley, “A Simple, Validated Approach for Design of Two-dimensional Periodic Particle Patterns via Acoustophoresis,” Materials & Design, Vol. 232, 112165, 2023. Acknowledgements This material is based upon work supported in part by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Advanced Materials and Manufacturing Technologies Office (AMMTO) Award Numbers DE-EE0009112 and DE-EE0010226. The views expressed herein do not necessarily represent the views of the U.S. Department of Energy or the United States Government.This work was funded in part by a Defense Advanced Research Projects Agency (DARPA) Young Faculty Award and Director's Fellowship under grant number D19AP00038. The views, opinions, and findings expressed in this work are those of the authors and should not be interpreted as representing the official views or policies of the Department of Defense or the U.S. Government, and no official endorsement should be inferred. This is approved for public release and distribution is unlimited.

Protonic Ceramic Electrochemical Cell Manufacturing at Idaho National Laboratory

Protonic Ceramic Electrochemical Cells (PCECs), operating at intermediate temperatures of 400-600oC, show great potential for hydrogen production and versatile chemical manufacturing. As this technology rapidly evolves, scaling up production in both quantity and size is crucial. This step bridges the gap between fundamental academic research on small button cells (e.g., 10 mm to 1 inch) and higher-technology readiness level development of industry-standard units (> 10x10 cm2) for stack assembly. At Idaho National Laboratory, we've made significant strides in this transition by applying advanced manufacturing technologies and our expertise in materials science and engineering. Our approach integrates materials, structural, and interface engineering research and development into the cell fabrication process, guided by a stringent quality assurance and quality control (QA&QC) system. This ensures the reliable, repeatable, and durable performance of PCECs.

A Review on Design and Mechanical Properties of Additively Manufactured NiTi Implants for Orthopedic Applications.

NiTi alloy has a wide range of applications as a biomaterial due to its high ductility, low corrosion rate, and favorable biocompatibility. Although Young’s modulus of NiTi is relatively low, it still needs to be reduced; one of the promising ways is by introducing porous structure. Traditional manufacturing processes, such as casting, can hardly produce complex porous structures. Additive manufacturing (AM) is one of the most advanced manufacturing technologies that can solve impurity issues, and selective laser melting (SLM) is one of the well-known methods. This paper reviews the developments of AM-NiTi with a particular focus on SLM-NiTi utilization in biomedical applications. Correspondingly, this paper aims to describe the three key factors, including powder preparation, processing parameters, and gas atmosphere during the overall process of porous NiTi. The porous structure design is of vital importance, so the unit cell and pore parameters are discussed. The mechanical properties of SLM-NiTi, such as hardness, compressive strength, tensile strength, fatigue behavior, and damping properties and their relationship with design parameters are summarized. In the end, it points out the current challenges. Considering the increasing application of NiTi implants, this review paper may open new frontiers for advanced and modern designs.

A controlled vocabulary and taxonomy for the submission of quality attributes for therapeutic proteins

Structured product quality data offer tremendous promise to revolutionize the submission of drug applications. However, the quality attributes for biological products do not have a systematic naming taxonomy, and consequently this limit poses a critical challenge in the development of systems for structured regulatory submissions. Here, we describe the creation of a controlled vocabulary with a structured taxonomical naming approach for quality attributes of therapeutic proteins. Additionally, we endeavor to make the case for why such systematic harmonized naming is required to support the successful implementation of structured data systems. We also describe the key principles of our structured naming approach, including a top-down view of the product and protein structure and a distinction between a quality attribute and the test to evaluate the attribute. Finally, we describe how this approach can accommodate emerging product types, advanced manufacturing technologies, and be used across the variety of submission sections in a regulatory dossier that discusses quality attributes.

Preface

With the continuous progress of science and technology, the innovation and development in the fields of advanced manufacturing and materials engineering has become an important force to promote global industrial upgrading. It is against this backdrop that the 2024 10th International Conference on Applied Materials and Manufacturing Technology (ICAMMT 2024) gathered scholars, researchers, and industry experts in Guangzhou, China from May 22nd to 23rd, 2024 via hybrid form to share their insights and advancements in the domains of applied materials and manufacturing technology. ICAMMT is a premier interdisciplinary platform for the presentation of new advances and research results in applied materials and manufacturing technology. ICAMMT 2024 brought together leading scientists, researchers, practitioners, and other personnel to present and discuss the most recent innovations, trends, and concerns as well as practical challenges encountered and solutions adopted in the domains of interest from around the world to share their experiences and research results in advanced manufacturing and materials engineering, and exchange views. Themed around advanced manufacturing and materials engineering, the Conference set up a number of topics, including but not limited to: Research and Development of New Materials, Mechanical Behavior &amp; Fracture, Advanced Forming Manufacturing and Equipment, Manufacturing Systems and Automation, Measure Control Technologies and Intelligent Systems, etc. Through in-depth discussion of these topics, the Conference gathered global wisdom and strength, and jointly promoted the innovative development of applied materials and manufacturing technology. The Conference agenda was designed to cater to a wide range of interests and expertise levels, including one main forum and two sub-forums. One of the highlights of the event was keynote speeches delivered by eight renowned experts in their respective fields at home and abroad. They discussed about the latest research results and experiences of advanced manufacturing technology and materials engineering, and shared their unique views on the development trend and research and development direction of the industry. Topics cover Discussion on Low-Carbon Development Approach of China’s Iron and Steel Industry (Prof. Liejun Li, South China University of Technology, China), High Performance Organic-Inorganichybrid Cement-Based Materials (Prof. Jiangxiong Wei, South China University of Technology, China), Applications of Light Alloys in Battery-Powered Electric Vehicles (Prof. Henry Hu, University of Windsor, Canada), Machine Vision and Human-Computer Interaction (Prof. Wei Xie, South China University of Technology, China), etc. These speeches not only provided a comprehensive overview of the latest trends and developments but also offered insights into the potential challenges and opportunities that lie ahead. Last but not the least is our gratitude. We would like to express our sincere thanks to all the authors, speakers, committee members, supporters, and all those involved for the complete success of the Conference, which has then given rise to this Proceedings of selected papers. Special thanks to the members of Journal of Physics: Conference Series for their efforts in making this volume published. The Committee of ICAMMT 2024 List of Committee Member is available in this Pdf.

Advancements in Coordination Chemistry and Trends in the Chemical Industry: Applications and Implications

Abstract: This research paper delves into the current advances in coordination chemistry alongside the evolving trends within the chemical industry, exploring their intersections and applications. Coordination chemistry has witnessed remarkable progress in recent years, driven by innovative synthetic methodologies and a deeper understanding of metal-ligand interactions. The study examines the synthesis and characterization of novel coordination complexes, highlighting their diverse structures and properties. Furthermore, it explores the role of coordination chemistry in various applications, ranging from catalysis and drug design to materials science and environmental remediation. Concurrently, the chemical industry is experiencing transformative shifts, embracing sustainable practices, and adapting to emerging regulatory frameworks. This paper investigates key trends shaping the chemical industry, such as green chemistry initiatives, circular economy principles, and the adoption of advanced manufacturing technologies. By synthesizing the latest research findings and industry developments, this study offers insights into the potential synergies between coordination chemistry advancements and the evolving landscape of the chemical industry, paving the way for innovative applications and sustainable solutions.

Use of the Simple Multicriteria Decision-Making (MCDM) Method for Optimization of the High-Alloy Steel Cutting Processby the Abrasive Water Jet

In the case of advanced manufacturing technologies, which include Abrasive Water Jet Machining, optimization of control parameters is necessary to achieve appropriate efficiency and quality. One of the optimization methods used in the presented research is SAW, from the Multi-Criteria Decision Making (MCDM) group. In multi-criteria decision-making (MCDM) situations, the criterion weights are crucial components that have a big impact on the outcomes. A novel technique called MEREC (MEthod based on the Removal Effects of Criteria) was presented to find the objective weights of the criteria. The research covered cutting high-alloy steel using AWJ, under the Design of Experiment (DoE) within the L9 orthogonal table. Abrasive flow rate, pressure, and feed were selected as control parameters. The cutting depth (beneficial) and the roughness of the cut surface Sa (non-beneficial) were taken as the output parameters. The result of the research is the determination of the impact of individual control parameters and the determination of a set of control parameters from the point of view of efficiency and quality.

Strategies of the countries’ innovative activity in development of intelligent systems

Development of intelligent systems based on artificial intelligence in the area of research and development of technical systems is a new competitive advantage and a growth driver for a country. The authors of the article present the indicators of innovative activity of the countries in development of intelligent systems: the share of the country’s patents in the number of patents for all countries, the number of national strategies in the area of intelligent systems in the country, the geography of implementation of the intelligent systems developed by a country. The authors introduce a term of “index of a country specialization in the sphere of intelligent technology”. Index of specialization is a correlation of factual number of types of patents registered in the country in the sphere of intelligent technology to 10 potentially possible types of patents. These include the patents on advanced manufacturing technologies, robotics, advanced materials, artificial intelligence, big data, the Internet of things, mobility, photonics, security, and digital twins. Using a cluster method, the authors classify 43 countries by the level of innovative activity in the sphere of development of intelligent systems, on the basis of the data provided by the World Intellectual Property Organization and the European Commission in 2023. This allowed developing a classification of 11 strategies of innovative activity in the sphere of development of intelligent systems (based on the scoring assessment). The proposed strategy classification makes it possible to perform benchmarking to study the country’s experience and evaluate the investment risks for the projects in development of intelligent systems.

Utilization of High-Performance Concrete Mixtures for Advanced Manufacturing Technologies

The presented experimental program focuses on the design of high-performance dry concrete mixtures, which could find application in advanced manufacturing technologies, for example, additive solutions. The combination of high-performance concrete (HPC) with advanced or additive technologies provides new possibilities for constructing architecturally attractive buildings with high material requirements. The purpose of this study was to develop a dry mixture made from high-performance concrete that could be distributed directly in advanced or additive technologies of solutions in pre-prepared condition with all input materials (except for water) in order to reduce both financial and labor costs. This research specifically aimed to improve the basic strength characteristics—including mechanical (assessed using compressive strength, tensile splitting strength, and flexural strength tests) and durability properties (assessed using tests of resistance to frost, water, and defrosting chemicals)—of hardened mixtures, with partial insight into the rheology of fresh mixtures (consistency as assessed using the slump-flow test). Additionally, the load-bearing capacity of the selected mixtures in the form of specimens with concrete reinforcement was tested using a three-point bending test. A reference mixture with two liquid plasticizers—the first based on polycarboxylate and polyphosphonate and the second based on polyether carboxylate—was modified using a powdered plasticizer based on the polymerization product Glycol to create a dry mixture; the reference mixture was compared with the developed mixtures with respect to the above-mentioned properties. In general, the results show that the replacement of the aforementioned liquid plasticizers by a powdered plasticizer based on the polymerization product Glycol in the given mixtures is effective up to 5% (of the cement content) with regard to the mechanical and durability properties. The presented work provides an overview of the compared characteristics, which will serve as a basis for future research into the development of additive manufacturing technologies in the conditions of the Czech Republic while respecting the principles of sustainable construction.

High-efficient hybrid arc and friction stir additive manufacturing of high-performance Al-Cu-Mg-Ag-Zr alloy: Microstructural evolution and precipitation behaviors with Ω/L12 co-precipitates

Cost-effective and convenient additive manufacturing technologies are recognized as suitable alternatives for achieving lightweight aluminum alloy components with dense and defect-free parts toward high mechanical properties. Herein, a high-efficient hybrid arc and friction stir additive manufacturing (HAFS-AM) technique was employed to fabricate a high-performance Al-Cu-Mg-Ag-Zr alloy part. The AC pulsed tungsten inert gas (TIG) was utilized for the rapid pre-deposition of Al-Cu-Mg-Ag-Zr alloy with high efficiency. Friction stir processing contributed to eliminating pore defects and refining coarse microstructure in the pre-deposited arc layers, accounting for enhancing mechanical properties. During the HAFS-AM, the coarse θ phase with continuous network morphology was completely broken and gradually dissolved into the α-Al matrix. The addition of Zr element promoted the precipitation of coherent L12-Al3Zr inducing dislocation shearing behavior. The Mg and Ag additions accelerated the precipitation of semi-coherent plate-like Ω and σ phases, where a critical size (thickness and diameter) of precipitates existed for deciding the behaviors of dislocation shearing and dislocation looping. The ultimate tensile strength and elongation of the HAFS-AMed steady-state layer reached 262 MPa and 18.8 %, which were increased by 21 % and 96 % compared to that of the arc layer, respectively. The combined effect of arc and friction stir with high efficiency achieved high-performance manufactured components, expediting the future industry application of advanced additive manufacturing technology.

Advances and Challenges in Biomanufacturing of Glycosylation of Natural Products

Glycosylation is one of the most common and important modifications in natural products (NPs), which can alter the biological activities and properties of NPs, effectively increase structural diversity, and improve pharmacological activities. The biosynthesis of glycosylation in natural products involves multiple complex biological processes, which are coordinated by many enzymes. UDP-glycosyltransferases (UGTs) play a crucial role in glycosylation modification, and have attracted long-term and widespread research attention. UGTs can catalyze the O-, C-, S-, and N-glycosylation of different substrates, producing a variety of glycosides with broad biological activity, while improving the solubility, stability, bioavailability, pharmacological activity, and other functions of NPs. In recent years, the rapid development of synthetic biology and advanced manufacturing technologies, especially the widespread application of artificial intelligence in the field of synthetic biology, has led to a series of new discoveries in the biosynthesis of NP glycosides by UGT. This work summarizes the latest progress and challenges in the field of NP glycosylation, covering the research results and potential applications of glycosylated derivatives of terpenes, flavonoids, polyphenols, aromatic compounds, and other compounds in terms of biogenesis. Looking to the future, research may leverage artificial intelligence-driven synthetic biology techniques to decipher genes related to the synthetic pathway, which is expected to further promote the large-scale synthesis and application of glycosylated NPs, and increase the diversity of NPs in the pharmaceutical, functional food, and cosmetic industries.

Surface crystallized supramolecular to achieve highly dispersed ultrafine nano-palladium in-situ deposition to promote thermal/electrocatalytic reduction

To promote the greening and economization of industrial production, the development of advanced catalyst manufacturing technology with high activity and low cost is an indispensable part. In this study, nitrogen-doped hollow carbon spheres (NHCSs) were used as anchors to construct a supramolecular coating formed by the self-assembly of boron clusters and β-cyclodextrin by surface crystallization strategy, with the help of the weak reducing agent characteristics of boron clusters, highly dispersed ultra-small nano-palladium particles were in-situ embedded on the surface of NHCSs. The deoxygenation hydrogenation of nitroaromatics and the reduction of nitrate to ammonia were used as the representatives of thermal catalytic reduction and electrocatalytic reduction respectively. The excellent properties of the constructed Pd/NHCSs were proved by the probe reaction. In the catalytic hydrogenation of nitroaromatics to aminoaromatics, the reaction kinetic rate and activation energy are at the leading level. At the same time, the constructed Pd/NHCSs can also electrocatalytically reduce nitrate to high value-added ammonia with high activity and selectivity, and the behavior of Pd/NHCSs high selectivity driving nitrate conversion was revealed by density functional theory and in situ attenuated total reflection Fourier transform infrared (ATRFTIR) technique. These results all reflect the feasibility and superiority of in-situ anchoring ultra-small nano-metals as catalysts by surface crystallization to build a supramolecular cladding with reducing properties, which is an effective way to construct high-activity and low-cost advanced catalysts.

DEM modeling of advanced manufacturing technologies: from SLS to 3D concrete printing

DEM modeling of advanced manufacturing technologies: from SLS to 3D concrete printing

High strength induced wide band gap formations in additively manufactured cubic metamaterial

Strength and band gap are the two basic physical features of the cubic metamaterial. How to design band gap characteristics with high strength of structure is the key for the further industrial application in vibration control of the cubic metamaterial. Here a cubic metamaterial is designed by optimal selection of crystal orientation angle to obtain wide band gaps with high strength. The prototype samples were fabricated using advanced additive manufacturing technology to tensile-pressure experiments and sine frequency sweep experiment, thereby demonstrating the validity of the obtained results. Results indicated that the normalized bandwidth of simple cubic (SC) metamaterials is 0.47 and the ultimate strength is 25.99 MPa. The normalized bandwidth is increased by 3.1 times and 47 times higher than that of the metamaterials of face-centered cubic (FCC) and body-centered cubic (BCC). Its ultimate strength is increased by 3.5 times and 6.7 times. The static simulation results revealed that the maximum mises stress values of SC, FCC, and BCC metamaterials were 1.71, 10.49, and 31.40 MPa respectively. The attenuation amplitude of the elastic wave measured by experiment is 80 dB, which is consistent with the simulation results. The bandwidths of cubic metamaterials exhibit a positive correlation with their strength. The variation in crystal orientation angles plays a crucial role in elucidating the underlying mechanism behind the positive correlation between the strength and the band gap. The further buckling analysis of SC metamaterial with high strength and wide bandgap characteristics reveals that the negative Poisson’s ratio structure experiences a reduction in bandwidth and strength as buckling deformation intensifies.

Advanced Design and Manufacturing Approaches for Structures with Enhanced Thermal Management Performance: A Review

AbstractAdvanced design methods and manufacturing techniques are crucial for developing thermal management structures, essential for the efficient operation of complex equipment. This study provides a thorough review of design methodologies and advanced manufacturing technologies for thermal management materials and structures. It identifies key challenges and critically evaluates the integration of innovative design principles, such as biomimicry and topology optimization, into thermal management solutions. The analysis delves into the evolution of design theories and preparation techniques, with a specific focus on modern needs and research directions, particularly highlighting components fabricated using additive manufacturing and their effectiveness in meeting advanced thermal management requirements. Current research focuses on designing structures tailored to various cooling methods, including air‐cooling, liquid‐cooling, heat exchanger cooling, and heat pipe cooling. These designs utilize phase change materials, electrocaloric cooling, and thermoelectric cooling materials to achieve optimal thermal management performance. Additionally, emerging innovations like solid‐liquid mixed heat transfer and the elastocaloric effect are garnering increased interest. Enhancing the design of thermal management structures through rigorous numerical simulations is critical for improving engineering applicability. However, overcoming challenges related to the commercialization and practical utilization of these advanced structures remains a pressing need.

17-4 PH Steel Parts Obtained through MEX and PBF-LB/M Technologies: Comparison of the Structural Properties.

The material extrusion (MEX) method utilizing highly filled metal filament presents an alternative to advanced additive metal manufacturing technologies. This process enables the production of metal objects through deposition and sintering, which is particularly attractive compared to powder bed fusion (PBF) technologies employing lasers or high-power electron beams. PBF requires costly maintenance, skilled operators, and controlled process conditions, whereas MEX does not impose such requirements. This study compares research on 17-4 PH steel manufactured using two different commercially available techniques: MEX and powder bed fusion with laser beam melting (PBF-LB/M). This research included assessing the density of printed samples, analyzing surface roughness in two printing planes, examining microstructure including porosity and density determination, and measuring hardness. The conducted research aimed to determine the durability and quality of the obtained samples and to evaluate their strength. The research results indicated that samples produced using the PBF-LB/M technology exhibited better density and a more homogeneous structure. However, MEX samples exhibited better strength properties (hardness).

Optimization of the grain boundary network and tensile properties of powder metallurgy-hot isostatic pressed Ni-based alloy Inconel 625

Powder metallurgy-hot isostatic pressing (PM-HIPing) is an advanced manufacturing technology for large-sized and complex-shaped components for nuclear applications. In the present study, a novel PM-HIPing strategy was proposed to optimize the grain boundary network and tensile properties of Ni-based alloy Inconel 625, and it was verified by a series of experiments. Samples with 69 % and 74 % of coincidence site lattice (CSL) grain boundaries were obtained when the narrow-size ranged powder was consolidated at 1140 °C and 1180 °C, respectively. The fraction of CSL grain boundaries was further increased to ∼78.5 % after a high temperature solution treatment. Room temperature yield strength and ultimate tensile strength of PM-HIPed alloy 625 were comparable to that of the wrought specimens, elongation of the specimens was ∼56–60 %, the samples all featured with dimple ductile dominant fracture mode.