Post processing of additive manufactured Mg alloys:Current status,challenges,and opportunities

Magnesium(Mg)and its alloys are emerging as a structural material for the aerospace,automobile,and electronics industries,driven by the imperative of weight reduction.They are also drawing notable attention in the medical industries owing to their biodegradability and a lower elastic modulus comparable to bone.The ability to manufacture near-net shape products featuring intricate geometries has sparked huge interest in additive manufacturing(AM)of Mg alloys,reflecting a transformation in the manufacturing sectors.However,AM of Mg alloys presents more formidable challenges due to inherent properties,particularly susceptibility to oxidation,gas trapping,high thermal expansion coefficient,and low solidification temperature.This leads to defects such as porosity,lack of fusion,cracking,delamination,residual stresses,and inhomogeneity,ultimately influencing the mechanical,corrosion,and surface properties of AM Mg alloys.To address these issues,post-processing of AM Mg alloys are often needed to make them suitable for application.The present article reviews all post-processing techniques adapted for AM Mg alloys to date,including heat treatment,hot isostatic pressing,friction stir processing,and surface peening.The utilization of these methods within the hybrid AM process,employing interlayer post-processing,is also discussed.Optimal post-processing conditions are reported,and their influence on the microstructure,mechanical,and corrosion properties are detailed.Additionally,future prospects and research directions are proposed.

Additive manufactured osseointegrated screws with hierarchical design

Bone screws are devices used to fix implants or bones to bones.However,conventional screws are mechanically fixed with thread and often face long-term failure due to poor osseointegration.To improve osseointegration,screws are evolving from solid and smooth to porous and rough.Additive manufacturing(AM)offers a high degree of manufacturing freedom,enabling the preparation of predesigned screws that are porous and rough.This paper provides an overview of the problems currently faced by bone screws:long-term loosening and screw breakage.Next,advances in osseointegrated screws are summarized hierarchically(sub-micro,micro,and macro).At the sub-microscale level,we describe surface-modification techniques for enhancing osseointegration.At the micro level,we summarize the micro-design parameters that affect the mechanical and biological properties of porous osseointegrated screws,including porosity,pore size,and pore shape.In addition,we highlight three promising pore shapes:triply periodic minimal surface,auxetic structure with negative Poisson ratio,and the Voronoi structure.At the macro level,we outline the strategies of graded design,gradient design,and topology optimization design to improve the mechanical strength of porous osseointegrated screws.Simultaneously,this paper outlines advances in AM technology for enhancing the mechanical properties of porous osseointegrated screws.AM osseointegrated screws with hierarchical design are expected to provide excellent long-term fixation and the required mechanical strength.

Characterization and Modeling of Mechanical Properties of Additively Manufactured Coconut Fiber-Reinforced Polypropylene Composites

In the face of the increased global campaign to minimize the emission of greenhouse gases and the need for sustainability in manufacturing, there is a great deal of research focusing on environmentally benign and renewable materials as a substitute for synthetic and petroleum-based products. Natural fiber-reinforced polymeric composites have recently been proposed as a viable alternative to synthetic materials. The current work investigates the suitability of coconut fiber-reinforced polypropylene as a structural material. The coconut fiber-reinforced polypropylene composites were developed. Samples of coconut fiber/polypropylene (PP) composites were prepared using Fused Filament Fabrication (FFF). Tests were then conducted on the mechanical properties of the composites for different proportions of coconut fibers. The results obtained indicate that the composites loaded with 2 wt% exhibited the highest tensile and flexural strength, while the ones loaded with 3 wt% had the highest compression strength. The ultimate tensile and flexural strength at 2 wt% were determined to be 34.13 MPa and 70.47 MPa respectively. The compression strength at 3 wt% was found to be 37.88 MPa. Compared to pure polypropylene, the addition of coconut fibers increased the tensile, flexural, and compression strength of the composite. In the study, an artificial neural network model was proposed to predict the mechanical properties of polymeric composites based on the proportion of fibers. The model was found to predict data with high accuracy.

Toward understanding the microstructure characteristics,phase selection and magnetic properties of laser additive manufactured Nd-Fe-B permanent magnets

Nd-Fe-B permanent magnets play a crucial role in energy conversion and electronic devices.The essential magnetic properties of Nd-Fe-B magnets,particularly coercivity and remanent magnetization,are significantly infuenced by the phase characteristics and microstructure.In this work,Nd-Fe-B magnets were manufactured using vacuum induction melting(VIM),laser directed energy deposition(LDED)and laser powder bed fusion(LPBF)technologies.Themicrostructure evolution and phase selection of Nd-Fe-B magnets were then clarified in detail.The results indicated that the solidification velocity(V)and cooling rate(R)are key factors in the phase selection.In terms of the VIM-casting Nd-Fe-B magnet,a large volume fraction of theα-Fe soft magnetic phase(39.7 vol.%)and Nd2Fe17Bxmetastable phase(34.7 vol.%)areformed due to the low R(2.3×10-1?C s-1),whereas only a minor fraction of the Nd2Fe14B hard magnetic phase(5.15 vol.%)is presented.For the LDED-processed Nd-Fe-B deposit,although the Nd2Fe14B hard magnetic phase also had a low value(3.4 vol.%)as the values of V(<10-2m s-1)and R(5.06×103?C s-1)increased,part of theα-Fe soft magnetic phase(31.7vol.%)is suppressed,and a higher volume of Nd2Fe17Bxmetastable phases(47.5 vol.%)areformed.As a result,both the VIM-casting and LDED-processed Nd-Fe-B deposits exhibited poor magnetic properties.In contrast,employing the high values of V(>10-2m s-1)and R(1.45×106?C s-1)in the LPBF process resulted in the substantial formation of the Nd2Fe14B hard magnetic phase(55.8 vol.%)directly from the liquid,while theα-Fe soft magnetic phase and Nd2Fe17Bxmetastable phase precipitation are suppressed in the LPBF-processed Nd-Fe-B magnet.Additionally,crystallographic texture analysis reveals that the LPBF-processedNd-Fe-B magnets exhibit isotropic magnetic characteristics.Consequently,the LPBF-processed Nd-Fe-B deposit,exhibiting a coercivity of 656 k A m-1,remanence of 0.79 T and maximum energy product of 71.5 k J m-3,achieved an acceptable magnetic performance,comparable to other additive manufacturing processed Nd-Fe-B magnets from MQP(Nd-lean)Nd-Fe-Bpowder.

Mechanical behavior and response mechanism of porous metal structures manufactured by laser powder bed fusion under compressive loading

Al Si10Mg porous protective structure often produces different damage forms under compressive loading,and these damage modes affect its protective function.In order to well meet the service requirements,there is an urgent need to comprehensively understand the mechanical behavior and response mechanism of AlSi10Mg porous structures under compressive loading.In this paper,Al Si10Mg porous structures with three kinds of volume fractions are designed and optimized to meet the requirements of high-impact,strong-energy absorption,and lightweight characteristics.The mechanical behaviors of AlSi10Mg porous structures,including the stress-strain relationship,structural bearing state,deformation and damage modes,and energy absorption characteristics,were obtained through experimental studies at different loading rates.The damage pattern of the damage section indicates that AlSi10Mg porous structures have both ductile and brittle mechanical properties.Numerical simulation studies show that the AlSi10Mg porous structure undergoes shear damage due to relative misalignment along the diagonal cross-section,and the damage location is almost at 45°to the load direction,which is the most direct cause of its structural damage,revealing the damage mechanism of AlSi10Mg porous structures under the compressive load.The normalized energy absorption model constructed in the paper well interprets the energy absorption state of Al Si10Mg porous structures and gives the sensitive location of the structures,and the results of this paper provide important references for peers in structural design and optimization.

Additively manufactured Ti–Ta–Cu alloys for the next-generation load-bearing implants

Bacterial colonization of orthopedic implants is one of the leading causes of failure and clinical complexities for load-bearing metallic implants. Topical or systemic administration of antibiotics may not offer the most efficient defense against colonization, especially in the case of secondary infection, leading to surgical removal of implants and in some cases even limbs. In this study, laser powder bed fusion was implemented to fabricate Ti3Al2V alloy by a 1:1 weight mixture of CpTi and Ti6Al4V powders. Ti-Tantalum(Ta)–Copper(Cu) alloys were further analyzed by the addition of Ta and Cu into the Ti3Al2V custom alloy. The biological,mechanical, and tribo-biocorrosion properties of Ti3Al2V alloy were evaluated. A 10 wt.% Ta(10Ta) and 3 wt.% Cu(3Cu) were added to the Ti3Al2V alloy to enhance biocompatibility and impart inherent bacterial resistance. Additively manufactured implants were investigated for resistance against Pseudomonas aeruginosa and Staphylococcus aureus strains of bacteria for up to 48 h. A 3 wt.% Cu addition to Ti3Al2V displayed improved antibacterial efficacy, i.e.78%–86% with respect to CpTi. Mechanical properties for Ti3Al2V–10Ta–3Cu alloy were evaluated, demonstrating excellent fatigue resistance, exceptional shear strength, and improved tribological and tribo-biocorrosion characteristics when compared to Ti6Al4V. In vivo studies using a rat distal femur model revealed improved early-stage osseointegration for alloys with10 wt.% Ta addition compared to CpTi and Ti6Al4V. The 3 wt.% Cu-added compositions displayed biocompatibility and no adverse infammatory response in vivo. Our results establish the Ti3Al2V–10Ta–3Cu alloy’s synergistic effect on improving both in vivo biocompatibility and microbial resistance for the next generation of load-bearing metallic implants.

UK manufacturers'sales decline 10%in Q12024

UK manufacturers experienced a challenging start to 2024,with sales in the first quarter(Q1)down 10 per cent on the previous quarter,according to a report by Unleashed.However,year-on-year growth showed a modest increase of 2 per cent,reflecting the Bank of England’s assessment of weak growth in the manufacturing sector.

Research on the Innovative Decisions of Supermarket Private Brands and Designated Manufacturers

One of the core competencies of a supermarket lies in its branding.With the continuous development of the market economy and the ongoing evolution of consumer demand,private brands have progressively emerged as significant contributors to supermarket growth.However,a pivotal developmental challenge for supermarkets is navigating the innovative decision-making process between private brands and designated manufacturers.This paper aims to investigate the innovative decisions between private brands and designated manufacturers,along with the relevant promotional strategies employed during entry into the United States market.

Effect of grain refinement induced by wire and arc additive manufacture (WAAM) on the corrosion behaviors of AZ31 magnesium alloy in NaCl solution

Additive manufacturing(AM)of Mg alloys has become a promising strategy for producing complex structures,but the corrosion performance of AM Mg components remains unexploited.In this study,wire and arc additive manufacturing(WAAM)was employed to produce single AZ31 layer.The results revealed that the WAAM AZ31 was characterized by significant grain refinement with non-textured crystallographic orientation,similar phase composition and stabilized corrosion performance comparing to the cast AZ31.These varied corrosion behaviors were principally ascribed to the size of grain,where cast AZ31 and WAAM AZ31 were featured by micro galvanic corrosion and intergranular corrosion,respectively.

The design, manufacture and application of multistable mechanical metamaterials-a state-of-the-art review

Multistable mechanical metamaterials are a type of mechanical metamaterials with special features,such as reusability,energy storage and absorption capabilities,rapid deformation,and amplified output forces.These metamaterials are usually realized by series and/or parallel of bistable units.They can exhibit multiple stable configurations under external loads and can be switched reversely among each other,thereby realizing the reusability of mechanical metamaterials and offering broad engineering applications.This paper reviews the latest research progress in the design strategy,manufacture and application of multistable mechanical metamaterials.We divide bistable structures into three categories based on their basic element types and provide the criterion of their bistability.Various manufacturing techniques to fabricate these multistable mechanical metamaterials are introduced,including mold casting,cutting,folding and three-dimensional/4D printing.Furthermore,the prospects of multistable mechanical metamaterials for applications in soft driving,mechanical computing,energy absorption and wave controlling are discussed.Finally,this paper highlights possible challenges and opportunities for future investigations.The review aims to provide insights into the research and development of multistable mechanical metamaterials.

Enhanced strength-ductility synergy in a wire and arc additively manufactured Mg alloy via tuning interlayer dwell time

Strength-ductility trade-off is a common issue in Mg alloys. This work proposed that a synergistic enhancement of strength and ductility could be achieved through tuning interlayer dwell time(IDT) in the wire and arc additive manufacturing(WAAM) process of Mg alloy.The thermal couples were used to monitor the thermal history during the WAAM process. Additionally, the effect of different IDTs on the microstructure characteristics and resultant mechanical properties of WAAM-processed Mg alloy thin-wall were investigated. The results showed that the stable temperature of the thin-wall component could reach 290 ℃ at IDT=0s, indicating that the thermal accumulation effect was remarkable. Consequently, unimodal coarse grains with an average size of 39.6 μm were generated, and the resultant room-temperature tensile property was poor. With the IDT extended to 60s, the thermal input and thermal dissipation reached a balance, and the stable temperature was only 170 ℃, closing to the initial temperature of the substrate. A refined grain structure with bimodal size distribution was obtained. The remelting zone had fine grains with the size of 15.2 μm, while the arc zone owned coarse grains with the size of 24.5 μm.The alternatively distributed coarse and fine grains lead to the elimination of strength-ductility trade-off. The ultimate tensile strength and elongation of the samples at IDT=60s are increased by 20.6 and 75.0% of those samples at IDT=0s, respectively. The findings will facilitate the development of additive manufacturing processes for advanced Mg alloys.

A facile strategy for tuning the density of surface-grafted biomolecules for melt extrusion-based additive manufacturing applications

Melt extrusion-based additive manufacturing(ME-AM)is a promising technique to fabricate porous scaffolds for tissue engi-neering applications.However,most synthetic semicrystalline polymers do not possess the intrinsic biological activity required to control cell fate.Grafting of biomolecules on polymeric surfaces of AM scaffolds enhances the bioactivity of a construct;however,there are limited strategies available to control the surface density.Here,we report a strategy to tune the surface density of bioactive groups by blending a low molecular weight poly(ε-caprolactone)5k(PCL5k)containing orthogonally reactive azide groups with an unfunctionalized high molecular weight PCL75k at different ratios.Stable porous three-dimensional(3D)scaf-folds were then fabricated using a high weight percentage(75 wt.%)of the low molecular weight PCL 5k.As a proof-of-concept test,we prepared films of three different mass ratios of low and high molecular weight polymers with a thermopress and reacted with an alkynated fluorescent model compound on the surface,yielding a density of 201-561 pmol/cm^(2).Subsequently,a bone morphogenetic protein 2(BMP-2)-derived peptide was grafted onto the films comprising different blend compositions,and the effect of peptide surface density on the osteogenic differentiation of human mesenchymal stromal cells(hMSCs)was assessed.After two weeks of culturing in a basic medium,cells expressed higher levels of BMP receptor II(BMPRII)on films with the conjugated peptide.In addition,we found that alkaline phosphatase activity was only significantly enhanced on films contain-ing the highest peptide density(i.e.,561 pmol/cm^(2)),indicating the importance of the surface density.Taken together,these results emphasize that the density of surface peptides on cell differentiation must be considered at the cell-material interface.Moreover,we have presented a viable strategy for ME-AM community that desires to tune the bulk and surface functionality via blending of(modified)polymers.Furthermore,the use of alkyne-azide“click”chemistry enables spatial control over bioconjugation of many tissue-specific moieties,making this approach a versatile strategy for tissue engineering applications.

Repositioning fertilizer manufacturing subsidies for improving food security and reducing greenhouse gas emissions in China

China removed fertilizer manufacturing subsidies from 2015 to 2018 to bolster market-oriented reforms and foster environmentally sustainable practices.However,the impact of this policy reform on food security and the environment remains inadequately evaluated.Moreover,although green and low-carbon technologies offer environmental advantages,their widespread adoption is hindered by prohibitively high costs.This study analyzes the impact of removing fertilizer manufacturing subsidies and explores the potential feasibility of redirecting fertilizer manufacturing subsidies to invest in the diffusion of these technologies.Utilizing the China Agricultural University Agri-food Systems model,we analyzed the potential for achieving mutually beneficial outcomes regarding food security and environmental sustainability.The findings indicate that removing fertilizer manufacturing subsidies has reduced greenhouse gas(GHG)emissions from agricultural activities by 3.88 million metric tons,with minimal impact on food production.Redirecting fertilizer manufacturing subsidies to invest in green and low-carbon technologies,including slow and controlled-release fertilizer,organic-inorganic compound fertilizers,and machine deep placement of fertilizer,emerges as a strategy to concurrently curtail GHG emissions,ensure food security,and secure robust economic returns.Finally,we propose a comprehensive set of government interventions,including subsidies,field guidance,and improved extension systems,to promote the widespread adoption of these technologies.

Pumpability of Manufactured Sand Self-compacting Concrete

By the addition of superplasticizer and air entraining agent,manufactured sand selfcompacting concrete(MS SCC)with slump flow varying from 500 to 700 mm and air content varying from 2.0%to 9.0%were prepared and the pumpability of MS SCC was studied by a sliding pipe rheometer(Sliper).According to the Kaplan’s model,the initial pump pressure and the pump resistance of MS SCC were obtained.Meanwhile,rheological properties including the yield stress and the plastic viscosity of MS SCC were measured by a rheometer.The experimental results show that the increase of slump flow contributes to a higher pumpability and a proper air content,i e,6%is beneficial for the pumpability of MS SCC.Due to the existence of stone powder and stronger angularity of MS,the initial pump pressure of MS SCC is only about 60%-88%that of river sand(RS)SCC with the same slump flow and air content,indicating that MS SCC possesses a higher pumpability than RS SCC.

Strengthening and toughening of additively manufactured Ti-6Al-4V alloy by hybrid deposition and synchronous micro-rolling

To overcome the disadvantages of inhomogeneous microstructures and poor mechanical properties of additively manufactured Ti-6Al-4V alloys,a novel technique of hybrid deposition and synchronous micro-rolling is proposed.The micro-rolling leads to equiaxed prior β grains,thin discontinuous intergranular α,and equiaxed primary α,in contrast to the coarse columnar prior β grains without the application of micro-rolling.The recrystallization by micro-rolling results in discontinuous intergranular α via the mechanism of strain and interface-induced grain boundary migration.The evolution of α globularization,driven by a solute concentration gradient,starts from the sub-boundary until the formation of equiaxed primary α.Simultaneous strengthening and toughening are achieved,which means an increase in yield strength,ultimate tensile strength,fracture elongation,and work hardening rate.The formation of α recrystallization leads to more fine grain boundaries to strengthen the yield strength,and the improvement of ductility is due to the better-coordinated deformation ability of discontinuous intergranular α and equiaxed primary α.As a result,the fracture mode in micro-rolling changes from intergranular type to transgranular type.

Regulations for the Manufacture and Control of Live Poliovirus Vaccine: International Experience and China’s Path

The eradication of poliomyelitis is a landmark achievement in the history of public health, providing strong protection for children’s health. The introduction of the Chinese Regulations for the Manufacture and Control of Live Poliovirus Vaccine is a prerequisite and safeguard for the large-scale production and use of domestically produced live poliovirus vaccines, serving as an indispensable component of vaccine safety. This article, based on archival documents, letters, collections of essays, and oral interviews, examines the historical experience of the development of Chinese Regulations for the Manufacture and Control of Live Poliovirus Vaccine. It contends that the emphasis on localization and the active engagement in international cooperation are critical factors in the swift introduction of Chinese Regulations for the Manufacture and Control of Live Poliovirus Vaccine.

Ballistic performance of additive manufacturing 316l stainless steel projectiles based on topology optimization method

Material and structure made by additive manufacturing(AM)have received much attention lately due to their flexibility and ability to customize complex structures.This study first implements multiple objective topology optimization simulations based on a projectile perforation model,and a new topologic projectile is obtained.Then two types of 316L stainless steel projectiles(the solid and the topology)are printed in a selective laser melt(SLM)machine to evaluate the penetration performance of the projectiles by the ballistic test.The experiment results show that the dimensionless specific kinetic energy value of topologic projectiles is higher than that of solid projectiles,indicating the better penetration ability of the topologic projectiles.Finally,microscopic studies(scanning electron microscope and X-ray micro-CT)are performed on the remaining projectiles to investigate the failure mechanism of the internal structure of the topologic projectiles.An explicit dynamics simulation was also performed,and the failure locations of the residual topologic projectiles were in good agreement with the experimental results,which can better guide the design of new projectiles combining AM and topology optimization in the future.

A Hybrid Deep Learning and Machine Learning-Based Approach to Classify Defects in Hot Rolled Steel Strips for Smart Manufacturing

Smart manufacturing is a process that optimizes factory performance and production quality by utilizing various technologies including the Internet of Things(IoT)and artificial intelligence(AI).Quality control is an important part of today’s smart manufacturing process,effectively reducing costs and enhancing operational efficiency.As technology in the industry becomes more advanced,identifying and classifying defects has become an essential element in ensuring the quality of products during the manufacturing process.In this study,we introduce a CNN model for classifying defects on hot-rolled steel strip surfaces using hybrid deep learning techniques,incorporating a global average pooling(GAP)layer and a machine learning-based SVM classifier,with the aim of enhancing accuracy.Initially,features are extracted by the VGG19 convolutional block.Then,after processing through the GAP layer,the extracted features are fed to the SVM classifier for classification.For this purpose,we collected images from publicly available datasets,including the Xsteel surface defect dataset(XSDD)and the NEU surface defect(NEU-CLS)datasets,and we employed offline data augmentation techniques to balance and increase the size of the datasets.The outcome of experiments shows that the proposed methodology achieves the highest metrics score,with 99.79%accuracy,99.80%precision,99.79%recall,and a 99.79%F1-score for the NEU-CLS dataset.Similarly,it achieves 99.64%accuracy,99.65%precision,99.63%recall,and a 99.64%F1-score for the XSDD dataset.A comparison of the proposed methodology to the most recent study showed that it achieved superior results as compared to the other studies.

Method for Detecting Industrial Defects in Intelligent Manufacturing Using Deep Learning

With the advent of Industry 4.0,marked by a surge in intelligent manufacturing,advanced sensors embedded in smart factories now enable extensive data collection on equipment operation.The analysis of such data is pivotal for ensuring production safety,a critical factor in monitoring the health status of manufacturing apparatus.Conventional defect detection techniques,typically limited to specific scenarios,often require manual feature extraction,leading to inefficiencies and limited versatility in the overall process.Our research presents an intelligent defect detection methodology that leverages deep learning techniques to automate feature extraction and defect localization processes.Our proposed approach encompasses a suite of components:the high-level feature learning block(HLFLB),the multi-scale feature learning block(MSFLB),and a dynamic adaptive fusion block(DAFB),working in tandem to extract meticulously and synergistically aggregate defect-related characteristics across various scales and hierarchical levels.We have conducted validation of the proposed method using datasets derived from gearbox and bearing assessments.The empirical outcomes underscore the superior defect detection capability of our approach.It demonstrates consistently high performance across diverse datasets and possesses the accuracy required to categorize defects,taking into account their specific locations and the extent of damage,proving the method’s effectiveness and reliability in identifying defects in industrial components.

Recent innovations in laser additive manufacturing of titanium alloys

Titanium(Ti)alloys are widely used in high-tech fields like aerospace and biomedical engineering.Laser additive manufacturing(LAM),as an innovative technology,is the key driver for the development of Ti alloys.Despite the significant advancements in LAM of Ti alloys,there remain challenges that need further research and development efforts.To recap the potential of LAM high-performance Ti alloy,this article systematically reviews LAM Ti alloys with up-to-date information on process,materials,and properties.Several feasible solutions to advance LAM Ti alloys are reviewed,including intelligent process parameters optimization,LAM process innovation with auxiliary fields and novel Ti alloys customization for LAM.The auxiliary energy fields(e.g.thermal,acoustic,mechanical deformation and magnetic fields)can affect the melt pool dynamics and solidification behaviour during LAM of Ti alloys,altering microstructures and mechanical performances.Different kinds of novel Ti alloys customized for LAM,like peritecticα-Ti,eutectoid(α+β)-Ti,hybrid(α+β)-Ti,isomorphousβ-Ti and eutecticβ-Ti alloys are reviewed in detail.Furthermore,machine learning in accelerating the LAM process optimization and new materials development is also outlooked.This review summarizes the material properties and performance envelops and benchmarks the research achievements in LAM of Ti alloys.In addition,the perspectives and further trends in LAM of Ti alloys are also highlighted.