Printability disparities in heterogeneous material combinations via laser directed energy deposition:a comparative study

Additive manufacturing provides achievability for the fabrication of bimetallic and multi-material structures;however,the material compatibility and bondability directly affect the parts’formability and final quality.It is essential to understand the underlying printability of different material combinations based on an adapted process.Here,the printability disparities of two common and attractive material combinations(nickel-and iron-based alloys)are evaluated at the macro and micro levels via laser directed energy deposition(DED).The deposition processes were captured using in situ high-speed imaging,and the dissimilarities in melt pool features and track morphology were quantitatively investigated within specific process windows.Moreover,the microstructure diversity of the tracks and blocks processed with varied material pairs was comparatively elaborated and,complemented with the informative multi-physics modeling,the presented non-uniformity in mechanical properties(microhardness)among the heterogeneous material pairs was rationalized.The differences in melt flow induced by the unlike thermophysical properties of the material pairs and the resulting element intermixing and localized re-alloying during solidification dominate the presented dissimilarity in printability among the material combinations.This work provides an in-depth understanding of the phenomenological differences in the deposition of dissimilar materials and aims to guide more reliable DED forming of bimetallic parts.

Cracking on a nickel-based superalloy fabricated by direct energy deposition

Cracks have consistently been a significant challenge limiting the development of additive manufactured nickel-based superalloys.It is essential to investigate the location of cracks and their forming mechanism.This study extensively examines the impact of solidification process,microstructural evolution,and stress concentration on crack initiation during direct energy deposition(DED).The results emphasize that the crack formation is significantly related to large-angle grain boundaries,rapid cooling rates.Cracks caused by large-angle grain boundaries and a fast-cooling rate predominantly appear near the edge of the deposited samples.Liquation cracks are more likely to form near the top of the deposited sample,due to the presence ofγ/γ'eutectics.The secondary dendritic arm and the carbides in the interdendritic regions can obstruct liquid flow during the final stage of solidification,which results in the formation of solidification cracks and voids.This work paves the way to avoid cracks in nickel-based superalloys fabricated by DED,thereby enhancing the performance of superalloys.

Effect of hot isostatic pressure on the microstructure and tensile properties of γ'-strengthened superalloy fabricated through induction-assisted directed energy deposition

The microstructure characteristics and strengthening mechanism of Inconel738LC(IN-738LC) alloy prepared by using induction-assisted directed energy deposition(IDED) were elucidated through the investigation of samples subjected to IDED under 1050℃ preheating with and without hot isostatic pressing(HIP,1190℃,105 MPa,and 3 h).Results show that the as-deposited sample mainly consisted of epitaxial columnar crystals and inhomogeneously distributed γ’ phases in interdendritic and dendritic core regions.After HIP,grain morphology changed negligibly,whereas the size of the γ’ phase became increasingly even.After further heat treatment(HT,1070℃,2 h + 845℃,24 h),the γ’ phase in the as-deposited and HIPed samples presented a bimodal size distribution,whereas that in the as-deposited sample showed a size that remained uneven.The comparison of tensile properties revealed that the tensile strength and uniform elongation of the HIP + HTed sample increased by 5% and 46%,respectively,due to the synergistic deformation of bimodal γ’phases,especially large cubic γ’ phases.Finally,the relationship between phase transformations and plastic deformations in the IDEDed sample was discussed on the basis of generalized stability theory in terms of the trade-off between thermodynamics and kinetics.

Influence of Scanning Patterns on Mechanical Behavior and Distortion in Laser Directed Energy Deposition

Laser Directed Energy Deposition (LDED) marks a critical advance in intelligent manufacturing, enabling efficient near-net shape production of metal parts. This method is especially beneficial for aerospace and defense applications that require high precision. However, issues such as deformation and heat accumulation during production still affect the quality of the final products, necessitating further optimization of process parameters. This paper studies the effects of three deposition strategies on 316L stainless steel parts using LDED. The three strategies based on unidirectional scanning (US), zigzag scanning (ZS), and square spiral scanning (SS) are investigated by solid samples and samples with a central hole. The surface smoothness, defects, and mechanical properties of 316L samples manufactured with the above strategies are discussed by means of surface topography tests and metallographic characterization. Experimental results indicate that the zigzag scanning strategy yielded better results for solid components, and the square spiral scanning strategy is suitable for samples with a central hole.

Review on laser directed energy deposited aluminum alloys

Lightweight aluminum(Al)alloys have been widely used in frontier fields like aerospace and automotive industries,which attracts great interest in additive manufacturing(AM)to process high-value Al parts.As a mainstream AM technique,laser-directed energy deposition(LDED)shows good scalability to meet the requirements for large-format component manufacturing and repair.However,LDED Al alloys are highly challenging due to their inherent poor printability(e.g.low laser absorption,high oxidation sensitivity and cracking tendency).To further promote the development of LDED high-performance Al alloys,this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys.The porosity,cracking,distortion,inclusions,element evaporation and resultant inferior mechanical properties(worse than laser powder bed fusion)are the key challenges in LDED Al alloys.Processing parameter optimizations,in-situ alloy design,reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al alloys.The underlying correlations between processes,alloy innovation,characteristic microstructures,and achievable performances in LDED Al alloys are discussed.The benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized.This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys.Future opportunities and perspectives in LDED high-performance Al alloys are also outlined.

Energy conversion and deposition behaviour in gravitational collapse of granular columns

The high-density gravitational collapse of granular columns is very similar to the movements of large collapsing columns in nature. Based on the development of dangerous columnar rock mass in fields, granular column collapse boundary condition in the physical experiments of this study is a new type of boundary conditions with a single free face and a three-dimensional deposit. Physical experiments have shown that the mobility of small particles during the collapse of granular columns was greater than that of large particles. For example, when particle size was increased from 5 to 15 mm, deposit runout was decreased by about 16.4%. When a column consisted of two particle types with different sizes, these particles could mix in the vicinity of layer interfaces and small particles might increase the mobility of large particles. In the process of collapse, potential and kinetic energy conversion rate is fluctuated. By increasing initial aspect ratio a, the ratio of the initial height of column to its length along flow direction,potential and kinetic energy conversion rate is decreased. For example, as a was increased from 0.5 to 4, the ratio of maximum kinetic energy obtained and total potential energy loss was decreased from47.6% to 7.4%. After movement stopped, an almost trapezoidal body remained in the column and a fanlike or fan-shaped accumulation was formed on the periphery of column. Using multiple exponential functions of the aspect ratio a, the planar morphology of the collapse deposit of granular columns could be quantitatively characterized. The movement of pillar dangerous rock masses with collapse failure mode could be evaluated using this granular column experimental results.

Microstructure and mechanical property of additively manufactured NiTi alloys:A comparison between selective laser melting and directed energy deposition

NiTi shape memory alloy(SMA)with nominal composition of Ni 50.8 at%and Ti 49.2 at%was additively manufactured(AM)by selective laser melting(SLM)and laser directed energy deposition(DED)for a comparison study,with emphasis on its phase composition,microstructure,mechanical property and deformation mechanism.The results show that the yield strength and ductility obtained by SLM are 100 MPa and 8%,respectively,which are remarkably different from DED result with 700 MPa and 2%.The load path of SLM sample presents shape memory effect,corresponding to martensite phase detected by XRD;while the load path of DED presents pseudo-elasticity with austenite phase.In SLM sample,fine grain and hole provide a uniform deformation during tensile test,resulting in a better elongation.Furthermore,the nonequilibrium solidification was studied by a temperature field simulation to understand the difference of the two 3D printing methods.Both temperature gradient G and growth rate R determine the microstructure and phase in the SLM sample and DED sample,which leads to similar grain morphologies because of similar G/R.While higher G×R of SLM leads to a finer grain size in SLM sample,providing enough driving force for martensite transition and subsequently changing texture compared to DED sample.

Effect of grain boundary Widmanstättenαcolony on the anisotropic tensile properties of directed energy deposited Ti-6Al-4V alloy

Columnar grain structure caused anisotropy in mechanical properties,especially in elongation,is an important concern for Ti-6Al-4 V alloy fabricated by directed energy deposition(DED).Several strategies have been proposed to reduce anisotropy by globularizing the grains,but these conventional approaches are costly and inefficient due to challenges faced during producing the columnarβ-grain structures.However,understanding the impact of columnar grain-related microstructures on the anisotropic deformation behavior is still necessary.Despite the recognition of the importance of grain boundary Widmannstättenαcolony(αWGB)as a grain-related microstructure,it has received limited attention in available literature on anisotropy in mechanical properties.This study employed in-situ induction heating during DED to controlαWGB formation,yielding three Ti-6Al-4 V samples with varyingαWGB sizes.Anisotropic deforma-tion ofαWGB and its impact on elongation in build and transverse directions were analyzed.αWGB width grew from 0.5μm to 32.4μm via diffusion-controlled growth due to reduced cooling rate.Transverse deformation led to dislocation movement and accumulation,causing early failure and worsened ductile anisotropy withinαWGB.Notably,largerαWGB size significantly exacerbated anisotropy in ductility.This work underscoresαWGB’s role in anisotropic deformation and offers insights for optimizing mechanical properties in DED-fabricated titanium alloys.

Revealing precipitation behavior and mechanical response of wire-arc directed energy deposited Mg-Gd-Y-Zr alloy by tailoring aging procedures

Mg-Gd-Y-Zr alloy,as a typical magnesium rare-earth(Mg-RE)alloy,is gaining popularity in the advanced equipment manufacturing fields owing to its noticeable age-hardening properties and high specific strength.However,it is extremely challenging to prepare wrought components with large dimensions and complex shapes because of the poor room-temperature processability of Mg-Gd-Y-Zr alloy.Herein,we report a wire-arc directed energy deposited(DED)Mg-10.45Gd-2.27Y-0.52Zr(wt.%,GW102K)alloy with high RE content presenting a prominent combination of strength and ductility,realized by tailored nanoprecipitates through an optimized heat treatment procedure.Specifically,the solution-treated sample exhibits excellent ductility with an elongation(EL)of(14.6±0.1)%,while the aging-treated sample at 200°C for 58 h achieves an ultra-high ultimate tensile strength(UTS)of(371±1.5)MPa.Besides,the aging-treated sample at 250°C for 16 h attains a good strength-ductility synergy with a UTS of(316±2.1)MPa and a EL of(8.5±0.1)%.Particularly,the evolution mechanisms of precipitation response induced by various aging parameters and deformation behavior caused by nanoprecipitates type were also systematically revealed.The excellent ductility resulted from coordinating localized strains facilitated by active slip activity.And the ultra-high strength should be ascribed to the dense nano-β'hampering dislocation motion.Additionally,the shearable nano-β1 contributed to the good strength-ductility synergy.This work thus offers insightful understanding into the nanoprecipitates manipulation and performance tailoring for the wire-arc DED preparation of large-sized Mg-Gd-Y-Zr components with complex geometries.

Formation mechanism of inherent spatial heterogeneity of microstructure and mechanical properties of NiTi SMA prepared by laser directed energy deposition

Ni51Ti49 at.%bulk was additively manufactured by laser-directed energy deposition(DED)to reveal the microstructure evolution,phase distribution,and mechanical properties.It is found that the localized remelting,reheating,and heat accumulation during DED leads to the spatial heterogeneous distribution of columnar crystal and equiaxed crystal,a gradient distribution of Ni4Ti3 precipitates along the building direction,and preferential formation of Ni4Ti3 precipitates in the columnar zone.The austenite transformation finish temperature(Af)varies from-12.65℃(Z=33 mm)to 60.35℃(Z=10 mm),corresponding to tensile yield strength(σ0.2)changed from 120±30 MPa to 570±20 MPa,and functional properties changed from shape memory effect to superelasticity at room temperature.The sample in the Z=20.4 mm height has the best plasticity of 9.6%and the best recoverable strain of 4.2%.This work provided insights and guidelines for the spatial characterization of DEDed NiTi.

Oxidative Molecular Layer Deposition Tailoring Eco-Mimetic Nanoarchitecture to Manipulate Electromagnetic Attenuation and Self-Powered Energy Conversion

Advanced electromagnetic devices,as the pillars of the intelligent age,are setting off a grand transformation,redefining the structure of society to present pluralism and diversity.However,the bombardment of electromagnetic radiation on society is also increasingly serious along with the growing popularity of"Big Data".Herein,drawing wisdom and inspiration from nature,an eco-mimetic nanoarchitecture is constructed for the first time,highly integrating the advantages of multiple components and structures to exhibit excellent electromagnetic response.Its electromagnetic properties and internal energy conversion can be flexibly regulated by tailoring microstructure with oxidative molecular layer deposition(oMLD),providing a new cognition to frequency-selective microwave absorption.The optimal reflection loss reaches≈−58 dB,and the absorption frequency can be shifted from high frequency to low frequency by increasing the number of oMLD cycles.Meanwhile,a novel electromagnetic absorption surface is designed to enable ultra-wideband absorption,covering almost the entire K and Ka bands.More importantly,an ingenious self-powered device is constructed using the eco-mimetic nanoarchitecture,which can convert electromagnetic radiation into electric energy for recycling.This work offers a new insight into electromagnetic protection and waste energy recycling,presenting a broad application prospect in radar stealth,information communication,aerospace engineering,etc.

Overview of Factors Affecting Dust Deposition on Photovoltaic Cells and Cleaning Methods

Dust deposition on the surface of photovoltaic (PV) cells poses a significant challenge to their efficiency, especially in arid regions characterized by desert and semi-desert conditions. Despite the pronounced impact of dust accumulation, these regions offer optimal solar radiation and minimal cloud cover, making them ideal candidates for widespread PV cell deployment. Various surface cleaning methods exist, each employing distinct approaches. Choosing an appropriate cleaning method requires a comprehensive understanding of the mechanisms involved in both dust deposition on module surfaces and dust adhesion to PV cell surfaces. The mechanisms governing dust deposition and adhesion are complex and multifaceted, influenced by factors such as the nature and properties of the dust particles, environmental climatic conditions, characteristics of protective coatings, and the specific location of the PV installation. These factors exhibit regional variations, necessitating the implementation of diverse cleaning approaches tailored to the unique conditions of each location. The first part of this article explores the factors influencing dust deposition on PV cell surfaces, delving into the intricate interplay of environmental variables and particle characteristics. Subsequently, the second part addresses various cleaning methods, offering an analysis of their respective advantages and disadvantages. By comprehensively examining the factors influencing dust accumulation and evaluating the effectiveness of different cleaning strategies, this article aims to contribute valuable insights to the ongoing efforts to optimize the performance and longevity of photovoltaic systems in diverse geographical contexts.

A review on additive/subtractive hybrid manufacturing of directed energy deposition(DED)process

Additive manufacturing(AM)processes are reliable techniques to build highly complex metallic parts.Direct energy deposition(DED)is one of the most common technologies to 3D print metal alloys.Despite a wide range of literature that has discussed the ability of DED in metal printing,weak binding,poor accuracy,and rough surface still exist in final products.Thus,limitations in 3D printing of metal powder and wire indicate post-processing techniques required to achieve high quality in both mechanical properties and surface quality.Therefore,hybrid manufacturing(HM),specifically additive/subtractive hybrid manufacturing(ASHM)of DED has been proposed to enhance product quality.ASHM is a capable process that combines two technologies with 3-axis or multi-axis machines.Different methods have been suggested to increase the accuracy of machines to find better quality and microstructure.In contrast,drawbacks in ASHM still exist such as limitations in existing reliable materials and poor accuracy in machine coordination to avoid collision in the multi-axes machine.It should be noted that there is no review work with focuses on both DED and hybridization of DED processes.Thus,in this review work,a unique study of DED in comparison to ASHM as well as novel techniques are discussed with the objective of showing the capabilities of each process and the benefits of using them for different applications.Finally,new gaps are discussed in ASHM to enhance the layer bonding and surface quality with the processes'effects on microstructures and performance.

ENERGY DEPOSITION BY LOW ENERGY IONS

Considering the ionizing energy of bound electrons, the energy depositions around the path of an ion whose energy is below 1 MeV/u are calculated by using track structure model. The results are in good agreement with experiments.

Effects of energy deposition on mechanical properties of sodium borosilicate glass irradiated by three heavy ions: P, Kr, and Xe

Sodium borosilicate glasses are candidate materials for high-level radioactive waste vitrification;therefore, understanding the irradiation effects in model borosilicate glass is crucial. Effects of electronic energy deposition and nuclear energy deposition induced by the impact of heavy ions on the hardness and Young’s modulus of sodium borosilicate glass were investigated. The work concentrates on sodium borosilicate glasses, henceforth termed NBS1 (60.0% SiO2, 15.0% B2O3, and 25.0% Na2O in mol%). The NBS1 glasses were irradiated by P, Kr, and Xe ions with 0.3 MeV, 4 MeV, and 5 MeV, respectively. The hardness and Young’s modulus of ion-irradiated NBS1 glasses were measured by nanoindentation tests. The relationships between the evolution of the hardness, the change in the Young’s modulus of the NBS1 glasses, and the energy deposition were investigated. With the increase in the nuclear energy deposition, both the hardness and Young’s modulus of NBS1 glasses dropped exponentially and then saturated. Regardless of the ion species, the nuclear energy depositions required for the saturation of hardness and Young’s modulus were apparent at approximately 1.2 × 10^20 keV/cm^3 and 1.8 × 10^20 keV/cm^3, respectively. The dose dependency of the hardness and Young’s modulus of NBS1 glasses was consistent with previous studies by Peuget et al. Moreover, the electronic energy loss is less than 4 keV/nm, and the electronic energy deposition is less than 3.0 × 10^22 keV/cm^3 in this work. Therefore, the evolution of hardness and Young’s modulus could have been primarily induced by nuclear energy deposition.

Theoretical analysis of ion kinetic energies and DLC film deposition by CH4＋ Ar （He） dielectric barrier discharge plasmas

The kinetic energy of ions in dielectric barrier discharge plasmas are analysed theoretically using the model of binary collisions between ions and gas molecules. Langevin equation for ions in other gases, Blanc law for ions in mixed gases, and the two-temperature model for ions at higher reduced field are used to determine the ion mobility. The kinetic energies of ions in CH4 ＋ Ar（He） dielectric barrier discharge plasma at a fixed total gas pressure and various Ar （He） concentrations are calculated. It is found that with increasing Ar （He） concentration in CH4 ＋ Ar （He） from 20% to 83%, the CH4＋ kinetic energy increases from 69.6 （43.9） to 92.1 （128.5）eV, while the Ar＋ （He＋） kinetic energy decreases from 97 （145.2） to 78.8 （75.5）eV. The increase of CH4＋ kinetic energy is responsible for the increase of hardness of diamond-like carbon films deposited by CH4 ＋ Ar （He） dielectric barrier discharge without bias voltage over substrates.

Numerical Simulation of Radial and Angular Distribution of γ-Ray's Energy Deposition in Scintillation Optical Fibre

Angular and radial distributions of the energy deposition of γ-ray radiation in scintillation optical fibres are simulated and analysed using the Geant4 system. The results show a linear relation between the energy deposition and the radius of the fibres. The deposition is roughly inversely proportional to sinθ with θ the incident angle relative to the fibre axis. The results could provide corrections to the measurements of the scintillation fibres used in monitoring the γ-ray radiation.

Age and Gender Dependent Deposition of Crude Nutrients and Energy in Fast Growing Meat-Type Chickens

Two consecutive growth studies were conducted to investigate the age-dependent nutrient and energy deposition in male and female meat-type chickens (Ross 308) based on feather and feather-free body fraction data determined according to the comparative slaughter technique. Birds were reared under standardized housing conditions (15 floor pens per gender, 5 birds per pen). Both the starter (day 1 to 22) and grower diets (day 22 to 36) were based on corn, wheat, soybean meal, soybean protein concentrate and crystalline feed amino acids. Diets were formulated to ensure an equal feed protein quality close to the ideal amino acid ratio by adjusting a constant mixture of the feed proteins. Individual body weight (BW) and feed intake per pen were recorded weekly. At the start (day 1) as well as on a weekly basis until the end of the 5th week, 15 birds per gender (each 3 pens of 5 birds) were selected and euthanized following 24 h feed deprivation. Subsequently, the feathers were manually removed and quantified. Crude nutrient analysed in representative samples of both feather and feather-free body fractions. The nutrient and energy deposition in the bodies of both genders were significantly increased with increasing age (p . Male birds deposited significantly higher body protein (p and female birds significantly more fat and energy in the whole body (p during the entire growth period. In contrast, no differences were found in protein contents of the BW gain between genders dependent on age (p > 0.05). However, the protein partitioning in the gain of both analyzed body fractions provided oppositional results. Accordingly, male birds yielded relatively more protein in the feather-free body fraction (p and females relatively more feather protein (p as related to the whole body protein gain.

Effects of Maternal Dietary Energy Restriction on Fat Deposition of Offspring

The study was carried out to investigate the effects of maternal dietary energy restriction on growth performance, serum indices and fat deposition of offspring. A total of 400 female Arbor Acres （AA） broiler breeders were studied. These female birds involved three experimental treatments and a control group with normal dietary energy diets （ND, 11.7 MJ of ME. kgt during the laying）. In treatments 2, 3 and 4, the energies of diets were 20%, 30% and 50% （LD20, LD30 and LD50） lower than those of the control, respectively. The study commenced at the beginning of the laying period when the total egg production reached 5% of the flock. All the broiler offspring were fed the same diets. The results showed that in low energy diets, offspring showed decreased 1-day-old weight, but 49-day-old weight was higher in LD20 diet （P〈0.05）. For offspring during days 1-49, the average daily gain （ADG） in LD20 group and the feed conversion ratio in LD50 group were improved as compared with those of the control （P〈0.05）. Compared with the control, abdominal fat percentage increased in 49-day-old offspring from LD30 diet （P〈0.05）; the fat content of breast muscle in offspring increased in broilers fed low energy diets （P〈0.05）. In 28-day-old offspring from breeders given LD20 and LD50 diets, liver fat percentages were higher compared with ND （P〈0.05）. The subcutaneous fat thickness in 28-day-old offspring from LD50 group and 49-day-old offspring from LD30 group was higher （P〈0.05）. On day 49, the serum cholesterol （CHO） of offspring from breeders fed LD20 diet and serum high-density lipoprotein （HDL） of offspring from breeders fed LD50 diet reduced compared with those of the control （P〈0.05）. In addition, a higher triiodothyronine （T3） content in serum was found in offspring from broiler breeders given LD20 and LD30 diets （P〈0.05）. Serum thyroxine （T4） in offspring significantly decreased with the decrease of diet energy （P〈0.05）. In conclusion, to a certain extent, dietary energy restriction in breeders could improve growth performance and promote lipid metabolism of offspring.

Effect of wire-arc directed energy deposition on the microstructural formation and age-hardening response of the Mg-9Al-1Zn(AZ91)alloy

In recent years,wire-arc directed energy deposition(wa DED),which is also commonly known as wire-arc additive manufacturing(WAAM),has emerged as a promising new fabrication technique for magnesium alloys.The major reason for this is the possibility of producing parts with a complex geometry as well as a fine-grained microstructure.While the process has been shown to be applicable for Mg-Al-Zn alloys,there is still a lack of knowledge in terms of the influence of the WAAM process on the age-hardening response.Consequently,this study deals with the aging response of a WAAM AZ91 alloy.In order to fully understand the mechanisms during aging,first,the as-built condition was analyzed by means of high-energy X-ray diffraction(HEXRD)and scanning electron microscopy.These investigations revealed a finegrained,equiaxed microstructure with adjacent areas of alternating Al content.Subsequently,the difference between single-and double-step aging as well as conventional and direct aging was studied on the as-built WAAM AZ91 alloy for the first time.The aging response during the various heat treatments was monitored via in situ HEXRD experiments.Corroborating electron microscopy and hardness studies were conducted.The results showed that the application of a double-step aging heat treatment at 325℃with pre-aging at 250℃slightly improves the mechanical properties when compared to the single-step heat treatment at 325℃.However,the hardness decreases considerably after the pre-aging step.Thus,aging at lower temperatures is preferable within the investigated temperature range of 250-325℃.Moreover,no significant difference between the conventionally aged and directly aged samples was found.Lastly,the specimens showed enhanced precipitation kinetics during aging as compared to cast samples.This could be attributed to a higher amount of nucleation sites and the particular temperature profile of the solution heat treatment.