Influence of layer thickness on formation quality,microstructure,mechanical properties,and corrosion resistance of WE43 magnesium alloy fabricated by laser powder bed fusion

Laser powder bed fusion(L-PBF)of Mg alloys has provided tremendous opportunities for customized production of aeronautical and medical parts.Layer thickness(LT)is of great significance to the L-PBF process but has not been studied for Mg alloys.In this study,WE43 Mg alloy bulk cubes,porous scaffolds,and thin walls with layer thicknesses of 10,20,30,and 40μm were fabricated.The required laser energy input increased with increasing layer thickness and was different for the bulk cubes and porous scaffolds.Porosity tended to occur at the connection joints in porous scaffolds for LT40 and could be eliminated by reducing the laser energy input.For thin wall parts,a large overhang angle or a small wall thickness resulted in porosity when a large layer thicknesses was used,and the porosity disappeared by reducing the layer thickness or laser energy input.A deeper keyhole penetration was found in all occasions with porosity,explaining the influence of layer thickness,geometrical structure,and laser energy input on the porosity.All the samples achieved a high fusion quality with a relative density of over 99.5%using the optimized laser energy input.The increased layer thickness resulted to more precipitation phases,finer grain sizes and decreased grain texture.With the similar high fusion quality,the tensile strength and elongation of bulk samples were significantly improved from 257 MPa and 1.41%with the 10μm layer to 287 MPa and 15.12%with the 40μm layer,in accordance with the microstructural change.The effect of layer thickness on the compressive properties of porous scaffolds was limited.However,the corrosion rate of bulk samples accelerated with increasing the layer thickness,mainly attributed to the increased number of precipitation phases.

Alloy design for laser powder bed fusion additive manufacturing:a critical review

Metal additive manufacturing(AM)has been extensively studied in recent decades.Despite the significant progress achieved in manufacturing complex shapes and structures,challenges such as severe cracking when using existing alloys for laser powder bed fusion(L-PBF)AM have persisted.These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes,overlooking the fast cooling rates,steep temperature gradients and multiple thermal cycles of L-PBF.To address this,there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies.This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF.It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys.The review begins by discussing the features of the L-PBF processes,focusing on rapid solidification and intrinsic heat treatment.Next,the printability of the four main existing alloys(Fe-,Ni-,Al-and Ti-based alloys)is critically assessed,with a comparison of their conventional weldability.It was found that the weldability criteria are not always applicable in estimating printability.Furthermore,the review presents recent advances in alloy development and associated strategies,categorizing them into crack mitigation-oriented,microstructure manipulation-oriented and machine learning-assisted approaches.Lastly,an outlook and suggestions are given to highlight the issues that need to be addressed in future work.

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Laser powder bed fusion(L-PBF) has attracted significant attention in both the industry and academic fields since its inception, providing unprecedented advantages to fabricate complex-shaped metallic components. The printing quality and performance of L-PBF alloys are infuenced by numerous variables consisting of feedstock powders, manufacturing process,and post-treatment. As the starting materials, metallic powders play a critical role in infuencing the fabrication cost, printing consistency, and properties. Given their deterministic roles, the present review aims to retrospect the recent progress on metallic powders for L-PBF including characterization, preparation, and reuse. The powder characterization mainly serves for printing consistency while powder preparation and reuse are introduced to reduce the fabrication costs.Various powder characterization and preparation methods are presented in the beginning by analyzing the measurement principles, advantages, and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed, focusing on steels, nickel-based superalloys, titanium and titanium alloys, and aluminum alloys. The evolution trends of powders and L-PBF parts vary depending on specific alloy systems, which makes the proposal of a unified reuse protocol infeasible. Finally,perspectives are presented to cater to the increased applications of L-PBF technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total costs from the perspective of powders.

Influence of heat treatment on microstructure,mechanical and corrosion behavior of WE43 alloy fabricated by laser-beam powder bed fusion

Magnesium(Mg)alloys are considered to be a new generation of revolutionary medical metals.Laser-beam powder bed fusion(PBF-LB)is suitable for fabricating metal implants withpersonalized and complicated structures.However,the as-built part usually exhibits undesirable microstructure and unsatisfactory performance.In this work,WE43 parts were firstly fabricated by PBF-LB and then subjected to heat treatment.Although a high densification rate of 99.91%was achieved using suitable processes,the as-built parts exhibited anisotropic and layeredmicrostructure with heterogeneously precipitated Nd-rich intermetallic.After heat treatment,fine and nano-scaled Mg24Y5particles were precipitated.Meanwhile,theα-Mg grainsunderwent recrystallization and turned coarsened slightly,which effectively weakened thetexture intensity and reduced the anisotropy.As a consequence,the yield strength and ultimate tensile strength were significantly improved to(250.2±3.5)MPa and(312±3.7)MPa,respectively,while the elongation was still maintained at a high level of 15.2%.Furthermore,the homogenized microstructure reduced the tendency of localized corrosion and favoredthe development of uniform passivation film.Thus,the degradation rate of WE43 parts was decreased by an order of magnitude.Besides,in-vitro cell experiments proved their favorable biocompatibility.

Microstructure and thermal properties of dissimilar M300–CuCr1Zr alloys by multi-material laser-based powder bed fusion

Multi-material laser-based powder bed fusion (PBF-LB) allows manufacturing of parts with 3-dimensional gradient and additional functionality in a single step. This research focuses on the combination of thermally-conductive CuCr1Zr with hard M300 tool steel.Two interface configurations of M300 on CuCr1Zr and CuCr1Zr on M300 were investigated. Ultra-fine grains form at the interface due to the low mutual solubility of Cu and steel. The material mixing zone size is dependent on the configurations and tunable in the range of0.1–0.3 mm by introducing a separate set of parameters for the interface layers. Microcracks and pores mainly occur in the transition zone.Regardless of these defects, the thermal diffusivity of bimetallic parts with 50vol% of CuCr1Zr significantly increases by 70%–150%compared to pure M300. The thermal diffusivity of CuCr1Zr and the hardness of M300 steel can be enhanced simultaneously by applying the aging heat treatment.

Analysis of mesoscopic mechanical dynamic characteristics of ballast bed with under sleeper pads

The meso-dynamical behaviour of a high-speed rail ballast bed with under sleeper pads(USPs)was studied.The geometrically irregular refined discrete element model of the ballast particles was constructed using 3D scanning techniques,and the 3D dynamic model of the rail-sleeper-ballast bed was constructed using the coupled discrete element method-multiflexible-body dynamics(DEM-MFBD)approach.We analyse the meso-mechanical dynamics of the ballast bed with USPs under dynamic load on a train and verify the correctness of the model in laboratory tests.It is shown that the deformation of the USPs increases the contact area between the sleeper and the ballast particles,and subsequently the number of contacts between them.As the depth of the granular ballast bed increases,the contact area becomes larger,and the contact force between the ballast particles gradually decreases.Under the action of the elastic USPs,the contact forces between ballast particles are reduced and the overall vibration level of the ballast bed can be reduced.The settlement of the granular ballast bed occurs mainly at the shallow position of the sleeper bottom,and the installation of the elastic USPs can be effective in reducing the stress on the ballast particles and the settlement of the ballast bed.

Numerical Study of Flow Features Around Submerged Circular and Square Piles at Flat and Scoured Beds Using OpenFOAM

Elucidating the flow features around piles in local scouring processes is crucial for studies of local scouring mechanisms and scour depth estimates.This study details the flow turbulence characteristics of two submerged piles that are determined by solving the Navier-Stokes equations with the improved delayed detached eddy simulation model.This model is verified by comparing experimental and numerical results for hydrodynamic parameters with the literature for both square-crossing piles(SCPs)and circular-crossing piles(CCPs).Original topographies of flat and scoured beds(i.e.,the initial and equilibrium scouring stages)are based on experimental results obtained by the authors in the present paper.SCP and CCP flow features in the scouring process are discussed.The results indicate that during the scouring process,the time-averaged drag coefficient and root mean square(rms)of the lift coefficient increase linearly in the CCP test,while the rms of the lift coefficient in the SCP test decreases linearly.Moreover,the minimum pressure coefficient is always located in the upstream corners in the SCP case but moves from 72.5°to 79.5°when the scour hole is completely developed in the CCP case.Downward flow behind the pile,which is generated by separated boundary layers above the top face of the pile,can reach the sand bed and turn the separated shear layers into patches of small vortices in the near-wake regions.Thus,the high shear stress zones are mainly at the scour edges under scoured-bed conditions.

Mechanical behaviours of bedded sandstone under hydromechanical coupling

The combination of the dipping effect and hydromechanical(H-M)coupling effect can easily lead to water inrush disasters in water-rich roadways with different dip angles in coal mines.Therefore,H-M coupling tests of bedded sandstones under identical osmotic pressure and various confining pressures were conducted.Then,the evolution curves of stress-strain,permeability and damage,macro-and mesoscopic failure characteristics were obtained.Subsequently,the mechanical behaviour was characterized,and finally the failure mechanism was revealed.The results showed that:(1)The failure of the sandstone with the bedding angle of 45°or 60°was the structure-dominant type,while that with the bedding angle of 0°,30°or 90°was the force-dominant type.(2)When the bedding angle was in the range of(0°,30°)or(45°,90°),the confining pressure played a dominant role in influencing the peak strength.However,withinβ∈(30°,45°),the bedding effect played a dominant role in the peak strength.(3)With the increase in bedding angle,the cohesion increased first,then decreased and finally increased,while the internal friction angle was the opposite.(4)When the bedding angle was 0°or 30°,the“water wedging”effect and the“bedding buckling”effect would lead to the forking or converging shear failure.When the bedding angle was 45°or 60°,the sliding friction effect would lead to the shear slipping failure.When the bedding angle was 90°,the combination of the“bedding buckling”effect and shear effect would lead to the mixed tension-shear failure.The above conclusions obtained are helpful for the prevention of water inrush disasters in water-rich roadways with different dips in coal mines.

The influences of perforating phase and bedding planes on the fracture deflection in laminated shale

The perforating phase leads to complex and diverse hydraulic fracture propagation behaviors in laminated shale formations. In this paper, a 2D high-speed imaging scheme which can capture the interaction between perforating phase and natural shale bedding planes was proposed. The phase field method was used to simulate the same conditions as in the experiment for verification and hydraulic fracture propagation mechanism under the competition of perforating phase and bedding planes was discussed.The results indicate that the bedding planes appear to be no influence on fracture propagation while the perforating phase is perpendicular to the bedding planes, and the fracture propagates along the perforating phase without deflection. When the perforating phase algins with the bedding planes, the fracture initiation pressure reserves the lowest value, and no deflection occurs during fracture propagation. When the perforating phase is the angle 45°, 60°and 75°of bedding planes, the bedding planes begin to play a key role on the fracture deflection. The maximum deflection degree is reached at the perforating phase of75°. Numerical simulation provides evidence that the existence of shale bedding planes is not exactly equivalent to anisotropy for fracture propagation and the difference of mechanical properties between different shale layers is the fundamental reason for fracture deflection. The findings help to understand the intrinsic characteristics of shale and provide a theoretical basis for the optimization design of field perforation parameters.

Optimal mining sequence for coal faces under a bedding slope:insight from landslide prevention

Repetitive mining beneath bedding slopes is identified as a critical factor in geomorphic disturbances, especially landslides and surface subsidence. Prior research has largely concentrated on surface deformation in plains due to multi-seam coal mining and the instability of natural bedding slopes, yet the cumulative impact of different mining sequences on bedding slopes has been less explored. This study combines drone surveys and geological data to construct a comprehensive three-dimensional model of bedding slopes. Utilizing FLAC3D and PFC2D models, derived from laboratory experiments, it simulates stress, deformation, and failure dynamics of slopes under various mining sequences. Incorporating fractal dimension analysis, the research evaluates the stability of slopes in relation to different mining sequences. The findings reveal that mining in an upslope direction minimizes disruption to overlying strata. Initiating extraction from lower segments increases tensile-shear stress in coal pillar overburdens, resulting in greater creep deformation towards the downslope than when starting from upper segments, potentially leading to localized landslides and widespread creep deformation in mined-out areas. The downslope upward mining sequence exhibits the least fractal dimensions, indicating minimal disturbance to both strata and surface. While all five mining scenarios maintain good slope stability under normal conditions, recalibrated stability assessments based on fractal dimensions suggest that downslope upward mining offers the highest stability under rainfall, contrasting with the lower stability and potential instability risks of upslope downward mining. These insights are pivotal for mining operations and geological hazard mitigation in multi-seam coal exploitation on bedding slopes.

Influence of the Nature of the Incoming Sludge on the Performance of a Vertical Flow Reed Beds in Dakar-Senegal

This work investigates the influence of the type sludge on drainage, plant development, purification performances and biosolids quality. Drainage properties were measured through the frequency of clogging, the percentage of leachate recovered and the dryness of accumulated sludge. Plant development was measured through the density, the height and the stem diameter. Purification performance was evaluated from the reduction rate. Biosolids quality was measured after 3 months of maturation. The results show that the clogging frequencies were 9.5%;0% and 3.7%;the volume of leachate recovered was 42.2%;20.4% and 24.7% and, the dryness was 33.4%;61.1% and 52.4% for FS-ST, FS-STT and SS respectively. Plants densities were about, with densities 197.1, 171.3 and 178.3 plants/m2 in beds fed respectively with FS-ST, FS-STT and SS. Despite the high removal rates, the concentrations of pollutants in the leachates are above the Senegalese standard NS 05-061 for discharge into the environment. The biosolids are all mature with C/N and NH4+/NO3?ratios lower than 12 and 1 respectively. The biosolids are also rich in organic and mineral elements. The concentrations of Ascaris eggs are higher than the WHO recommendations. These biosolids should be stored for additional time or composted.

Filtration performance and modeling of granular bed for dust removal from coal pyrolytic vapors

Dust removal from pyrolytic vapors at high temperatures is an obstacle to the industrialization of the coal pyrolysis process.In this work,a granular bed with expanded perlites as filtration media was designed and integrated into a 10 t·d^(–1)coal pyrolysis facility.The testing results showed that around 97.56%dust collection efficiency was achieved.As a result,dust content in tar was significantly lowered.The pressure drop of the granular bed maintained in the range of 356 Pa to 489 Pa.The dust size in the effluent after filtration exhibited a bimodal distribution,which was attributed to the heterogeneity of the dust components.The effects of filtration bed on pyrolytic product yields were also discussed.A modified filtration model based on the macroscopic phenomenological theory was proposed to describe the performance of the granular bed.The computation results were well agreed with the experimental data.

Hydrodynamic analysis of carbon nanotube clusters in distributor-less conical fluidized beds with step-by-step scaling

As a high-performance material with great application potential,the application of carbon nanotubes has been limited by their production volume.A distributor-less conical fluidized bed is the main equipment used in the industrial production of carbon nanotubes.To improve the production volume and product quality of carbon nanotubes,the study of fluidized-bed-diameter scaling is important.Three different diameters of distributor-less conical fluidized beds were established,and then the particle behavior and bubble characteristics of carbon nanotube clusters at these bed diameters were investigated.Time-series and wavelet analysis methods were used to analyze the pressure-fluctuation signals inside the fluidized beds.Results showed that the distributor-less design caused the airflow to break through the middle of the bed,which did not change with the change in bed diameter.The powder-bridging phenomenon of carbon nanotube clusters in a 100-mm-diameter fluidized bed was related to the special microstructure of carbon nanotube clusters.The frequency of pressure fluctuations in the bed decreased nonlinearly with increasing bed diameter.This study can guide the design and scale-up of distributor-less conical fluidized beds,especially for the scale-up of carbon nanotube production equipment,which can contribute to the improvement of carbon nanotubes’capacity and quality in industrial production.

Influence of High-Density Bedding Plane Characteristics on Hydraulic Fracture Propagation in Shale Oil Reservoir

The existence of high-density bedding planes is a typical characteristic of shale oil reservoirs.Understanding the behavior of hydraulic fracturing in high-density laminated rocks is significant for promoting shale oil production.In this study,a hydraulic fracturing model considering tensile failure and frictional slip of the bedding planes is established within the framework of the unified pipe-interface element method(UP-IEM).The model developed for simulating the interaction between the hydraulic fracture and the bedding plane is validated by comparison with experimental results.The hydraulic fracturing patterns in sealed and unsealed bedding planes are compared.Additionally,the effects of differential stress,bedding plane permeability,spacing,and the friction coefficient of the bedding plane are investigated.The results showed that a single main fracture crossing the bedding planes is more likely to form in sealed bedding planes under high differential stress.The decrease in bedding plane permeability and the increase in the friction coefficient also promote the fracture propagating perpendicular to the bedding planes.Shale with high-density bedding planes has a poorer fracturing effect than that with low-density bedding planes,as the hydraulic fracture is prone to initiate and propagate along the bedding planes.Moreover,higher injection pressure is needed to maintain fracture propagation along the bedding.An increase in bedding density will lead to a smaller fracturing area.Fracturing fluid seepage into the bedding planes slows shale fracturing.It is recommended that increasing the injection flow rate,selecting alternative fracturing fluids,and employing multi-well/multi-cluster fracturing may be efficient methods to improve energy production in shale oil reservoirs.

High-Efficiency Dynamic Scanning Strategy for Powder Bed Fusion by Controlling Temperature Field of the Heat-Affected Zone

Improvement of fabrication efficiency and part performance was the main challenge for the large-scale powder bed fusion(PBF)process.In this study,a dynamic monitoring and feedback system of powder bed temperature field using an infrared thermal imager has been established and integrated into a four-laser PBF equipment with a working area of 2000 mm×2000 mm.The heat-affected zone(HAZ)temperature field has been controlled by adjusting the scanning speed dynamically.Simultaneously,the relationship among spot size,HAZ temperature,and part performance has been established.The fluctuation of the HAZ temperature in four-laser scanning areas was decreased from 30.85℃to 17.41℃.Thus,the consistency of the sintering performance of the produced large component has been improved.Based on the controllable temperature field,a dynamically adjusting strategy for laser spot size was proposed,by which the fabrication efficiency was improved up to 65.38%.The current research results were of great significance to the further industrial applications of large-scale PBF equipment.

Mechanical and damping performances of TPMS lattice metamaterials fabricated by laser powder bed fusion

Lattice metamaterials based on three-period minimum surface(TPMS)are an effective means to achieve lightweight and high-strength materials which are widely used in various fields such as aerospace and ships.However,its vibration and noise reduction,and damping properties have not been fully studied.Therefore,in this study,the TPMS structures with parameterization were designed by the method of surface migration,and the TPMS structures with high forming quality was manufactured by laser powder bed fusion(LPBF).The mechanical properties and energy absorption characteristics of the beam and TPMS structures were studied and compared by quasi-static compression.The modal shapes of the beam lattice structures and TPMS structures were obtained by the free modal analysis,and the damping properties of two structures were obtained by modal tests.For the two structures after heat treatment with the same porosity of 70%,the yield strength of the beam lattice structure reaches 40.76 MPa,elastic modulus is 20.38 GPa,the energy absorption value is 32.23 MJ·m^(-3),the damping ratio is 0.52%.The yield strength,elastic modulus,energy absorption value,and damping ratio of the TPMS structure are 50.74 MPa,25.37 GPa,47.34 MJ·m^(-3),and 0.99%,respectively.The results show that TPMS structures exhibit more excellent mechanical properties and energy absorption,better damping performance,and obvious advantages in structural load and vibration and noise reduction compared with the beam lattice structures under the same porosity.

Experimental study on secondary air mixing along the bed height in a circulating fluidized bed with a multitracer-gas method

A multitracer-gas method was proposed to study the secondary air(SA)mixing along the bed height in a circulating fluidized bed(CFB)using carbon monoxide(CO),oxygen(O_(2)),and carbon dioxide(CO_(2))as tracer gases.Experiments were carried out on a cold CFB test rig with a cross-section of 0.42 m×0.73 m and a height of 5.50 m.The effects of superficial velocity,SA ratio,bed inventory,and particle diameter on the SA mixing were investigated.The results indicate that there are some differences in the measurement results obtained using different tracer gases,wherein the deviation between CO and CO_(2) ranges from 42%to 66%and that between O_(2) and CO_(2) ranges from 45%to 71%in the lower part of the fluidized bed.However,these differences became less pronounced as the bed height increased.Besides,the high solid concentration and fine particle diameter in the CFB may weaken the difference.The measurement results of different tracer gases show the same trends under the variation of operating parameters.Increasing superficial velocity and SA ratio and decreasing particle diameter result in better mixing of the SA.The effect of bed inventory on SA mixing is not monotonic.

Hole cleaning evaluation and installation spacing optimization of cuttings bed remover in extended-reach drilling

In extended-reach or long-horizontal drilling,cuttings usually deposit at the bottom of the annulus.Once cuttings accumulate to a certain thickness,complex problems such as excessive torque and drag,tubing buckling,and pipe stuck probably occur,which results in a lot of non-productive time and remedial operations.Cuttings bed remover can efficiently destroy deposited cuttings in time through hydraulic and mechanical stirring effects.This paper aims to build a method for hole cleaning evaluation and installation spacing optimization of cuttings bed remover to improve the wellbore cleaning effect.Firstly,a Computational Fluid Dynamics approach with Eulerian—Eulerian multiphase model was utilized to investigate the mechanism of cuttings transportation,and a new type of cuttings bed remover was designed.Next,an evaluation method of hole cleaning effect of remover was established.After that,the effects of several drilling parameters on hole cleaning including flow rate of drilling fluid,rotational speed of drillpipe,rate of penetration,wellbore size,rheological property of drilling fluid,and remover eccentricity on the performance of cuttings bed remover were investigated.The results demonstrate that the new type of remover with streamline blade performs better than conventional removers.The efficiency of hole cleaning is greatly improved by increasing the rotational speed of drillpipe,flow rate of drilling fluid,remover eccentricity,and 6 rpm Fann dial reading for drilling fluid.While higher rate of penetration and large wellbore size result in worse hole cleaning.These findings can serve as an important guide for the structure optimization design of cuttings bed remover and installation spacing of removers.

Unveiling the cellular microstructure-property relations in martensitic stainless steel via laser powder bed fusion

Laser powder bed fusion(LPBF)is a widely recognized additive manufacturing technology that can fabricate complex components rapidly through layer-by-layer formation.However,there is a paucity of research on the effect of laser scanning speed on the cellular microstructure and mechanical properties of martensitic stainless steel.This study systematically investigated the influence of laser scanning speed on the cellular microstructure and mechanical properties of a developed Fe11Cr8Ni5Co3Mo martensitic stainless steel produced by LPBF.The results show that increasing the laser scanning speed from 400 to 1000 mm/s does not lead to a noticeable change in the phase fraction,but it reduces the average size of the cellular microstructure from 0.60 to 0.35μm.The scanning speeds of 400 and 1000 mm/s both had adverse effects on performances of sample,resulting in inadequate fusion and keyhole defects respectively.The optimal scanning speed for fabricating samples was determined to be 800 mm/s,which obtained the highest room temperature tensile strength and elongation,with the ultimate tensile strength measured at(1088.3±2.0)MPa and the elongation of(16.76±0.10)%.Furthermore,the mechanism of the evolution of surface morphology,defects,and energy input were clarified,and the relationship between cellular microstructure size and mechanical properties was also established.

Deep bed filtration model for cake filtration and erosion

Many phenomena in nature and technology are associated with the filtration of suspensions and colloids in porous media. Two main types of particle deposition,namely, cake filtration at the inlet and deep bed filtration throughout the entire porous medium, are studied by different models. A unified approach for the transport and deposition of particles based on the deep bed filtration model is proposed. A variable suspension flow rate, proportional to the number of free pores at the inlet of the porous medium, is considered. To model cake filtration, this flow rate is introduced into the mass balance equation of deep bed filtration. For the cake filtration without deposit erosion,the suspension flow rate decreases to zero, and the suspension does not penetrate deep into the porous medium. In the case of the cake filtration with erosion, the suspension flow rate is nonzero, and the deposit is distributed throughout the entire porous medium. An exact solution is obtained for a constant filtration function. The method of characteristics is used to construct the asymptotics of the concentration front of suspended and retained particles for a filtration function in a general form. Explicit formulae are obtained for a linear filtration function. The properties of these solutions are studied in detail.