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.

Numerical simulation on residual stress and deformation for WAAM parts of aluminum alloy based on temperature function method

Wire arc additive manufacture(WAAM) is a new technique to fabricate large-scale complex aluminum alloy components.However, the performance of the parts is critically influenced by residual stresses and deformation. A sequentially thermal-mechanical coupled model of residual stress and deformation for aluminum alloy WAAM parts was established based on commercial FE software ABAQUS. The temperature field was calculated by the moving heat source(MHS) method. The temperature function was obtained according to the distribution of the peak temperature. Furthermore, the MHS method and segmented temperature function(STF) method were used to calculate the residual stress and deformation. The results show that the STF method satisfies both the efficiency and accuracy requirements. 1-segment, 3-segment, and 5-segment STF methods can shorten the time for mechanical analysis by 91%, 79%, 63%, respectively.The error of the residual stress and deformation are all less than 20%. STF method provides an effective way to predict the residual stress and deformation of large-scale WAAM parts.

基于动态再结晶软化效应的CuCrZr和35CrMo高温流变行为本构模型（英文）

为了研究热变形过程中动态再结晶对金属流变行为的影响,采用Gleeble-3800热模拟机对CuCrZr合金和35CrMo钢进行了高温压缩实验.通过观察热变形后样品的金相组织,证明了样品在热变形过程中经历了明显的动态再结晶,且动态再结晶晶粒尺寸随着变形温度的升高和应变速率的降低而增大.以应力-位错密度的关系为理论依据,定义了由动态再结晶所引起的净软化作用η.η与Z参数之间呈三次递减关系.计算得到的CuCrZr合金和35CrMo钢的最大η值分别为21.9%和29.8%.基于所提出的动态再结晶软化效应,构建了两种合金的高温流动行为本构模型.并对模型参数进行了定义和求解.所建模型的预测值与实验所得的数据高度吻合.

Hollow FeCoNiAl microspheres with stabilized magnetic properties for microwave absorption

Development of high-performance microwave absorption materials(MAM)with stabilized magnetic properties at high temperatures is specifically essential but remains challenging.Moreover,the Snoke's limitation restrains the microwave absorption(MA)property of magnetic materials.Modulating alloy components is considered an effective way to solve the aforementioned problems.Herein,a hollow medium-entropy FeCoNiAl alloy with a stable magnetic property is prepared via simple spray-drying and two-step annealing for efficient MA.FeCoNiAl exhibited an ultrabroad effective absorption band(EAB)of 5.84 GHz(12.16–18 GHz)at a thickness of just 1.6 mm,revealing an excellent absorption capability.Furthermore,the MA mechanism of FeCoNiAl is comprehensively investigated via off-axis holography.Finally,the electromagnetic properties,antioxidant properties,and residual magnetism at high temperatures of FeCoNiAl alloys are summarized in detail,providing new insights into the preparation of MAM operating at elevated temperatures.

Digital twin model of gas turbine and its application in warning of performance fault

The digital twin-driven performance model provides an attractive option for the warn gas-path faults of the gas turbines.However,three technical difficulties need to be solved:(1)low modeling precision caused by individual differences between gas turbines,(2)poor solution efficiency due to excessive iterations,and(3)the false alarm and missing alarm brought by the traditional fixed threshold method.This paper proposes a digital twin model-based early warning method for gas-path faults that breaks through the above obstacles from three aspects.Firstly,a novel performance modeling strategy is proposed to make the simulation effect close to the actual gas turbine by fusing the mechanism model and measurement data.Secondly,the idea of controlling the relative accuracy of model parameters is developed.The introduction of an error module to the existing model can greatly shorten the modeling cycle.The third solution focuses on the early warning based on the digital twin model,which self-learns the alarm threshold of the warning feature of gas-path parameters using the kernel density estimation.The proposed method is utilized to analyze actual measured data of LM2500+,and the results verify that the new-built digital model has higher accuracy and better efficiency.The comparisons show that the proposed method shows evident superiority in early warning of performance faults for gas turbines over other methods.

Creep rupture behavior and microstructural evolution of modified 9Cr-1Mo heat-resistant steel

High-temperature creep rupture behavior of modified 9Cr-lMo steel used for steam cooler was investigated at temperature of 838 and 923 K and stress ranging from 100 to 250 MPa.Based on the analysis of creep rate-time curves,it is found that the creep rupture life decreases with the increase in the applied stress and temperature.The creep damage tolerance factor has been identified as a value of 8.In the normalized and tempered condition,the studied steel shows typical martensitic microstructure with Cr-rich M23C6 and Nb-or V-rich MX precipitates.Moreover,the Laves phase has been found along the grain boundaries.The fracture morphology characterized by field emission scanning electron microscope is adopted to reveal the creep failure mechanisms.The investigated results indicate the occurrence of the transgranular fracture under all the creep test conditions.