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中国机械工程学报：增材制造前沿（英文）
中国机械工程学报：增材制造前沿（英文）
中国机械工程学报：增材制造前沿（英文）/Journal Chinese Journal of Mechanical Engineering: Additive Manufacturing Frontiers
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    Editorial

    Dichen Li
    1-2页
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    Additive Manufacturing of Integrated Micro/Macro Structures Driven by Diversified Functions-30 years of Development of Additive Manufacturing in Xi'an Jiaotong University

    Xiaoyong TianDichen LiQin LianLing Wang...
    3-26页
    查看更多>>摘要：Scientists and engineers are looking forward to new manufacturing technologies to realize the integrated fabri-cation of macro shape and microstructure for the components with a short production chain,which can also save materials and reduce energy consumption.Additive manufacturing(AM)technology is a new fabrication pattern with a character of a lay-by-lay material deposition.The components are fabricated in a bottom-up way,from points,lines,to layers and volume,which provided a capability to solve the impossible integrated fabrication problem for micro-and macro-structure by using conventional manufacturing technologies.Thus,based on inte-grated fabrication of micro-and macro-structures,research team in Xi'an Jiaotong University has been focusing on technological innovations and applications of advanced additive manufacturing technologies.Novel additive manufacturing principles have been proposed and explored,by which new AM processes and equipment for met-als,composites,ceramics,and biomaterials have been developed to support the industrial applications.Additive manufacturing and cutting-edge applications of advanced composite structure,metamaterials,bio-implants,and monocrystal alloy components have been investigated to push the new development of integrated fabrication of micro-and macro-structures.
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    High-Performance Aluminum-Based Materials Processed by Laser Powder Bed Fusion:Process,Microstructure,Defects and Properties Coordination

    He LiuDongdong GuLixia XiHan Zhang...
    27-50页
    查看更多>>摘要：Significant contributions have been made to understanding the processing of various metal materials using laser powder bed fusion(LPBF)for the design and fabrication of high-performance metal components in many fields.For laser additive manufacturing,aluminum-based materials are regarded as difficult-to-fabricate materials be-cause of their special physical properties,including low density,low laser absorption,high thermal conductivity,and ease of oxidation.Currently,LPBF-formed structural materials require high densification,fine grains,high specific strength,high ductility,and optimized physical or chemical properties.Therefore,comprehensive un-derstanding of the fabrication and performance of Al-based materials processed by LPBF is of significant value.This paper covers emerging research on aluminum-based materials using LPBF,providing an overall view of the basic scientific mechanisms behind manufacturing.The state-of-the-art researches of aluminum-based materials for LPBF formability as well as the microstructures,properties and corresponding metallurgical mechanisms are reviewed.The mechanisms of some of the main defects(pores,cracks,balling,and oxide inclusions)and control measures are also discussed.A summary and outlook for the further development of Al-based materials for LPBF are addressed.
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    Recent Advances in Additive Manufacturing Technology:Achievements of the Rapid Manufacturing Center in Huazhong University of Science and Technology

    Yusheng ShiChunze YanBo SongBin Su...
    51-89页
    查看更多>>摘要：Additive manufacturing(AM)technology enables the creation of a wide variety of assemblies and complex shapes from three-dimensional model data in a bottom-up,layer-by-layer manner.Therefore,AM has revolutionized the modern manufacturing industry,attracting increasing interest from both academic and industrial fields.The Rapid Manufacturing Center(RMC)of the School of Materials Science and Engineering at the Huazhong Univer-sity of Science and Technology(HUST),one of the earliest and most powerful AM research teams in China,has been engaged in AM research since 1991.Aiming to address the"stuck neck"problems of specific high-strength products for AM,the RMC has conducted full-chain research in the aspects of special materials,processes,equip-ment,and applications for AM.Moreover,it has formed a multi-disciplinary research team over the past three decades.Relevant research achievements in the AM field include winning five national awards,more than ten first prizes,and more than ten second prizes at the provincial and ministerial levels.The RMC was complimented as"the world's most influential organization in the laser AM field in 2018"by Virtual and Physical Prototyping(an international authoritative magazine of AM).Moreover,their industrialization achievements were evaluated as"having affected countries such as Singapore,South Korea,and the United States"by an international author-itative Wohlers Report on AM.In this study,we first summarize the representative research achievements of the RMC in the AM field.These include the preparation and processing technology of high-performance polymeric,metallic,and ceramic materials for AM;advanced processing technology and software/equipment for AM;and typical AM-fabricated products and their applications.Further,we discuss the latest research achievements in cutting-edge 4D printing in terms of feedstock selection,printing processes,induction strategies,and potential ap-plications.Finally,we provide insights into the future directions of AM technology development:(i)Evolving from three-dimensional printing to multi-dimensional printing,(ⅱ)transitioning from plane slicing to curved surface slicing to woven slicing,(ⅲ)enhancing efficient formation from dot-line-sheet-volume printing,(ⅳ)shifting from single material to multi-materials AM,(ⅴ)advancing from the multiscale direction of macroscopic-mesoscopic-microscopic structures,(ⅵ)integrating material preparation with forming integration,(ⅶ)expanding from small batch to large batch.
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    A Survey of Topology Optimization Methods Considering Manufacturable Structural Feature Constraints for Additive Manufacturing Structures

    Shutian LiuQuhao LiJingyu HuWenjiong Chen...
    90-111页
    查看更多>>摘要：Additive manufacturing(AM)has made significant progress in recent years and has been successfully applied in various fields owing to its ability to manufacture complex geometries.This method efficiently expands the design space,allowing for the creation of products with better performance than ever before.With the emergence of new manufacturing technologies,new design methods are required to efficiently utilize the expanded design space.Therefore,topology optimization methods have attracted the attention of researchers because of their ability to generate new and optimized designs without requiring prior experience.The combination of AM and topology optimization has proven to be a powerful tool for structural innovation in design and manufacturing.However,it is important to note that AM does not eliminate all manufacturing restrictions but instead replaces them with a different set of design considerations that designers must consider for the successful implementation of these technologies.This has motivated research on topology optimization methods that incorporate manufacturable constraints for AM structures.In this paper,we present a survey of the latest studies in this research area,with a particular focus on developments in China.Additionally,we discuss the existing research gaps and future development trends.
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    Smart Bionic Structures:Connecting Nature and Technology through Additive Manufacturing

    Xingran LiShuang ZhangPengfei JiangMinghao Nie...
    112-129页
    查看更多>>摘要：The ability of organisms to adjust to environmental changes offers valuable insights into the development and creation of innovative smart systems.As requirements increase,the ability of smart materials to change their shapes has become a broader aim beyond their original capabilities.In contrast to conventional manufacturing methods,additive manufacturing(AM)skillfully combines precise three-dimensional structures and the intricate response mechanisms of biological organisms with smart materials.This combination enables the production of smart bionic structures with programmable shapes and features.Trends such as dynamic modulation,responsive-ness to multiple stimuli,and the integration of functions are emerging as significant in the development of smart bionic structures.This review first presents smart structures that nature has designed and built in various organ-isms,highlighting the relationship between the structural characteristics and patterns of deformation.The review then discusses how smart bionic structures developed using AM techniques respond to different stimuli.Addi-tionally,the potential uses of smart bionic structures in biomedicine,intelligent robotics,origami construction,and aerospace are discussed.Finally,the challenges and future prospects for smart bionic structures are exam-ined with the goal of offering innovative solutions for creating the next generation of smart systems through interdisciplinary research.
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    Advances in Digital Multi-Material Composite Sand-Mold Binder-Jetting Forming Technology and Equipment

    Haoqin YangZhongde ShanDandan YanJianpei Shi...
    130-147页
    查看更多>>摘要：In response to the demand for environmentally friendly and sustainable manufacturing processes for intricate castings used in advanced equipment,binder jetting technology has emerged as a leading method for achieving rapid casting design and manufacturing.This technology has attracted much interest from research institutions,universities,and enterprises worldwide.Binder jetting-based sand-mold additive manufacturing can be used to manufacture complex sand molds(cores)directly and does not require traditional molds,expediting the produc-tion of complex castings and the accompanying process refinement.The exceptional design and manufacturing versatility afforded by this technology has enabled a profound transformation in the foundry industry,advancing the digitization,sustainability,and intelligent evolution of sand casting.This paper explores the recent research progress and achievements in the field of binder jetting sand-mold additive manufacturing in four dimensions:materials,design methods,process technologies,and system equipment.Finally,the characteristics and applica-tion advantages of binder jetting technology are analyzed,and the future development trends and challenges of binder jetting-based sand-mold additive manufacturing technology are investigated.
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    Interface Stability Homogeneity of Large-Scale Laser-Melting-Deposited Titanium Alloy Components

    Yong XieZhenyu YanJiangtao NiPeng Dong...
    148-157页
    查看更多>>摘要：Interface stability homogeneity control remains a challenging problem in large-scale laser-melting-deposited ti-tanium(LLMDT)alloy components for aerospace applications.In this study,the homogeneity of the interface stability of LLMDT components after post heat treatment was investigated.Recrystallized grains nucleated and grew in the equiaxed and columnar grain regions in the LLMDT part,whereas they did not form in the interface re-gion because the recrystallization driving force in the interface region was lower than that in the LLMDT part.The microstructures of the LLMDT components showed coarsened α lamellae,and their width varied from 1.65 μm to 2.18 μm.The α lamellae did not completely coarsen during post heat treatment(950 ℃/1 h/air cooling+550 ℃/4 h/air cooling)because of the low coarsening driving force.For the LLMDT components,the ultimate tensile strength(UTS)and yield strength(YS)were slightly different in different regions owing to the slight difference in the width of the α lamellae.The elongation(EL)of the LLMDT components exhibited no difference,and there was nearly zero anisotropic ductility.The highest fluctuation ratios of the UTS,YS,and EL were 3.11％,3.8％,and 7.18％,respectively.The tensile properties of the LLMDT components showed no difference in the different regions,indicating interface stability homogeneity.
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    Sub-Rapid-Solidification Dominated Microstructure Modification and Strength Increment for Wire-Arc Directed Energy Deposited Al-Ce-Mg Alloys

    Yueling GuoYangyu YanJinlong HuQifei Han...
    158-168页
    查看更多>>摘要：Conventional cast Al-Ce alloys are challenged by the increasing demand for improved mechanical properties.To address this issue,in this study,wire-arc directed energy deposition(WA-DED)is employed for the fabrication of Al-15Ce-3Mg(wt％)alloy components.We aimed to tune the microstructure and mechanical properties via the inherent sub-rapid-solidification effect of WA-DED.In addition to significant microstructure refinement,a decrease in arc heat input leads to a larger cooling rate,up to 346 ℃/s,and triggers the transition from hyper-eutectic to near-eutectic a-Al/Al11Ce3 microstructures with the suppression of primary Al11Ce3 intermetallics.Such microstructural modification improves the mechanical properties,resulting in higher yield and ultimate tensile strengths than those of the as-cast counterpart alloy.The fracture process involves the formation of dim-ples around Al11Ce3,cracking of large Al11Ce3 particles,and growth,merging,and fracture of pores.The strength increment is mainly contributed by particle-size strengthening mediated by microstructure refinement as well as the targeted formation of near-eutectic α-Al/Al11Ce3 microstructures.
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    Laser Powder Bed Fusion of GH4099 Superalloy:Parameter Optimization and Effect of Heat Treatment on Microstructure and Mechanical Properties

    Yunfei NieQian TangZhonghua LiJun Song...
    169-180页
    查看更多>>摘要：Ni-Cr-Co-W superalloy(GH4099)can be used to manufacture high-temperature structural components of aero-engine combustion chambers for long-term service below 900 ℃.This study provides a comprehensive evaluation of the GH4099 superalloy fabricated using the laser powder bed fusion(LPBF)technique,focusing on the opti-mization of processing parameters and a systematic investigation of the microstructural evolution and mechanical properties of the as-deposited and heat-treated samples.An optimal parameter combination was established using the response surface method(RSM)design and the variance method.The as-deposited GH4099 alloy is primarily composed of columnar crystals grown epitaxially and M23C6 carbides without the generation of the γ'-phase.After solution treatment,recrystallization and grain growth occurred,with the alloy remaining as large,irregu-larly shaped polygonal columnar crystals.The aging process precipitated substantial γ'-phase,which internally existed as a mixture of equiaxed and columnar crystals.LPBF-GH4099 superalloy exhibited a maximum room-temperature tensile strength of 1137.80 MPa and a high-temperature tensile strength of 780 MPa at 800 ℃.Various strengthening mechanisms were observed in the as-deposited and heat-treated samples.The most sig-nificant grain boundary strengthening effect was observed in the deposit state,while solution strengthening was primarily due to the segregation of elements,such as Mo,W,and Cr,in the γ matrix.Precipitation strengthening,predominantly due to the γ'-phase,emerged as the main strengthening mechanism for the GH4099 superalloy post-aging treatment.This study presents significant insights into the LPBF-GH4099 alloy and provides a solid foundation for future studies and practical applications in this field.
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