Experimental Investigation on Magnetic Abrasive Finishing for Internal Surfaces of Waveguides Produced by Selective Laser Melting.

To enhance the surface quality of metal 3D-printed components, magnetic abrasive finishing (MAF) technology was employed for post-processing polishing. Experimental investigation employing response surface methodology was conducted to explore the impact of processing gap, rotational speed of the magnetic field, auxiliary vibration, and magnetic abrasive particle (MAP) size on the quality enhancement of internal surfaces. A regression model correlating roughness with crucial process parameters was established, followed by parameter optimization. Ultimately, the internal surface finishing of waveguides with blind cavities was achieved, and the finishing quality was comprehensively evaluated. Results indicate that under optimal process conditions, the roughness of the specimens decreased from Ra 2.5 µm to Ra 0.65 µm, reflecting a reduction rate of 74%. Following sequential rough and fine processing, the roughnesses of the cavity bottom, side wall, and convex surface inside the waveguide reduced to 0.59 µm, 0.61 µm, and 1.9 µm, respectively, from the original Ra above 12 µm. The findings of this study provide valuable technical insights into the surface finishing of metal 3D-printed components.

Recent Advances in 4D Printing of Advanced Materials and Structures for Functional Applications.

4D printing has attracted tremendous worldwide attention during the past decade. This technology enables the shape, property, or functionality of printed structures to change with time in response to diverse external stimuli, making the original static structures alive. The revolutionary 4D-printing technology offers remarkable benefits in controlling geometric and functional reconfiguration, thereby showcasing immense potential across diverse fields, including biomedical engineering, electronics, robotics, and photonics. Here, a comprehensive review of the latest achievements in 4D printing using various types of materials and different additive manufacturing techniques is presented. The state-of-the-art strategies implemented in harnessing various 4D-printed structures are highlighted, which involve materials design, stimuli, functionalities, and applications. The machine learning approach explored for 4D printing is also discussed. Finally, the perspectives on the current challenges and future trends toward further development in 4D printing are summarized.

Interface Hardness Analysis of between IN625 and CoCrMo Manufactured by Pulsed Wave Laser Powder Bed Fusion.

The nuclear and petrochemical industries often require multi-metal parts that are corrosion-resistant, heat-resistant, and possess high strength to enhance equipment safety and reduce downtime. Additive manufacturing technology enables the rapid and flexible processing of multi-metal parts to meet these stringent demands. This study is aimed at investigating the interface hardness between CoCrMo/IN625 to determine optimal processing parameters that can be utilized in manufacturing reliable and durable multi-metal parts. The result indicates that when the volumetric energy density, Ev, is at or below 20 J/mm3, microfluidic forces are unable to sufficiently diffuse between the two metals, leading to insufficient diffusion, and the high hardness CoCrMo acts as a support, resulting in a significantly higher interface hardness. As Ev increases, intense recoil pressure within the microfluidic forces disrupts the melt pool, allowing for full diffusion between the two metals. The fully diffused high-hardness CoCrMo has been diluted by the low-hardness IN625, thus reducing the interface hardness. Considering the interface hardness, strength, and printing efficiency (time and energy consumption), we recommend a range of 35 J/mm3 < Ev ≤ 75 J/mm3. In this range, the average values for interface hardness and tensile strength of the samples are approximately 382 HV and 903 MPa, respectively.

Interface Analysis between Inconel 625 and Cobalt-Chromium Alloy Fabricated by Powder Bed Fusion Using Pulsed Wave Laser.

A few components used in the aerospace and petrochemical industries serve in corrosive environments at high temperatures. Corrosion-resistant metals or unique processes, such as coating and fusion welding, are required to improve the performance of the parts. We have used laser powder bed fusion (LPBF) technology to deposit a 5 mm thick corrosion-resistant CoCrMo layer on a high-strength IN625 substrate to improve the corrosion resistance of the core parts of a valve. This study found that when the laser volumetric energy density (EV) ≤ 20, the tensile strength increases linearly with the increase in EV, and the slope of the curve is approximately 85°. The larger the slope, the greater the impact of EV on the intensity. When EV > 20, the sample strength reaches the maximum tensile strength. When the EV increases from 0 to 20, the fracture position of the sample shifts from CoCrMo to IN625. When EV ≤ 38, the strain increases linearly with the increase in EV, and the slope of the curve is approximately 67.5°. The sample strain rate reaches the maximum when EV > 38. Therefore, for an optimal sample strength and strain, EV should be greater than 38. This study provides theoretical and technical support for the manufacturing of corrosion-resistant dissimilar metal parts using LPBF technology.

Multimetal Research in Powder Bed Fusion: A Review.

This article discusses the different forms of powder bed fusion (PBF) techniques, namely laser powder bed fusion (LPBF), electron beam powder bed fusion (EB-PBF) and large-area pulsed laser powder bed fusion (L-APBF). The challenges faced in multimetal additive manufacturing, including material compatibility, porosity, cracks, loss of alloying elements and oxide inclusions, have been extensively discussed. Solutions proposed to overcome these challenges include the optimization of printing parameters, the use of support structures, and post-processing techniques. Future research on metal composites, functionally graded materials, multi-alloy structures and materials with tailored properties are needed to address these challenges and improve the quality and reliability of the final product. The advancement of multimetal additive manufacturing can offer significant benefits for various industries.

Modeling the Crack Interference in X80 Oil and Gas Pipeline Weld.

Based on the numerical simulation method of the virtual crack closure technique (VCCT), an interference model was established to investigate the physical problem of two interacting cracks of different sizes in the welding zone of oil and gas pipelines. The obtained results of the current interference problem were compared with those of single crack case. Various crack configurations, such as different crack spacing and different crack sizes, were analyzed. The characteristic quantity fluid pressure load P during the crack propagation process, the peak value of the von Mises stress distribution field of the crack growth path, as well as the difference ∆Bx between the peak value of the magnetic induction intensity component at the crack and the value of the magnetic induction intensity component at its symmetrical position were calculated. The crack interaction scale factors, including γP, γMises, and γΔBx, were compared and analyzed. The numerical modeling results show that when the unequal-length double cracks interfere with each other, the cracks are more likely to propagate toward each other. The tendency of the double-cracks to propagate toward each other gradually weakens as the distance between the crack tips increases and is finally the same as that of single-crack cases. It was also found that the effect of large-sized cracks on small-sized cracks is greater than that of small-sized ones on large-sized ones. The numerical modeling results could be applied for the prediction and analysis of multicrack damage in oil and gas pipeline welds.

Multi-Scale Topology Optimization of Femoral Stem Structure Subject to Stress Shielding Reduce.

Hip replacement femoral implants are made of substantial materials that all have stiffness considerably higher than that of bone, which can cause significant bone resorption secondary to stress shielding and lead to severe complications. The topology optimization design method based on the uniform distribution of material micro-structure density can form a continuous mechanical transmission route, which can better solve the problem of reducing the stress shielding effect. A multi-scale parallel topology optimization method is proposed in this paper and a topological structure of type B femoral stem is derived. Using the traditional topology optimization method (Solid Isotropic Material with Penalization, SIMP), a topological structure of type A femoral stem is also derived. The sensitivity of the two kinds of femoral stems to the change of load direction is compared with the variation amplitude of the structural flexibility of the femoral stem. Furthermore, the finite element method is used to analyze the stress of type A and type B femoral stem under multiple conditions. Simulation and experimental results show that the average stress of type A and type B femoral stem on the femur are 14.80 MPa, 23.55 MPa, 16.94 MPa and 10.89 MPa, 20.92 MPa, 16.50 MPa, respectively. For type B femoral stem, the average error of strain is -1682µÎµ and the average relative error is 20.3% at the test points on the medial side and the mean error of strain is 1281µÎµ and the mean relative error is 19.5% at the test points on the outside.

Super Hydrophobic SiO2/Phenolic Resin-Coated Filter Screen and Its Application in Efficient Oil-Water Separation.

The discharge of industrial liquid waste continues to cause more and more environmental problems. The current research aims at developing a durable and highly efficient filter screen for oil-water separation. In this paper, hydrophobic nano-SiO2 and phenolic resin were used as raw materials. Hydrophobic SiO2 particles were fixed on the surface of the coated filter screen by heating and curing the anchored particles. The surface morphology, element composition, surface roughness and water contact angle of the prepared super hydrophobic SiO2/phenolic resin-coated filter screen were analyzed and discussed by using SEM, EDS, AFM, OCA and other instruments. The results showed that the prepared filter screen contained Si, O, C elements, which proved that the resin coating film had adhered to the filter screen surface. When the aperture of the phenolic resin-coated filter screen was 400 meshes, the drainage angle reached a maximum value of 153.8° ± 0.8°. When two layers of hydrophobic SiO2 phenolic resin were coated on the screen, the surface of the filter screen had a sufficient nano-porous structure and high roughness. The tests showed that the minimum water contact angle of the filter screen exceeded 150°, which indicated excellent chemical resistance. Through the analysis of oil-water separation efficiency of isooctane, gasoline, n-hexane, dodecane, edible oil, dichloromethane and trichloromethane, it was concluded that the lowest separation efficiency for edible oil was 97.2%, and the highest separation efficiency for n-hexane was 99.4%. After 50 cycles of separation, the oil-water separation efficiency for n-hexane was still at 99%.