1
|
Zhang T, Chen D, Yang H, Zhao W, Wang Y, Zhou H. Spreading Behavior of Non-Spherical Particles with Reconstructed Shapes Using Discrete Element Method in Additive Manufacturing. Polymers (Basel) 2024; 16:1179. [PMID: 38732648 PMCID: PMC11085633 DOI: 10.3390/polym16091179] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/18/2024] [Revised: 04/12/2024] [Accepted: 04/17/2024] [Indexed: 05/13/2024] Open
Abstract
The spreading behavior of particles has a significant impact on the processing quality of additive manufacturing. Compared with spherical metal material, polymer particles are usually non-spherical in shape. However, the effects of particle shape and underlying mechanisms remain unclear. Here, the spreading process of particles with reconstructed shapes (non-spherical particles decomposed into several spherical shapes by stereo-lithography models) are simulated by integrating spherical particles with the discrete element method. The results show that more cavities form in the spreading beds of particles with reconstructed shapes than those of spheres with blade spreading. Correspondingly, particles with reconstructed shapes have lower packing densities, leading to more uniform packing patterns. Slow propagation speeds of velocity and angular velocity lead to "right-upwards" turning boundaries for particles with reconstructed shapes and "right-downwards" turning boundaries for spherical particles. Moreover, as the blade velocity increases, the packing density decreases. Our calculation results verify each other and are in good agreement with the experiment, providing more details of the behavior of non-spherical particles before additive manufacturing. The comprehensive comparison between polymer non-spherical particles and spherical particles helps develop a reasonable map for the appropriate choice of operating parameters in real processes.
Collapse
Affiliation(s)
- Tengfang Zhang
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;
| | - Dan Chen
- College of Advanced Interdisciplinary Studies & Hunan Provincial Key Laboratory of Novel NanoOptoelectronic Information Materials and Devices, National University of Defense Technology, Changsha 410073, China;
- Nanhu Laser Laboratory, National University of Defense Technology, Changsha 410073, China
| | - Hui Yang
- Wuhan Second Ship Design and Research Institute, Wuhan 430000, China; (H.Y.); (W.Z.)
| | - Wei Zhao
- Wuhan Second Ship Design and Research Institute, Wuhan 430000, China; (H.Y.); (W.Z.)
| | - Yunming Wang
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;
| | - Huamin Zhou
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;
| |
Collapse
|
2
|
Yan S, Zhang F, Luo L, Wang L, Liu Y, Leng J. Shape Memory Polymer Composites: 4D Printing, Smart Structures, and Applications. RESEARCH (WASHINGTON, D.C.) 2023; 6:0234. [PMID: 37941913 PMCID: PMC10629366 DOI: 10.34133/research.0234] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 07/20/2023] [Accepted: 09/01/2023] [Indexed: 11/10/2023]
Abstract
Shape memory polymers (SMPs) and their composites (SMPCs) are smart materials that can be stably deformed and then return to their original shape under external stimulation, thus having a memory of their shape. Three-dimensional (3D) printing is an advanced technology for fabricating products using a digital software tool. Four-dimensional (4D) printing is a new generation of additive manufacturing technology that combines shape memory materials and 3D printing technology. Currently, 4D-printed SMPs and SMPCs are gaining considerable research attention and are finding use in various fields, including biomedical science. This review introduces SMPs, SMPCs, and 4D printing technologies, highlighting several special 4D-printed structures. It summarizes the recent research progress of 4D-printed SMPs and SMPCs in various fields, with particular emphasis on biomedical applications. Additionally, it presents an overview of the challenges and development prospects of 4D-printed SMPs and SMPCs and provides a preliminary discussion and useful reference for the research and application of 4D-printed SMPs and SMPCs.
Collapse
Affiliation(s)
- Shiyu Yan
- Centre for Composite Materials and Structures,
Harbin Institute of Technology (HIT), No.2 Yikuang Street, Harbin 150000, People’s Republic of China
| | - Fenghua Zhang
- Centre for Composite Materials and Structures,
Harbin Institute of Technology (HIT), No.2 Yikuang Street, Harbin 150000, People’s Republic of China
| | - Lan Luo
- Centre for Composite Materials and Structures,
Harbin Institute of Technology (HIT), No.2 Yikuang Street, Harbin 150000, People’s Republic of China
| | - Linlin Wang
- Centre for Composite Materials and Structures,
Harbin Institute of Technology (HIT), No.2 Yikuang Street, Harbin 150000, People’s Republic of China
| | - Yanju Liu
- Department of Astronautic Science and Mechanics,
Harbin Institute of Technology (HIT), No. 92 West Dazhi Street, Harbin 150000, People’s Republic of China
| | - Jinsong Leng
- Centre for Composite Materials and Structures,
Harbin Institute of Technology (HIT), No.2 Yikuang Street, Harbin 150000, People’s Republic of China
| |
Collapse
|
3
|
Phua A, Smith J, Davies CH, Cook PS, Delaney GW. Understanding the structure and dynamics of local powder packing density variations in metal additive manufacturing using set Voronoi analysis. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118272] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
|
4
|
Influence of layer thickness and substrate bed on the void fraction of powder layers for laser powder bed fusion. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118293] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
|
5
|
Wu Q, Qiao C, Yao D, An X, Zhang H, Fu H, Yang X, Zou Q. Research on improving the spreadability of viscous powder in additive manufacturing. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.118061] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
|
6
|
Robinson J, Munagala SP, Arjunan A, Simpson N, Jones R, Baroutaji A, Govindaraman LT, Lyall I. Electrical Conductivity of Additively Manufactured Copper and Silver for Electrical Winding Applications. MATERIALS (BASEL, SWITZERLAND) 2022; 15:7563. [PMID: 36363154 PMCID: PMC9659250 DOI: 10.3390/ma15217563] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/29/2022] [Revised: 10/13/2022] [Accepted: 10/19/2022] [Indexed: 06/16/2023]
Abstract
Efficient and power-dense electrical machines are critical in driving the next generation of green energy technologies for many industries including automotive, aerospace and energy. However, one of the primary requirements to enable this is the fabrication of compact custom windings with optimised materials and geometries. Electrical machine windings rely on highly electrically conductive materials, and therefore, the Additive Manufacturing (AM) of custom copper (Cu) and silver (Ag) windings offers opportunities to simultaneously improve efficiency through optimised materials, custom geometries and topology and thermal management through integrated cooling strategies. Laser Powder Bed Fusion (L-PBF) is the most mature AM technology for metals, however, laser processing highly reflective and conductive metals such as Cu and Ag is highly challenging due to insufficient energy absorption. In this regard, this study details the 400 W L-PBF processing of high-purity Cu, Ag and Cu-Ag alloys and the resultant electrical conductivity performance. Six Cu and Ag material variants are investigated in four comparative studies characterising the influence of material composition, powder recoating, laser exposure and electropolishing. The highest density and electrical conductivity achieved was 88% and 73% IACS, respectively. To aid in the application of electrical insulation coatings, electropolishing parameters are established to improve surface roughness. Finally, proof-of-concept electrical machine coils are fabricated, highlighting the potential for 400 W L-PBF processing of Cu and Ag, extending the current state of the art.
Collapse
Affiliation(s)
- John Robinson
- Additive Manufacturing of Functional Materials (AMFM) Research Group, School of Engineering, University of Wolverhampton, Telford Innovation Campus, Telford TF2 9NT, UK
- Additive Analytics Ltd., Telford TF3 1EB, UK
- Aceon Group, Telford TF3 3BJ, UK
| | - Sai Priya Munagala
- Electrical Energy Management Group, Department of Electrical and Electronic Engineering, University of Bristol, Bristol BS8 1TR, UK
| | - Arun Arjunan
- Additive Manufacturing of Functional Materials (AMFM) Research Group, School of Engineering, University of Wolverhampton, Telford Innovation Campus, Telford TF2 9NT, UK
| | - Nick Simpson
- Electrical Energy Management Group, Department of Electrical and Electronic Engineering, University of Bristol, Bristol BS8 1TR, UK
| | | | - Ahmad Baroutaji
- Additive Manufacturing of Functional Materials (AMFM) Research Group, School of Engineering, University of Wolverhampton, Telford Innovation Campus, Telford TF2 9NT, UK
| | - Loganathan T. Govindaraman
- Additive Manufacturing of Functional Materials (AMFM) Research Group, School of Engineering, University of Wolverhampton, Telford Innovation Campus, Telford TF2 9NT, UK
| | - Iain Lyall
- Additive Manufacturing of Functional Materials (AMFM) Research Group, School of Engineering, University of Wolverhampton, Telford Innovation Campus, Telford TF2 9NT, UK
| |
Collapse
|
7
|
Singh A, Rajput AS, Kapil S, Das M. Parameter sensitivity analysis of centrifugal spreaders for dispersing metallic powders and material property evaluation for DEM simulation. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117958] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
|
8
|
Yao D, Wang J, Cai Y, Zhao T, An X, Zhang H, Fu H, Yang X, Zou Q, Wang L. Composition regulation of composite materials in laser powder bed fusion additive manufacturing. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117795] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
|
9
|
Li E, Zhou Z, Wang L, Zou R, Yu A. Particle scale modelling of powder recoating and melt pool dynamics in laser powder bed fusion additive manufacturing: A review. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117789] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
|
10
|
Cheng T, Chen H, Wei Q. The Role of Roller Rotation Pattern in the Spreading Process of Polymer/Short-Fiber Composite Powder in Selective Laser Sintering. Polymers (Basel) 2022; 14:polym14122345. [PMID: 35745919 PMCID: PMC9227338 DOI: 10.3390/polym14122345] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2022] [Revised: 05/30/2022] [Accepted: 06/06/2022] [Indexed: 02/04/2023] Open
Abstract
In this study, for the first time, a forward-rotating roller is proposed for the spreading of CF/PA12 composite powder in the selective laser sintering (SLS) process. The mesoscopic kinetic mechanism of composite particle spreading is investigated by utilizing the “multi-spherical” element within the discrete element method (DEM). The commercial software EDEM and the open-source DEM particle simulation code LIGGGHTS-PUBLIC are used for the simulations in this work. It is found that the forward-rotating roller produces a strong compaction on the powder pile than does the conventional counter-rotating roller, thus increasing the coordination number and mass flow rate of the particle flow, which significantly improves the powder bed quality. In addition, the forward-rotating pattern generates a braking friction force on the particles in the opposite direction to their spread, which affects the particle dynamics and deposition process. Therefore, appropriately increasing the roller rotation speed to make this force comparable to the roller dragging force could result in faster deposition of the composite particles to form a stable powder bed. This mechanism allows the forward-rotating roller to maintain a good powder bed quality, even at a high spreading speed, thus providing greater potential for the industry to improve the spreading efficiency of the SLS process.
Collapse
Affiliation(s)
- Tan Cheng
- State Key Lab of Materials Forming and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;
| | - Hui Chen
- Department of Mechanical Engineering, National University of Singapore, Singapore 117575, Singapore
- Correspondence: (H.C.); (Q.W.)
| | - Qingsong Wei
- State Key Lab of Materials Forming and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;
- Correspondence: (H.C.); (Q.W.)
| |
Collapse
|
11
|
Melt pool dynamics and pores formation in multi-track studies in laser powder bed fusion process. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117533] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
|
12
|
Ganesan VV, Amerinatanzi A, Jain A. Discrete Element Modeling (DEM) simulations of powder bed densification using horizontal compactors in metal additive manufacturing. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117557] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
|
13
|
Pressure capability analysis of magnetic powder seals and pole tooth design by multiparameter optimization. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117410] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
|
14
|
Yao D, Wang J, Li M, Zhao T, Cai Y, An X, Zou R, Zhang H, Fu H, Yang X, Zou Q. Segregation of 316L stainless steel powder during spreading in selective laser melting based additive manufacturing. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.117096] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
|
15
|
|
16
|
Mechanized spreading of ceramic powder layers for additive manufacturing characterized by transmission x-ray imaging: Influence of powder feedstock and spreading parameters on powder layer density. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.117053] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
|
17
|
Wang L, Zhou Z, Li E, Shen H, Yu A. Powder deposition mechanism during powder spreading with different spreader geometries in powder bed fusion additive manufacturing. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.10.017] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/09/2023]
|
18
|
Lupone F, Padovano E, Casamento F, Badini C. Process Phenomena and Material Properties in Selective Laser Sintering of Polymers: A Review. MATERIALS 2021; 15:ma15010183. [PMID: 35009332 PMCID: PMC8746045 DOI: 10.3390/ma15010183] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/10/2021] [Revised: 12/17/2021] [Accepted: 12/23/2021] [Indexed: 11/16/2022]
Abstract
Selective laser sintering (SLS) is a powder bed fusion technology that uses a laser source to melt selected regions of a polymer powder bed based on 3D model data. Components with complex geometry are then obtained using a layer-by-layer strategy. This additive manufacturing technology is a very complex process in which various multiphysical phenomena and different mechanisms occur and greatly influence both the quality and performance of printed parts. This review describes the physical phenomena involved in the SLS process such as powder spreading, the interaction between laser beam and powder bed, polymer melting, coalescence of fused powder and its densification, and polymer crystallization. Moreover, the main characterization approaches that can be useful to investigate the starting material properties are reported and discussed.
Collapse
|
19
|
The effect of recoater geometry and speed on granular convection and size segregation in powder bed fusion. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.08.058] [Citation(s) in RCA: 10] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/27/2023]
|
20
|
Yao D, Liu X, Wang J, Fan W, Li M, Fu H, Zhang H, Yang X, Zou Q, An X. Numerical insights on the spreading of practical 316 L stainless steel powder in SLM additive manufacturing. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.05.082] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
|