Multi-scale defects in powder-based additively manufactured metals and alloys

J Fu, H Li, X Song, MW Fu - Journal of Materials Science & Technology, 2022 - Elsevier
Defect formation is a critical challenge for powder-based metal additive manufacturing (AM).
Current understanding on the three important issues including formation mechanism …

Control of grain structure, phases, and defects in additive manufacturing of high-performance metallic components

T Mukherjee, JW Elmer, HL Wei, TJ Lienert… - Progress in Materials …, 2023 - Elsevier
The properties and serviceability of 3D-printed metal parts depend on a variety of attributes.
These include the chemical composition, phases, morphology, spatial distributions of grain …

Solidification in metal additive manufacturing: challenges, solutions, and opportunities

S Chandra, J Radhakrishnan, S Huang, S Wei… - Progress in Materials …, 2024 - Elsevier
The physics of alloy solidification during additive manufacturing (AM) in methods such as
laser powder bed fusion (LPBF), electron beam powder bed fusion (EPBF), and laser …

[HTML][HTML] Holistic computational design within additive manufacturing through topology optimization combined with multiphysics multi-scale materials and process …

M Bayat, O Zinovieva, F Ferrari, C Ayas… - Progress in Materials …, 2023 - Elsevier
Additive manufacturing (AM) processes have proven to be a perfect match for topology
optimization (TO), as they are able to realize sophisticated geometries in a unique layer-by …

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

S Sharma, SS Joshi, MV Pantawane… - International …, 2023 - journals.sagepub.com
This review article provides a critical assessment of the progress made in computational
modelling of metal-based additive manufacturing (AM) with emphasis on its ability to predict …

Solute trapping and non-equilibrium microstructure during rapid solidification of additive manufacturing

N Ren, J Li, R Zhang, C Panwisawas, M Xia… - Nature …, 2023 - nature.com
Solute transport during rapid and repeated thermal cycle in additive manufacturing (AM)
leading to non-equilibrium, non-uniform microstructure remains to be studied. Here, a fully …

Simulation of powder bed metal additive manufacturing microstructures with coupled finite difference-Monte Carlo method

TM Rodgers, D Moser, F Abdeljawad… - Additive …, 2021 - Elsevier
Grain-scale microstructure evolution during additive manufacturing is a complex physical
process. As with traditional solidification methods of material processing (eg casting and …

Physics-embedded graph network for accelerating phase-field simulation of microstructure evolution in additive manufacturing

T Xue, Z Gan, S Liao, J Cao - npj Computational Materials, 2022 - nature.com
The phase-field (PF) method is a physics-based computational approach for simulating
interfacial morphology. It has been used to model powder melting, rapid solidification, and …

Effects of microstructure and inherent stress on residual stress induced during powder bed fusion with roller burnishing

S Sunny, R Mathews, H Yu, A Malik - International Journal of Mechanical …, 2022 - Elsevier
A hybrid metal-additive manufacturing (AM) process that combines laser-based powder bed
fusion (PBF-LB) with interlayer burnishing is investigated using a comprehensive modeling …

A novel high-efficient finite element analysis method of powder bed fusion additive manufacturing

Y Cao, X Lin, N Kang, L Ma, L Wei, M Zheng, J Yu… - Additive …, 2021 - Elsevier
This paper aims to develop a high-efficient finite element (FE) model by combining the
equivalent boundary condition method (EBCM) and dynamic mesh method (DMM) for …