Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. The predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.     

A Ti3C2Tx-carbon black-acrylic epoxy coating for 304SS bipolar plates with enhanced corrosion resistant and conductivity

A conducting and anticorrosive coating is crucial for the application of metal bipolar plates (BP) in proton exchange membrane fuel cell (PEMFC). In this work, a Ti₃C₂T_x (T)-carbon black (C)-acrylic epoxy (AE) coating is prepared on 304 stainless steel (SS) with enhanced corrosion resistance and conductivity. The corrosion resistance of the T-C-AE coating is investigated in a 0.5 M H₂SO₄ solution as compared to the AE, T, and T-AE coatings. The T-C-AE coated 304SS exhibits the strongest corrosion resistance with the most positive corrosion potential and the lowest corrosion current density of 0.00673 μA cm^?2 in all the samples, while retaining intact and compact surface morphology with the lowest metal ion dissolution even after immersed for 720 h. The addition of Ti₃C₂T_x and carbon black into the AE matrix greatly decreases interfacial contact resistance (ICR), and the T-C-AE coating achieves a low ICR of 15.5 mΩ cm^?2 under 140 N cm^?2 compaction force. The excellent anticorrosion performance is mainly attributed to the physical barrier and the cathodic protection provided by the stacked Ti₃C₂T_x (MXene) nanosheets in the T-C-AE coating. This eco-friendly, conducting, and anticorrosive T-C-AE coating has a good application prospect on SS BP of PEMFC.     

Ag nanoparticles-polypyrrole-carbon black/mesoporous TiO2 novel nanocomposite as ultrafast visible-light-driven photocatalyst

Effective design and fabrication of novel visible light-oriented photocatalysts is an existing challenging task that requires further dedicated efforts, and it has been always a main concern among the scientific community. This study deals with the design and fabrication of an extremely active and ultrafast ternary photocatalyst based on Ag nanoparticles, polypyrrole doped carbon black (PPy-C) and mesoporous TiO₂ (m-TiO₂). Sol-gel methodology along with sonication and photodeposition routes have been employed for the successful creation of the ternary framework. Ternary photocatalyst composed of uniform spherical titania nanoparticles (10–15 nm in size) perfectly intermingled with the polymeric linkage of PPy-C. Fruitful creation of unique trio photocatalyst between AgNPs, PPy-C and m-TiO₂ was confirmed by XPS and XRD. FTIR analysis further supports the development of nanocomposite photocatalyst. TEM analysis showed uniform spherical m-TiO₂ nanoparticles (10–15 nm in size) covered by PPy-C with compact nodes like appearance interlocked very well among each other. The newly developed Ag@PPy-C/m-TiO₂ ternary photocatalyst exhibited band gap energy in desired visible range of spectra. The photocatalytic efficiency for all created photocatalysts has been evaluated taking Imidacloprid (insecticide derivative) and methylene blue (MB) dye as target pollutants. The novel Ag@PPy-C/m-TiO₂ photocatalyst produced astonishing results with ultrafast removal of both Imidacloprid as well MB dye under visible light irradiation. The newly created ultrafast Ag@PPy-C/m-TiO₂ photocatalyst has removed 96.0% of the insecticide Imidacloprid in only 25 min with almost ? 2.65 times more efficient than bare m-TiO₂ towards the removal of insecticide derivative. The present report offers a highly encouraging and vastly talented Ag@PPy-C/m-TiO₂ ternary photocatalyst, enabling the ideal management of extremely lethal and notorious chemicals.     

Designing amorphous formulations of polyphenols with naringin by spray-drying for enhanced solubility and permeability

Naringin (NAR), a major flavanone (FVA) glycoside, is a component of food mainly obtained from grapefruit. We used NAR as a food additive to improve the solubility and permeability of hydrophobic polyphenols used as supplements in the food industry. The spray-dried particles (SDPs) of NAR alone show an amorphous state with a glass transition temperature (T_g) at 93.2 °C. SDPs of hydrophobic polyphenols, such as flavone (FVO), quercetin (QCT), naringenin (NRG), and resveratrol (RVT) were prepared by adding varying amounts of NAR. All SDPs of hydrophobic polyphenols with added NAR were in an amorphous state with a single T_g, but SDPs of hydrophobic polyphenols without added NAR showed diffraction peaks derived from each crystal. The SDPs with NAR could keep an amorphous state after storage at a high humidity condition for one month, except for SDPs of RVT/NAR. SDPs with NAR enhanced the solubility of hydrophobic polyphenols, especially NRG solubility, which was enhanced more than 9 times compared to NRG crystal. The enhanced solubility resulted in the increased membrane permeability of NRG. The antioxidant effect of the hydrophobic NRG was also enhanced by the synergetic effect of NAR. The findings demonstrated that NAR could be used as a food additive to enhance the solubility and membrane permeability of hydrophobic polyphenols.     

The influence of FeNi nanoparticles on the microstructures and soft magnetic properties of FeSi soft magnetic composites

In this work, a new type of FeSi/FeNi soft magnetic powder core (SMPC) was successfully fabricated by coating FeNi nanoparticles on the surface of FeSi micrometer powder. The effects of different contents of FeNi nanoparticles on the micromorphology, internal structures, and soft magnetic properties of SMPCs were studied. The results show that FeNi nanoparticles adhere to the surface of FeSi powder, which can effectively fill the air gap between FeSi powder and is beneficial to the compaction of the powder cores during the pressing process. Thus, the density of the SMPCs is increased. Compared to FeSi SMPCs, the comprehensive soft magnetic properties of FeSi/FeNi SMPCs have been greatly improved. When adding 15 wt% FeNi nanoparticles, the SMPCs exhibit excellent magnetic properties with high effective permeability (increased by 43.8 %) and low core loss (decreased by 22.1 %). The high performance FeSi/FeNi SMPCs prepared in this work are expected to be widely used in power choke coils, uninterruptible power supplies, and boosts and inverter inductors.     

Rapid synthesis of Y3Al5O12 powders via plasma electrolysis

Yttrium aluminum garnet (Y₃Al₅O₁₂, YAG) is an important functional material. However, the strict and complicated preparation has limited its wide application. This study aimed to rapidly synthesize Y₃Al₅O₁₂ by plasma electrolysis for the first time. The prepared powder was studied from topography, structure and elements by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The powder had a good crystal form with a spherical shape. The single kind of diffraction peak of Y₃Al₅O₁₂ in XRD revealed the high purity of the synthesized powders. The study of the relationship between the applied voltage and the synthesized powder revealed a threshold voltage of 210 V under the present condition. The higher voltage led to the damage of the electrode due to excessive heat. The synthesis of the YAG powder had a melt-quench process. The two processes were carried out at the same time.     

Evolution of precursor powders prepared by oxalate freeze drying towards high performance Bi-2212 wires

Bi₂Sr₂CaCu₂O_x (Bi-2212) precursor powders were synthesized by the oxalate freeze drying (OFD) method. In comparison with the traditional method, the novel method could shorten the processing steps and thus improve the fabrication efficiency of precursor powder. The phase, microstructure and superconducting properties of Bi-2212 precursor powders and wires were characterized by X-ray diffraction, scanning electron microscopy and four-probe method, respectively. The thermal behavior, surface area and particle size of powders were also discussed. The results indicated that large surface area and small particle size might improve the reactivity and uniformity of powders. These properties were beneficial for the rapid and homogeneous formation of Bi-2212. High-purity crystallized Bi-2212 powders without Bi-2201 and alkaline-earth cuprates phases could be achieved. Furthermore, multi-filamentary Bi-2212 wires with OFD powders showed good microstructures without noticeable pores and large secondary particles. Therefore, high engineering critical current densities (J_e) of 1619 A/mm² and critical current densities (J_c) of 7039 A/mm² were obtained in Bi-2212 wires at 4.2K, self field. It indicated that the oxalate freeze drying method would be a potential candidate for the mass production of high performance Bi-2212 wires.