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.     

Compressive strength and wear properties of SiC/Al6061 composites reinforced with high contents of SiC fabricated by pressure-assisted infiltration

Pressure-assisted infiltration was used to synthesize SiC/Al 6061 composites containing high weight percentages of SiC. A combination of PEG and glass water was used to fabricate SiC preforms and the effect of the presence of glass water on the microstructure and mechanical properties of the preforms was evaluated by performing compression tests on the preforms. Also, the compressive strength and the hardness of the SiC/Al composites were investigated. The results revealed that the glass water improved the compressive strength of the preforms by about five times. The microstructural characterization of the composites showed that the penetration of the aluminum melt into the preforms was completed and almost no porosity could be seen in the microstructures of the composites. Moreover, the composite containing 75 wt% SiC exhibited the highest compressive strength as well as the maximum hardness. The results of the wear tests showed that increasing the SiC content reduces the wear rate so that the Al-75 wt% SiC composite has a lower wear rate and a lower coefficient of friction than those of Al-67 wt% SiC composite. This indicated higher wear resistance in these composites than the Al alloy due to the formation of a tribological layer on the surface of the composites.     

Influence of Al2O3 on the electrical conductivity and structure of calcium-silicate-based melts

Electrical conductivity and structure of the CaO-SiO₂-based mold flux melts with various Al₂O₃ contents were investigated. The results show that the electrical conductivity increases with the addition of Al₂O₃ from 2 wt% to 4 wt%, but decreases with the further increase of Al₂O₃ from 4 wt% to 8 wt%. Correspondingly, the apparent activation energy reduces firstly from 55.12 ± 1.20 kJ mol to 41.09± 0.38 kJ mol, and then increases from 41.09 ± 0.38 kJ mol to 98.99 ± 1.42 kJ mol. The structure analyses suggest that complex structural units, such as Si-O-Al, Al-O⁰, Si-O-Si and Q³(Si), reduce first, but increase with the further addition of Al₂O₃. Conversely, these simple structural units, such as Al-O^-, Q⁰(Si), Q¹(Si) and Q²(Si) vary in the opposite way with the change of Al₂O₃ content. From the variations of electrical conductivity, activation energy and structural units, it can be found that when Al₂O₃ works as network breaker to simplify the melt structure, the energy barrier for transportation of conducting ions/ionic reduce, which results in the increase of electrical conductivity; while when Al₂O₃ becomes into network former, the conductivity increases, correspondingly.     

Self-limited growth of nanocrystals in phosphosilicate melts during cooling

In this Letter, we demonstrate that the spontaneous nanophase-separation can greatly enhance the heterogeneous nucleation in the investigated phosphosilicate melts. The two separated phases are found to be the phosphate-rich phase as the floppy domain and the silicate-rich phases as rigid phase. We found that sodium phosphate nanocrystals form in the phosphate-rich phase during melt cooling. The growth of these nanocrystals are self-limited, i.e., limited by the surrounding silicate-rich phase with higher viscosity, and hence lower ionic diffusion compared to the phosphate-rich phase. Our results show that the substitution of B₂O₃ or Al₂O₃ for partial Na₂O enhances the spontaneous nucleation, although the viscosity of silicate-rich matrix phase is increased by such substitution. This implies that the compositional substitution enhances nanophase separation and thereby lowers the activation energy for non-isothermal crystallization. This work indicates that nanophase separation is crucial for fabrication of transparent glass-ceramics from phosphosilicate melts.     

Crystallization characteristics of CaO–Al2O3–SiO2–Li2O–B2O3 mold flux with different values of w(CaO)/w(Al2O3)

The effect of C/A ratio (abbreviation of w(CaO)/w(Al₂O₃)) on the crystallization characteristics was investigated. With an increase in C/A ratio from 1.1 to 1.8, the crystallization ability first decreased and then increased; the crystallization ability is weakest and strongest with C/A ratios of 1.5 and 1.8, respectively. Increasing C/A ratio, the crystalline phase changed from LiAlO₂ and CaO·Al₂O₃ to LiAlO₂ and 3CaO·Al₂O₃. The Li⁺ ions in the slag took precedence over Ca²⁺ ions to participate in charge compensation because the mold flux contains Al3+ which is more advantageous for a monovalent cation, and LiAlO₂ formed preferentially over CaO·Al₂O₃. With a further increase in C/A ratio, 3CaO·Al₂O₃ formed from the combination of Ca²⁺ ions and Q_Al² units, and the precipitated amount of 3CaO·Al₂O₃ increased.     

Novel preparation approach with a 2-step process for spherical particles with high drug loading and controlled size distribution using melt granulation: MALCORE®

A novel approach for preparing drug-containing particles (DCPs) with controlled size distribution and high drug loading was developed using melt granulation. This approach comprises two steps. First, melting component adsorbed particles (MAs) were prepared by mixing and heating the melting components with a porous carrier using a high shear granulator. Second, DCPs were prepared by layering the drug on MAs using a fluidized bed rotor granulator. The time taken for both steps was within 30 min. Adding the polymer in the second step remarkably increased the viscosity of the mixture of melting components and the polymer. Therefore, DCPs could be successfully loaded with a high amount of drug (70% w/w). The particle size distribution of the DCPs was narrow, and it depended on that of the MAs. The flowability of the DCPs was excellent, and the sphericity was close to 1. A unique particle formulation mechanism was suggested based on the observation of DCPs using scanning electron microscopy. The manufacturing time and DCP characteristics were not affected by the manufacturing scale. In conclusion, we have successfully developed a highly efficient novel approach for preparing optimal DCPs through melt granulation, named “Melt Adsorption and Layering with Porosity Core” (MALCORE®).     

High-entropy titanate pyrochlore as newly low-thermal conductivity ceramics

Low-thermal conductivity ceramics play an indispensable role in maximizing the efficiency and durability of hot end components. Pyrochlore, particularly zirconate pyrochlore, is currently a highly promising and widely studied candidate for its extremely low thermal conductivity. However, there are still few pyrochlores that offer both stiffness, insulation, and good thermal expansion properties. In this work, the solidification method was innovatively introduced into the preparation of titanate pyrochlore, and combined it with the compositional design of high-entropy. Through careful composition design and solidification control, the high-density and uniform elements distributed high-entropy titanate pyrochlore ceramics were successfully prepared. These samples possess high hardness (15.88 GPa) and Young’s modulus (295.5 GPa), low thermal conductivity (0.947 W·m^?1·K^?1), excellent thermal expansion coefficient (11.6 ×10^?6/K) and an exquisite balance between stiffness and insulation (E/κ, 312.1 GPa·W^?1·m·K), in which the E/κ exhibits the highest value among the current reported works.     

Effects of raw material homogenization on the structure of basalt melt and performance of fibers

In this study, basalt from a base in Hebei, China, was selected as the raw material. Water-quenched basalt glasses and basalt fibers were prepared at different homogenization times and temperatures. The water-quenched glass structure was characterized by XRD and a Raman spectrometer followed by fitting of their Raman spectra by Gaussian curves to obtain information about melt structure. The fiber performance was characterized by fiber strength meter and fiber fineness meter. The results demonstrate that homogenization time and temperature had significant effects on the structure of basalt melt. The degree of polymerization of the melt increased with increasing homogenization time and decreased with increasing homogenization temperature. The fiber strength increased with increasing the degree of polymerization. As the homogenization time and temperature increased, coefficients of variation of fiber strength and fiber diameter decreased, indicating enhanced fiber stability.     

Joint Effect of Compatibilizer and Organo-Montmorillonite on Compatibilization of Polyamide-6/Poly(phenylene oxide) Blend: Morphology and Properties

Compatibilizer (styrene–maleic anhydride copolymer, SMA) and organo-montmorillonite (OMMT) were introduced into immiscible polyamide-6 (PA6)/ poly(phenylene oxide) (PPO) blend to obtain quaternary nanocomposites simply by melt extrusion. OMMT tactoids formed in PA6/PPO/OMMT ternary blend would become smaller or disappear with the addition of SMA. Besides, viscosity of SMA compatibilized PA6/PPO blend decreased a lot with the addition of OMMT. Based on these results, a mechanism for joint effect of SMA and OMMT in compatibilizing PA6 and PPO was proposed. We further studied water absorption and tensile properties of the nanocomposites, which were in consistent with the proposed mechanism.     

用于FDM的导电ABS/MWCNT复合材料的制备

采用熔融共混法将丙烯腈-丁二烯-苯乙烯共聚物(ABS)与多壁碳纳米管(MWCNT)复合,并对所得的复合材料进行了力学性能、热性能和电学性能分析。结果表明,添加MWCNT能够提高复合材料的力学性能、电导率和耐热性,力学性能在MWCNT添加量为2%时最佳,电导率随MWCNT添加量的增加而增大,MWCNT添加量为4%时,其电导率能达到4.35×10-6S/m。将添加4%MWCNT的复合材料拉丝,然后以三种打印方向进行熔融沉积(FDM)打印,研究了打印试样的力学性能,用扫描电镜(SEM)观察了其断面形貌。结果表明,水平方向打印的试样力学强度最好,侧向打印的试样次之,垂直方向打印的样品由于仅靠丝材的层间黏结,其力学强度比较差,与纯ABS丝材打印试样相比,复合丝材打印试样的拉伸强度和弯曲强度均有明显提高,冲击强度有所下降。