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Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING 2025年 194卷

作者： Talabi, Segun Isaac Chawla, Komal Rodriguez, Brittany Barakat, Abdallah Meraki, Yalcin Phadatare, Akash Brander, Marco Seta, Berin Spangenberg, Jon Wu, H. Felix Vaidya, Uday Kunc, Vlastimil Hassen, Ahmed Arabi Kumar, Vipin Oak Ridge Natl Lab Mfg Sci Div 2350 Cherahala Blvd Knoxville TN 37932 USA Univ Tennessee Knoxville TN USA Tech Univ Denmark Dept Civil & Mech Engn Lyngby Denmark US DOE Washington DC USA Univ Tennessee Knoxville Tickle Coll Engn Knoxville TN USA Inst Adv Composites Mfg Innovat Knoxville TN USA

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm-10.16 mm), temperature (230-250 degrees C), and extruder screw speed (150-280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A(xx) similar to 0.65) and low porosity (similar to 3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (similar to 93 MPa) under these conditions. These findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

关键词： Design of experiments Fiber orientation Large-format additive manufacturing Porosity processing parameters

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Laser Cladding of Fe-NbC Alloy on AISI 304L: The Effect of processing parameters on Microstructure and Wear

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JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE 2025年第1期34卷 686-698页

作者： Pacheco, Jeferson T. Meura, Vitor H. Teixeira, Moises F. da Silva, Leandro J. de Oliveira, Ana Sofia C. M. Inst SENAI Inovacao Sistemas Manufatura & Proc Las R Arno Waldemar Dohler 308 Joinville SC Brazil Univ Fed Parana UFPR Ctr Politecn Programa Pos Graduacao Engn Mecan PGMec Curitiba PR Brazil

Increasing the service life of components operating under wear conditions is the target of several industrial areas. Special alloys can improve the performance of components, but their processability can be a challenge. This work embraces this challenge assessing the effect of processing parameters by laser cladding on the microstructure and wear of Fe-NbC coatings. Single beads coatings were deposited with varying laser power, scanning speed and pre-placed powder layer thicknesses. The crack-free beads coatings were characterized for their dilution, microstructure, microhardness and wear. Sound coatings were obtained for higher laser power, lower scanning speed and lower thickness of the pre-placed powder layer, i.e., conditions with higher energy density. Increasing the energy density decreases the amount of NbC in the microstructure, but no significant impact on microhardness was measured. However, better wear performance was observed for the higher energy density, showing that processing parameters have a great influence on the microstructure and properties of Fe-NbC coatings.

关键词： Fe-NbC laser cladding microstructure processing parameters wear

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Unveiling the molten pool evolution and defects under different processing parameters in pure tantalum fabricated via laser powder bed fusion

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JOURNAL OF MANUFACTURING PROCESSES 2025年 144卷 311-325页

作者： Yang, Zhenyu Zhu, Jiangqi Liu, Yajun Pan, Chao Wu, Dan Deng, Zhaoyang Wang, Di Shi, Rongpei Wang, Gang Qiu, Zhaoguo Liu, Min Yan, Xingchen South China Univ Technol Sch Mat Sci & Engn Guangzhou 510641 Peoples R China Guangdong Acad Sci Inst New Mat Guangdong Prov Key Lab Modern Surface Engn Technol Guangdong Hong Kong Joint Lab Modern Surface Engn Guangzhou 510651 Guangdong Peoples R China Capital Med Univ Beijing Jishuitan Hosp Beijing Res Inst Traumatol & Orthopaed Beijing 100035 Peoples R China Beijing Chunlizhengda Med Instruments Co Ltd Beijing 101112 Peoples R China South China Univ Technol Sch Mech & Automot Engn Guangzhou 510641 Peoples R China Harbin Inst Technol Sch Mat Sci & Engn Shenzhen 518055 Peoples R China

Tantalum (Ta) is an important biomedical material for the preparation of implants due to its excellent mechanical and biological properties. However, the presence of defects has a significant impact on the implantation effect. The stability and flow state of the molten pool, which is controlled by processing parameters, are of great significance for the formation of defect-free components fabricated by laser powder bed fusion (LPBF). To date, the relationship among processing parameters, molten pool evolution, and defects has not been established yet. In this paper, single-track and bulk samples of pure Ta were fabricated using LPBF technology, and a powder-resolved computational fluid dynamics (CFD) model of pure Ta was established to study heat transfer and fluid flow characteristics in the molten pool. The effects of processing parameter variations on the types and quantities of defects were systematically analyzed, and the formation mechanisms of defects were revealed by combining simulation results of molten pool evolution under different parameters. The results show that increasing the laser energy density would promote higher temperature and faster velocity fields within the molten pool. Under the elevated temperature field, the spreading speed was faster than the solidification speed of the molten Ta, and the melt of powders was more sufficient, resulting in fewer keyholes after solidification. Under the rapid velocity field, the Marangoni convection was intense, which would lead to difficulty for bubbles to escape and an increase in gas pores. The coordination of temperature and velocity fields in the molten pool determined the types and quantities of defects in LPBF samples. Unmelted Ta powders acted as barriers to prevent the epitaxial growth of grains, depending on the melting state. This article presents a profound analysis of processing parameters, defects, molten pools, and microstructure changes, and is expected to provide scientific and theoretical

关键词： Defects LPBF Molten pool processing parameters Tantalum

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Studying the effect of processing parameters on the microstructure, strength, hardness, and corrosion characteristics of friction stir dissimilar welded AA5083 and AA7075 aluminum alloys reinforced with Al-SiC matrix

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Heliyon 2025年第1期11卷 e41362页

作者： Abdeltawab, Noha M. Elshazly, Mohamed Shash, Ahmed Y. El-Sherbiny, M. Department of Mechanical Design and Production Faculty of Engineering Cairo University Giza 12316 Egypt Faculty of Engineering and Materials Science German University in Cairo Cairo Egypt

The complementary properties of corrosion resistance and ballistic resistance of AA5083 and AA7075, respectively, explain the significance of welding these two alloys in the marine armor industry. This study investigates a novel Al-SiC matrix reinforcement with a different SiC weight ratio in dissimilar friction stir welding of the AA5083/AA7075 joint at different transverse and rotational speeds. The study deduced that the novel matrix can play an important role in improving strength and ductility simultaneously. Maximum strength takes place under conditions of 50 % SiC in Al-SiC matrix, 900 rpm rotational speed, and 40 mm/min transverse speed of value 209.8 MPa, which is equal to 90 % strength of the base metal AA5083, and the maximum strain takes place at 25 % SiC in Al-SiC matrix, 900 rpm rotational speed, and 20 mm/min transverse speed, with improved strain by 2 % than the softer alloy AA5083. Corrosion weight loss decreased by increasing the SiC weight ratio in the Al-SiC matrix, where it improved by 47.9 % compared to the base metal alloy of AA5083 at 75 % SiC in the Al-SiC matrix, 900 rpm rotational speed, and 20 mm/min transverse speed. © 2024 The Authors

关键词： AA5083/AA7075 welding Aluminum silicon carbide matrix Dissimilar friction stir welding processing parameters

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processing parameters affecting cold spay coatings performances

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2014年第1-4期71卷 263-277页

作者： Cavaliere, P. Silvello, A. Univ Salento Dept Innovat Engn I-73100 Lecce Italy

In the present paper, the microstructural and mechanical properties of metal-metal cold spray deposits are described. Different spray particles coatings (Al-, Ti-, Ni-based particles) deposited on different substrates (Al-, Ti-, Fe-, Ni-, Mg-based bulk materials) were produced and their mechanical and microstructural properties were characterized. Microhardness, porosity, grain size and adhesion strength of the coatings were analyzed as a function of processing parameters such as particle velocity, particle dimensions, gas density, substrate hardness, and temperature. The results were employed to build a database used to obtain a provisional model through a multi-objective optimization software. For each different substrate and particle type, the working points were defined in terms of processing parameters to optimize mechanical and microstructural behavior of coatings. The error calculation of the final properties of the deposits demonstrated the precision of the developed model.

关键词： Cold spray processing parameters Optimization

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processing parameters Optimization for Material Deposition Efficiency in Laser Metal Deposited Titanium Alloy

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Lasers in Manufacturing and Materials processing 2016年第1期3卷 9-21页

作者： Mahamood, Rasheedat M. Akinlabi, Esther T. Department of Mechanical Engineering Science University of Johannesburg Johannesburg 2006 South Africa Department of Mechanical Engineering University of Ilorin Ilorin 23400003 Nigeria

Ti6Al4V is an important Titanium alloy that is mostly used in many applications such as: aerospace, petrochemical and medicine. The excellent corrosion resistance property, the high strength to weight ratio and the retention of properties at high temperature makes them to be favoured in most applications. The high cost of Titanium and its alloys makes their use to be prohibitive in some applications. Ti6Al4V can be cladded on a less expensive material such as steel, thereby reducing cost and providing excellent properties. Laser Metal Deposition (LMD) process, an additive manufacturing process is capable of producing complex part directly from the 3-D CAD model of the part and it also has the capability of handling multiple materials. processing parameters play an important role in LMD process and in order to achieve desired results at a minimum cost, then the processing parameters need to be properly controlled. This paper investigates the role of processing parameters: laser power, scanning speed, powder flow rate and gas flow rate, on the material utilization efficiency in laser metal deposited Ti6Al4V. A two-level full factorial design of experiment was used in this investigation, to be able to understand the processing parameters that are most significant as well as the interactions among these processing parameters. Four process parameters were used, each with upper and lower settings which results in a combination of sixteen experiments. The laser power settings used was 1.8 and 3 kW, the scanning speed was 0.05 and 0.1 m/s, the powder flow rate was 2 and 4 g/min and the gas flow rate was 2 and 4 l/min. The experiments were designed and analyzed using Design Expert 8 software. The software was used to generate the optimized process parameters which were found to be laser power of 3.2 kW, scanning speed of 0.06 m/s, powder flow rate of 2 g/min and gas flow rate of 3 l/min. © 2015, Springer Science+Business Media New York.

关键词： Additive manufacturing Deposition efficiency Design of experiment Laser metal deposition processing parameters Titanium alloy

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processing parameters in manufacturing bio-based composites and their finishing with low temperature cure powder coating 20

Processing parameters in manufacturing bio-based composites ...

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20th International Conference on Composite Materials, ICCM 2015

作者： De Silva, Karnika K G Dranebois, Clémence Rao, Sanjeev Coombs, Ben Bhattacharyya, Debes Smith, Dawn A Taylor, Mark P Products Accelerator - Chemicals and Materials Engineering Department University of Auckland New Zealand Scion 49 Sala Street Rotorua3010 New Zealand Centre for Advanced Composite Materials Mechanical Engineering Department University of Auckland New Zealand

This study is based on evaluating several environmentally friendly aspects in processing and finishing fibre composites such as low-cost Medium Density Fibre (MDF) boards. These include, introducing sustainable materials to replace currently used toxic formaldehyde based binders and adding value to the composites with solvent-free powder coating with aesthetic finishes. The practicality of using conductive fillers, to enable uniform electrical conductivity on the surface of the panels to achieve uniform surface finish with powder coating is also looked into. This is a relatively new concept in composites to facilitate powder coating. The key properties investigated here in the manufacture of MDF include internal bond strength, modulus of rupture, modulus of elasticity and electrical conductivity. In finishing of the composites, a low-temperature powder coating formulation is evaluated using a thermal analysis method by Differential Scanning Calorimeter (DSC) to study the cure behaviour of powders during processing. In both investigations, full factorial design of experiments (DoE) was used as the most significant tool to detect the factors influencing to optimise the processing parameters to maximise the responses. The focus of this project includes mechanisms for preserving the technological knowledge through new business models funded by the NZ government to support the NZ manufacturing sector, for accelerating innovations and commercialization with targeted research into new products and markets. © 2015 International Committee on Composite Materials. All rights reserved.

关键词： Design of Experiments MDF panels Powder coating processing parameters

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Optimum Design of processing parameters during ISM Process of Ti-47Ni-9Nb

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Journal of Materials Science & Technology 2001年第1期17卷 75-76页

作者： Jingjie GUO Yuan LIU Hongsheng DING Yanqing SU Jun JIA School of Materials Science and Engineering Harbin institute of TechnologyHarbin 150001China

Using direct finite difference method, a numerical model for simulating the temperature field in the charge during induction skull melting (ISM) has been developed. On the basis of the model, the temperature field in Ti- 47Ni-9Nb ingot has been calculated under various melting conditions. Finally, the processing parameters (melting power, melting-down time and the final melt temperature) have been optimized.

关键词： ISM Process temperature field finite difference method processing parameters melt temperature numerical model

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Effect of hot isostatic pressing processing parameters on microstructure and properties of Ti60 high temperature titanium alloy

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China Foundry 2023年第1期20卷 49-56页

作者： Tian-yu Liu Kun Shi Jun Zhao Shi-bing Liu You-wei Zhang Hong-yu Liu Tian-yi Liu Xiao-ming Chen Xin-min Mei Shenyang Research Institute of Foundry Co. Ltd.Shenyang 110022China State Key Laboratory of Light Alloy Casting Technology for High-end Equipment Shenyang 110022China

Hot isostatic pressing parameters are critical to Ti60 high temperature titanium alloy castings which have wide application perspective in *** order to obtain optimal processing parameters,the effects of hot isostatic pressing parameters on defects,composition uniformity,microstructure and mechanical properties of Ti60 cast high temperature titanium alloy were investigated in *** show that increasing temperature and pressure of hot isostatic pressing can reduce defects,especially,the internal defects are substantially eliminated when the temperature exceeds 920℃or the pressure exceeds 125 *** higher temperature and pressure can improve the microstructure ***,the higher pressure can promote the composition *** the temperature increases from 880℃to 960℃,α-laths are *** with increasing pressure,the grain size of prior-βphase,the widths ofα-laths andα-colony are *** tensile strength of Ti60 alloy is 949 MPa,yield strength is 827 MPa,and the elongation is 11%when the hot isostatic pressing parameters are 960℃/125 MPa/2 h,which exhibits the best match between the strength and plasticity.

关键词： hot isostatic pressing processing parameters Ti60 titanium alloy defects composition uniformity microstructure mechanical properties

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processing parameters Influence on Microhardness in Laser Metal Deposited Titanium Alloy using Design if Experiment 8

Processing Parameters Influence on Microhardness in Laser Me...

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8th International Conference on Materials processing and Characterization (ICMPC)

作者： Mahamood, Rasheedat M. Akinlabi, Esther T. Univ Johannesburg Dept Mech Engn Sci Auckland PkKingsway Campus ZA-2006 Johannesburg South Africa

Laser Metal Deposition (LMD) is an additive manufacturing process for producing complex parts directly from the Computer Aided Design (CAD) model of the part and for repair of an existing worn out part. The LMD process is governed by processing parameters: laser power, gas flow rate, powder flow rate and scanning speed that influence the microhardness produced during the LMD process. In this study, statistical design of experiment to was employed to investigate the influence of processing parameters on the microhardness of laser metal deposited of Ti6Al4V powder on Ti6Al4V substrate. Full factorial design was used in this study because of its ability to capture the main effects and possible interaction effects of these processing parameters. Each processing parameters was set at low and high values and a total of sixteen (16) experiments was performed and the microhardness of each sample was measured and analyzed. (C) 2018 Elsevier Ltd. All rights reserved.

关键词： Laser Metal Deposition Full factorial design Microhardness processing parameters Titanium alloy

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