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Alloy design for laser powder bed fusion additive manufacturing:a critical review

International Journal of Extreme Manufacturing 2024年第2期6卷 29-63页

作者： Zhuangzhuang Liu Qihang Zhou Xiaokang Liang Xiebin Wang Guichuan Li Kim Vanmeensel Jianxin Xie Key Laboratory for Advanced Materials Processing(MOE) Institute for Advanced Materials and TechnologyUniversity of Science and Technology BeijingBeijing 100083People’s Republic of China Beijing Advanced Innovation Center for Materials Genome Engineering University of Science and Technology BeijingBeijing 100083People’s Republic of China Beijing Laboratory of Metallic Materials and Processing for Modern Transportation Institute for Advanced Materials and TechnologyUniversity of Science and Technology BeijingBeijing 100083People’s Republic of China Capital Aerospace Machinery Corporation Limited Beijing 100076People’s Republic of China Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials(Ministry of Education) Shandong UniversityJingshi Road 17923Jinan 250061People’s Republic of China Department of Materials Engineering KU LeuvenLeuven 3001Belgium

Metal additive manufacturing(AM)has been extensively studied in recent *** the significant progress achieved in manufacturing complex shapes and structures,challenges such as severe cracking when using existing alloys for laser powder bed fusion(L-PBF)AM have *** challenges arise because commercial alloys are primarily designed for conventional casting or forging processes,overlooking the fast cooling rates,steep temperature gradients and multiple thermal cycles of *** address this,there is an urgent need to develop novel alloys specifically tailored for L-PBF *** review provides a comprehensive summary of the strategies employed in alloy design for *** aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing *** review begins by discussing the features of the L-PBF processes,focusing on rapid solidification and intrinsic heat ***,the printability of the four main existing alloys(Fe-,Ni-,Al-and Ti-based alloys)is critically assessed,with a comparison of their conventional *** was found that the weldability criteria are not always applicable in estimating ***,the review presents recent advances in alloy development and associated strategies,categorizing them into crack mitigation-oriented,microstructure manipulation-oriented and machine learning-assisted ***,an outlook and suggestions are given to highlight the issues that need to be addressed in future work.

关键词： laser powder bed fusion alloy design printability crack mitigation

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Phase-field simulation of lack-of-fusion defect and grain growth during laser powder bed fusion of Inconel 718

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International Journal of Minerals,Metallurgy and materials 2023年第11期30卷 2224-2235页

作者： Miaomiao Chen Renhai Shi Zhuangzhuang Liu Yinghui Li Qiang Du Yuhong Zhao Jianxin Xie Beijing Advanced Innovation Center for Materials Genome Engineering University of Science and Technology BeijingBeijing 100083China Key Laboratory for Advanced Materials Processing(MOE) Institute for Advanced Materials and TechnologyUniversity of Science and Technology BeijingBeijing 100083China Beijing Laboratory of Metallic Materials and Processing for Modern Transportation Institute for Advanced Materials and TechnologyUniversity of Science and Technology BeijingBeijing 100083China SINTEF Industry Oslo 0314Norway School of Materials Science and Engineering North University of ChinaTaiyuan 030051China

The anisotropy of the structure and properties caused by the strong epitaxial growth of grains during laser powder bed fusion(L-PBF)significantly affects the mechanical performance of Inconel 718 alloy components such as turbine *** defects(lack-of-fusion Lo F)in components processed via L-PBF are detrimental to the strength of the *** purpose of this study is to investigate the effect of laser scanning parameters on the epitaxial grain growth and LoF formation in order to obtain the parameter space in which the microstructure is refined and LoF defect is *** temperature field of the molten pool and the epitaxial grain growth are simulated using a multiscale model combining the finite element method with the phase-field *** LoF model is proposed to predict the formation of LoF defects resulting from insufficient melting during *** mitigation and grain-structure control during L-PBF can be realized simultaneously in the *** simulation shows the input laser energy density for the as-deposited structure with fine grains and without LoF defects varied from 55.0–62.5 J·mm^(-3)when the interlayer rotation angle was 0°–90°.The optimized process parameters(laser power of 280 W,scanning speed of 1160 mm·s^(-1),and rotation angle of 67°)were computationally *** these conditions,the average grain size was 7.0μm,and the ultimate tensile strength and yield strength at room temperature were(1111±3)MPa and(820±7)MPa,respectively,which is 8.8%and10.5%higher than those of *** results indicating the proposed multiscale computational approach for predicting grain growth and Lo F defects could allow simultaneous grain-structure control and defect mitigation during L-PBF.

关键词： Inconel 718 alloy laser powder bed fusion scanning parameter optimization lack-of-fusion phase-field method finite element method

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Thermal fatigue and wear of compacted graphite iron brake discs with various thermomechanical properties

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China Foundry 2024年第3期21卷 248-256页

作者： Gui-quan Wang Zhuo Xu Zhong-li Liu Xiang Chen Yan-xiang Li School of Nuclear Equipment and Nuclear Engineering Yantai UniversityYantai 264005ShandongChina School of Materials Science and Engineering Tsinghua UniversityBeijing 100084China Key Laboratory for Advanced Materials Processing Technology Ministry of EducationBeijing 100084China

The increase in payload capacity of trucks has heightened the demand for cost-effective yet high performance brake *** this work,the thermal fatigue and wear of compacted graphite iron brake discs were investigated,aiming to provide an experimental foundation for achieving a balance between their thermal and mechanical *** graphite iron brake discs with different tensile strengths,macrohardnesses,specific heat capacities and thermal diffusion coefficients were produced by changing the proportion and strength of *** peak temperature,pressure load and friction coefficient of compacted graphite iron brake discs were analyzed through inertia friction *** morphology of thermal cracks and 3D profiles of the worn surfaces were also *** is found that the thermal fatigue of compacted graphite iron discs is determined by their thermal properties.A compacted graphite iron with the highest specific heat capacity and thermal diffusion coefficient exhibits optimal thermal fatigue *** of the matrix at low temperatures significantly weakens the function of alloy strengthening in hindering the propagation of thermal *** the reduced hardness,increasing the ferrite proportion can mitigate wear loss resulting from low disc temperatures and the absence of abrasive wear.

关键词： compacted graphite iron brake disc thermomechanical properties thermal fatigue wear

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Exploring a balance between strength and ductility of hexagonal BN nanoplatelet reinforced ZK61 magnesium composite

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Journal of Magnesium and Alloys 2024年第5期12卷 1899-1910页

作者： Kewei Zhang Xiaolong Lu Yufeng Sun Shaokang Guan Yao Chen School of Materials Science and Engineering Zhengzhou UniversityZhengzhou 450001China Key Laboratory of Advanced Magnesium Alloys in Henan Province Zhengzhou UniversityZhengzhou 450002China Key Laboratory of Advanced Materials Processing&Mold Ministry of EducationZhengzhou 450002China School of Mechanical and Electrical Engineering Soochow UniversitySuzhou 215021China

The practical applications of magnesium(Mg)alloys are usually beset by their relatively low strength and limited *** we attempt to fabricate hexagonal BN nanoplatelet(BNNP)reinforced ZK61 magnesium composites using a combination of spark plasma sintering and friction stir *** resulting composites exhibit microstructural characteristics of homogeneous dispersion of BNNP in Mg matrix with refined equiaxed grains and(0002)basal texture roughly surrounding the pin column *** electron microscopy observation illustrates that trace amounts of Mg_(3)N_(2)and MgB_(2)form at BNNP-Mg interface,in which Mg_(3)N_(2)locates at the basal plane of a BNNP and MgB_(2)grows at its open *** spatial distribution of Mg_(3)N_(2)and MgB_(2)facilitates interfacial wetting and stronger BNNP-Mg interface in such a way that interfacial products act as anchors bonding between *** comparison with monolithic ZK61 alloy,the BNNP/ZK61 composites display simultaneous improvements in yield strength,hardness and ductility,achieving good strength-ductility *** research is expected to shed some light on BNNP potentials for designing and producing magnesium composites with high strength and good ductility.

关键词： BN nanoplatelet Magnesium composite Strength Ductility Spark plasma sintering Friction stir processing

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Artificial Intelligence Meets Flexible Sensors:Emerging Smart Flexible Sensing Systems Driven by Machine Learning and Artificial Synapses

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Nano-Micro Letters 2024年第1期16卷 235-273页

作者： Tianming Sun Bin Feng Jinpeng Huo Yu Xiao Wengan Wang Jin Peng Zehua Li Chengjie Du Wenxian Wang Guisheng Zou Lei Liu Department of Mechanical Engineering State Key Laboratory of Tribology in Advanced EquipmentKey Laboratory for Advanced Manufacturing by Materials Processing TechnologyMinistry of Education of PR ChinaTsinghua UniversityBeijing 100084People’s Republic of China College of Materials Science and Engineering Shanxi ProvinceTaiyuan University of TechnologyTaiyuan 030024People’s Republic of China

The recent wave of the artificial intelligence(AI)revolution has aroused unprecedented interest in the intelligentialize of human *** an essential component that bridges the physical world and digital signals,flexible sensors are evolving from a single sensing element to a smarter system,which is capable of highly efficient acquisition,analysis,and even perception of vast,multifaceted *** challenging from a manual perspective,the development of intelligent flexible sensing has been remarkably facilitated owing to the rapid advances of brain-inspired AI innovations from both the algorithm(machine learning)and the framework(artificial synapses)*** review presents the recent progress of the emerging AI-driven,intelligent flexible sensing *** basic concept of machine learning and artificial synapses are *** new enabling features induced by the fusion of AI and flexible sensing are comprehensively reviewed,which significantly advances the applications such as flexible sensory systems,soft/humanoid robotics,and human activity *** two of the most profound innovations in the twenty-first century,the deep incorporation of flexible sensing and AI technology holds tremendous potential for creating a smarter world for human beings.

关键词： Flexible electronics Wearable electronics Neuromorphic Memristor Deep learning

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Diffusion mechanism of immiscible Fe-Mg system induced by high-density defects at the steel/Mg composite interface

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Journal of materials Science & Technology 2023年第13期144卷 150-160页

作者： Yanlan Sun Xuefeng Liu Wenjing Wang Yaohua Yang Weiliang Zhang Beijing Advanced Innovation Center for Materials Genome Engineering University of Science and Technology BeijingBeijing 100083China Beijing Laboratory of Metallic Materials and Processing for Modern Transportation University of Science and Technology BeijingBeijing 100083China Key Laboratory for Advanced Materials Processing of Ministry of Education University of Science and Technology BeijingBeijing 100083China

Due to positive mixing heat between Fe and Mg,it is difficult to diffuse for Fe-Mg at the interface of steel/Mg laminated composites,resulting in the inability to achieve high-strength metallurgical *** this paper,20#steel/Mg laminated composites were prepared by large deformation rolling and subse-quent diffusion heat treatment *** interfacial bonding strength was improved by constructing high-density crystal defects at the interface to promote element *** mechanisms of interface morphology evolution and element diffusion were analyzed by finite element simulation and theoretical *** results show after diffusion heat treatment,the bond strength of the large deformation rolled interface was increased from 14 to 30 ***-Mg transition layer with about 80 nm thickness as well as high-density vacancies,dislocations and grain boundaries were formed in the large deforma-tion rolled interface *** diffusion heat treatment,Mg elements diffused into grain interior and grain boundary regions of 20#steel under the effect of heat-force coupling,and the thickness of Fe-Mg transition layer increased to 150 nm,forming an Fe-based supersaturated solid *** in-terface with high-density defects constituted a non-equilibrium *** 20#steel internal energy in the non-equilibrium interface is able to overcome positive mixing heat of immiscible Fe-Mg system and provide the driving force for Mg elements *** elemental diffusion by constructing high-density defects can be a new concept to achieve metallurgical bonding at the interface of immiscible metal laminated composites.

关键词： Steel/Mg composite interface Immiscible Fe-Mg system Non-equilibrium interface Diffusion mechanism

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Bioabsorbable fabrication of molybdenum nitride/carbon nanocomposites for supercapacitors and metal ion batteries with robust stability

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Rare Metals 2023年第12期42卷 4212-4225页

作者： Qiang-Hong Wu Huan-Zhong Zeng You-Zhi Wu Fen Ran State Key Laboratory of Advanced Processing and Recycling of Non-Ferrous Metals School of Materials Science and EngineeringLanzhou University of TechnologyLanzhou 730050China

Metal nitride is one of the best anode materials of the energy storage device;however,the low stability of the pure metal nitride limits its wide *** this work,a new method of bioabsorbable fabrication was developed for preparing molybdenum nitride that corporates into the porous carbon *** molybdenum ions in pollutions could be easily absorbed by Ligustrum quihoui,and the transportation,accumulation,and circulation of molybdenum ions in Ligustrum quihoui were *** obtained composite material of biochar and molybdenum nitride is employed as anode material of supercapacitors and batteries which exhibits good electrochemical performance,especially the rate and long lifespan ***,it is found that the specific capacity is344 F·g^(-1)at current density of 0.5 A·g^(-1)in 2 mol·L^(-1)KOH,and the capacitance retention and coulomb efficiency are above 90%after 10,000 *** should be noted that the novel approach combines fabricating anode materials with advanced nanostructure and suppressing the environmental problems with metal pollution at the same time.

关键词： Metal pollution Ligustrum quihoui Supercapacitors Metal ions batteries Anode materials

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Multiphase reaction spinning of high-temperature resistant weavable SiO_(2)-Kevlar hybrid aerogel fibers

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Nano Research 2025年第1期18卷 424-433页

作者： Yunna Chen Wenlu Zhang Qingyang Li Wenbin Li Chong He School of Textile Science and Engineering Wuhan Textile UniversityWuhan 430200China State Key Laboratory of New Textile Materials and Advanced Processing Technologies Wuhan Textile UniversityWuhan 430200China

advanced aerogel fibers possess numerousadvantages amalgamating the attributes of aerogels and fibermaterials, rendering them invaluable in the realm of thermalmanagement and regulation. However, the achievement ofrobust mechanical properties and increased temperaturestability is still a major challenge for the majority of aerogelfibers. Herein, SiO_(2)-Kevlar hybrid aerogel fibers with bioniccore-shell structure were prepared by reaction spinning andweaved into fabric. Kevlar nanowires dispersion is pumpedinto a bath comprising a self-synthesized silica sol, whichfacilitates the hybridization of biphasic aerogels through thegel reaction. Precise control over the diameter (200-800 μm)and structure of the wet gel fibers was achieved throughmeticulous adjustment of the spinning solution composition and spinning parameters. Subsequent freeze-drying processfacilitates the formation of a core-shell hybrid structure, in which the SiO_(2) aerogel layer effectively encapsulate the Kevlaraerogel core fiber. Taking full advantage of the mechanical properties of the Kevlar core fiber, the resulting SiO_(2)-Kevlaraerogel fibers exhibit commendable weaving characteristics (51.8 MPa). Furthermore, SiO_(2)-Kevlar aerogel fabrics exhibitenhanced thermal insulation characteristics with a thermal conductivity of 0.037 W/(m·K). As a result of the presence ofexternal SiO_(2) aerogel layer, the overall temperature resistance performance of the SiO_(2)-Kevlar fabric reach up to 700 ℃.

关键词： aerogel fibers SiO_(2)aerogel Kevlar aerogel reaction spinning thermal protective performance

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Blow spinning mass production of melamine@polyacrylonitrile composite nanofibers with enhanced flame-retardant and strengths

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Progress in Natural Science:materials International 2023年第5期33卷 634-643页

作者： Jiahao He Wenlu Zhang Xinpeng Jin Chong He Wenbin Li School of Textile Science and Engineering Wuhan Textile University State Key Laboratory of New Textile Materials and Advanced Processing Technologies Wuhan Textile University

To achieve the scalable production of high-performance melamine-based flame retardant nanofibers, solution blowing spinning technology was employed into the continuous spinning of melamine(MA)@polyacrylonitrile(PAN) composite fibers. Propelled by the compressed air current, spinnable MA@PAN solutions can be shaped into nanofiber with a high flow rate over 50 m L/h. Among different melamine-based materials,melamine phosphate(MPP) exhibited excellent solubility in the solution, exceeding 30 wt%, ensuring that the MPP@PAN nanofiber products demonstrated exceptionally robust flame-retardant performance. Furthermore,through fiber textile needle punching technology, loose fiber sponge can be organized into enhanced fiber blankets. These MPP@PAN nanofiber products exhibited outstanding flame retardant and thermal insulation properties, rendering them pivotal as the flame-retardant materials in extreme environments.

关键词： Composites Flame retardance Nanofibers High temperature materials Mechanical properties

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Solution blow spinning mass production of mullite nanofiber from environment friendly aqueous Al–Si solutions

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Progress in Natural Science:materials International 2023年第5期33卷 691-700页

作者： Xinpeng Jin Jiugang Li Chi Zhang Keshuai Liu Chong He Wenbin Li School of Textile Science and Engineering Wuhan Textile University State Key Laboratory of New Textile Materials and Advanced Processing Technologies Wuhan Textile University

Achieving large-scale production of high-performance mullite ceramic nanofibers posed a formidable ***, an air heating-solution blow spinning technique was designed for the mass fabrication of mullite nanofibers at high speeds, ranging from 6 to 60 ml/h. Spinnable aqueous Al–Si solution systems, employing various aluminum sources, were systematically investigated. The optimization of the solution blow spinning apparatus involved the incorporation of a hot air blow device capable of dispensing streams of hot, dry air. Comprehensive investigations were conducted to examine the impact of variables such as spinning solution viscosity, spinning rate, and spinning distance on the resulting mullite fiber diameter and morphology. Following sintering at 1200°C, mullite fiber cotton was successfully synthesized, exhibiting diameters spanning from 500 nm to 5 μm. These mullite nanofiber cotton demonstrated exceptional attributes, including robust temperature stability(up to 1300°C), remarkable thermal insulation properties and superior filtration efficiency.

关键词： Solution blow spinning Mullite nanofiber Aqueous solution Thermal insulation

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