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Development of lunar regolith composite and structure via laser-assisted sintering

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0662-2

摘要： Aiming at the exploration and resource utilization activities on the Moon, in situ resource utilization and in situ manufacturing are proposed to minimize the dependence on the ground transportation supplies. In this paper, a laser-assisted additive manufacturing process is developed to fabricate lunar regolith composites with PA12/SiO2 mixing powders. The process parameters and composite material compositions are optimized in an appropriate range through orthogonal experiments to establish the relationship of process–structure–property for lunar regolith composites. The optimal combination of composite material compositions and process parameters are mixing ratio of 50/50 in volume, laser power of 30 W, scanning speed of 3500 mm/s, and scanning hatch space of 0.2 mm. The maximum tensile strength of lunar regolith composites reaches 9.248 MPa, and the maximum depth of surface variation is 120.79 μm, which indicates poor powder fusion and sintering quality. Thereafter, the mechanical properties of laser-sintered lunar regolith composites are implemented to the topology optimization design of complex structures. The effectiveness and the feasibility of this laser-assisted process are potentially developed for future lightweight design and manufacturing of the solar panel installed on the lunar rover.

关键词： in situ manufacturing     laser-assisted powder fusion process     mechanical properties     topological structure design    

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Advances in polishing of internal structures on parts made by laser-based powder bed fusion

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0724-0

摘要： The internal structures of metallic products are important in realizing functional applications. Considering the manufacturing of inner structures, laser-based powder bed fusion (L-PBF) is an attractive approach because its layering principle enables the fabrication of parts with customized interior structures. However, the inferior surface quality of L-PBF components hinders its productization progress seriously. In this article, process, basic forms, and applications relevant to L-PBF internal structures are reviewed comprehensively. The causes of poor surface quality and differences in the microstructure and property of the surface features of L-PBF inner structures are presented to provide a perspective of their surface characteristics. Various polishing technologies for L-PBF components with inner structures are presented, whereas their strengths and weaknesses are summarized along with a discussion on the challenges and prospects for improving the interior surface quality of L-PBF parts.

关键词： laser-based powder bed fusion     polishing     internal structures     surface quality     surface features     post process     additive manufacturing    

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Orientation effect of electropolishing characteristics of 316L stainless steel fabricated by laser powderbed fusion

《机械工程前沿（英文）》 2021年 第16卷 第3期   页码 580-592 doi: 10.1007/s11465-021-0633-7

摘要： 3D metal printing process has attracted increasing attention in recent years due to advantages, such as flexibility and rapid prototyping. This study aims to investigate the orientation effect of electropolishing characteristics on different surfaces of 316L stainless steel fabricated by laser powder bed fusion (L-PBF), considering that the rough surface of 3D printed parts is a key factor limiting its applications in the industry. The electropolishing characteristics on the different surfaces corresponding to the building orientation in selective laser melting are studied. Experimental results show that electrolyte temperature has critical importance on the electropolishing, especially for the vertical direction to the layering plane. The finish of electropolished surfaces is affected by the defects generated during L-PBF process. Thus, the electropolished vertical surface has higher surface roughness Sa than the horizontal surface. The X-ray photoelectron spectroscopy spectra show that the electropolished horizontal surface has higher Cr/Fe element ratio than the vertical surface. The electropolished horizontal surface presents higher corrosion resistance than the vertical surface by measuring the anodic polarization curves and fitting the equivalent circuit of experimental electrochemical impedance spectroscopy.

关键词： electropolishing     laser powder bed fusion     316L stainless steel     corrosion resistance     microstructure    

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alloying of CoCrFeMnNi high-entropy alloy from elemental feedstock toward high-throughput synthesis via laserpowder bed fusion

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0727-x

摘要： High-entropy alloys (HEAs) are considered alternatives to traditional structural materials because of their superior mechanical, physical, and chemical properties. However, alloy composition combinations are too numerous to explore. Finding a rapid synthesis method to accelerate the development of HEA bulks is imperative. Existing in situ synthesis methods based on additive manufacturing are insufficient for efficiently controlling the uniformity and accuracy of components. In this work, laser powder bed fusion (L-PBF) is adopted for the in situ synthesis of equiatomic CoCrFeMnNi HEA from elemental powder mixtures. High composition accuracy is achieved in parallel with ensuring internal density. The L-PBF-based process parameters are optimized; and two different methods, namely, a multi-melting process and homogenization heat treatment, are adopted to address the problem of incompletely melted Cr particles in the single-melted samples. X-ray diffraction indicates that HEA microstructure can be obtained from elemental powders via L-PBF. In the triple-melted samples, a strong crystallographic texture can be observed through electron backscatter diffraction, with a maximum polar density of 9.92 and a high ultimate tensile strength (UTS) of (735.3 ± 14.1) MPa. The homogenization heat-treated samples appear more like coarse equiaxed grains, with a UTS of (650.8 ± 16.1) MPa and an elongation of (40.2% ± 1.3%). Cellular substructures are also observed in the triple-melted samples, but not in the homogenization heat-treated samples. The differences in mechanical properties primarily originate from the changes in strengthening mechanism. The even and flat fractographic morphologies of the homogenization heat-treated samples represent a more uniform internal microstructure that is different from the complex morphologies of the triple-melted samples. Relative to the multi-melted samples, the homogenization heat-treated samples exhibit better processability, with a smaller composition deviation, i.e., ≤ 0.32 at.%. The two methods presented in this study are expected to have considerable potential for developing HEAs with high composition accuracy and composition flexibility.

关键词： laser powder bed fusion (L-PBF)     in situ alloying     high-entropy alloys     heat treatment     rapid synthesis    

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Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

Omotoyosi H. FAMODIMU, Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG

《机械工程前沿（英文）》 2018年 第13卷 第4期   页码 520-527 doi: 10.1007/s11465-018-0521-y

摘要：

Laser melting of aluminium alloy—AlSi10Mg has increasingly been used to create specialised products in various industrial applications, however, research on utilising laser melting of aluminium matrix composites in replacing specialised parts have been slow on the uptake. This has been attributed to the complexity of the laser melting process, metal/ceramic feedstock for the process and the reaction of the feedstock material to the laser. Thus, an understanding of the process, material microstructure and mechanical properties is important for its adoption as a manufacturing route of aluminium metal matrix composites. The effects of several parameters of the laser melting process on the mechanical blended composite were thus investigated in this research. This included single track formations of the matrix alloy and the composite alloyed with 5% and 10% respectively for their reaction to laser melting and the fabrication of density blocks to investigate the relative density and porosity over different scan speeds. The results from these experiments were utilised in determining a process window in fabricating near-fully dense parts.

关键词： selective laser melting     additive manufacturing     mechanical alloying     powder metallurgy     aluminium metal matrix composite    

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一种新型激光打印压缩诱导扭转柔顺机构的成型过程和力学变形行为 Article

高捷, 顾冬冬, 马成龙, 戴冬华, 席丽霞, 林开杰, 高彤, 朱继宏, 杜月欣

《工程（英文）》 2022年 第15卷 第8期   页码 133-142 doi: 10.1016/j.eng.2021.03.032

摘要：

本文采用激光粉末床熔融（LPBF）技术成型了一种基于自由约束拓扑（FACT）方法设计的新型压缩诱导扭转（CIT）柔顺机构。研究了LPBF 打印参数对激光打印CIT 柔顺机构成型性和压缩性能的影响。在375~450 W的优化激光功率范围内，样品的致密化水平均保持在98%以上，所获得的LPBF制造的CIT柔顺机构的相对密度随施加激光功率的变化不明显。增加激光功率有利于消除CIT 柔顺机构斜杆内的残余冶金孔隙。在450 W的激光功率下实现了0.2%的最高尺寸精度和20 μm的最低表面粗糙度。LPBF成型CIT柔顺机构的变形行为表现为四个典型阶段：弹性阶段、非均匀塑性变形阶段、强度破坏阶段和变形破坏阶段（或不稳定变形阶段）。采用450 W激光功率最优成形的CIT 柔顺机构在破坏前的累积压缩应变可达20%，展现了较大的变形能力。通过有限元模拟和实验验证相结合的方法，研究了CIT 柔顺机构的扭转行为和力学性能。在LPBF成型CIT柔顺机构的应变达到15%之前实现了轴向压缩应变与旋转角度之间的近似线性关系。

关键词： 激光3D打印     激光粉末床熔融     压缩诱导扭转柔顺机构     压缩-扭转性能     力学性能    

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Two-dimensional modeling of sintering of a powder layer on top of nonporous substrate

Tiebing CHEN, Yuwen ZHANG,

《机械工程前沿（英文）》 2010年 第5卷 第2期   页码 143-148 doi: 10.1007/s11465-010-0006-0

摘要： Selective laser sintering (SLS) of a two-component metal powder layer on the top of multiple sintered layers by a moving Gaussian laser beam is modeled. The loose metal powder layer is composed of a powder mixture with significantly different melting points. The physical model that accounts the shrinkage induced by melting is described by using a temperature-transforming model. The effects of the porosity and the thickness of the atop loose powder layer with different numbers of the existing sintered metal powder layers below on the sintering process are numerically investigated. The present work will provide a better understanding to simulate much more complicated three-dimensional SLS process.

关键词： laser     sintering     melting     solidification     heat transfer    

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Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal

《机械工程前沿（英文）》 2023年 第18卷 第2期 doi: 10.1007/s11465-022-0744-9

摘要： Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

关键词： difficult-to-machine metal material     green machining     high-speed dry milling     laser energy field-assisted milling     ultrasonic energy field-assisted milling     cryogenic minimum quantity lubrication energy field-assisted milling    

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Review on mechanism and process of surface polishing using lasers

Arun KRISHNAN, Fengzhou FANG

《机械工程前沿（英文）》 2019年 第14卷 第3期   页码 299-319 doi: 10.1007/s11465-019-0535-0

摘要： Laser polishing is a technology of smoothening the surface of various materials with highly intense laser beams. When these beams impact on the material surface to be polished, the surface starts to be melted due to the high temperature. The melted material is then relocated from the ‘peaks to valleys’ under the multidirectional action of surface tension. By varying the process parameters such as beam intensity, energy density, spot diameter, and feed rate, different rates of surface roughness can be achieved. High precision polishing of surfaces can be done using laser process. Currently, laser polishing has extended its applications from photonics to molds as well as bio-medical sectors. Conventional polishing techniques have many drawbacks such as less capability of polishing freeform surfaces, environmental pollution, long processing time, and health hazards for the operators. Laser polishing on the other hand eliminates all the mentioned drawbacks and comes as a promising technology that can be relied for smoothening of initial topography of the surfaces irrespective of the complexity of the surface. Majority of the researchers performed laser polishing on materials such as steel, titanium, and its alloys because of its low cost and reliability. This article gives a detailed overview of the laser polishing mechanism by explaining various process parameters briefly to get a better understanding about the entire polishing process. The advantages and applications are also explained clearly to have a good knowledge about the importance of laser polishing in the future.

关键词： laser polishing     surface roughness     process parameters     mechanism    

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Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Zilin HUANG,Gang WANG,Shaopeng WEI,Changhong LI,Yiming RONG

《机械工程前沿（英文）》 2016年 第11卷 第3期   页码 242-249 doi: 10.1007/s11465-016-0397-7

摘要：

Laser hot wire cladding, with the prominent features of low heat input, high energy efficiency, and high precision, is widely used for remanufacturing metal parts. The cladding process, however, needs to be improved by using a quantitative method. In this work, volumetric defect ratio was proposed as the criterion to describe the integrity of forming quality for cladding layers. Laser deposition experiments with FV520B, one of martensitic stainless steels, were designed by using the Taguchi method. Four process variables, namely, laser power (P), scanning speed (Vs), wire feed rate (Vf), and wire current (I), were optimized based on the analysis of signal-to-noise (S/N) ratio. Metallurgic observation of cladding layer was conducted to compare the forming quality and to validate the analysis method. A stable and continuous process with the optimum parameter combination produced uniform microstructure with minimal defects and cracks, which resulted in a good metallurgical bonding interface.

关键词： process optimization     Taguchi method     signal-to-noise (S/N) ratio     volumetric defect ratio     laser hot wire cladding    

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微观选择性激光熔化技术发展的现状及未来展望 Review

Balasubramanian Nagarajan, Zhiheng Hu, Xu Song, Wei Zhai, Jun Wei

《工程（英文）》 2019年 第5卷 第4期   页码 702-720 doi: 10.1016/j.eng.2019.07.002

摘要：

增材制造（AM）能将各种材料制成形状复杂的部件，因此在制造业中越来越受到青睐。选择性激光熔化（SLM）是一种常见的AM技术，它基于粉床熔融法（PBF）来处理金属，但目前只专注于大中型元件的制作。本文综述了微型金属材料SLM的研究现状。与通常用于微观AM的直接写入技术相比，微观SLM由于许多因素而更加具有吸引力，包括更快的周期时间、流程简单性和材料通用性。此外，本文综合评价了利用SLM和选择性激光烧结（SLS）制造微尺度零件的各种研究工作和商业系统，不仅从微观尺度上找出了SLM存在的问题，包括粉末重涂、激光光学和粉末粒度等， 还详细阐述了SLM未来的发展方向。文章详细回顾了粉床技术中现有的粉末重涂方法，并描述了在AM领域实施干粉分配方法的新进展。对AM部件的一些二次整理技术进行了回顾，重点介绍了细微加工特征的应用以及与微观SLM系统的结合。

关键词： 增材制造     选择性激光熔化     微细加工     混合处理     粉床重涂    

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选区激光熔化纯钨——粉末粒径对激光吸收的影响和扫描轨迹形成机理研究 Article

章佳窈, 顾冬冬, 杨莹, 张红梅, 陈洪宇, 戴冬华, 林开杰

《工程（英文）》 2019年 第5卷 第4期   页码 736-745 doi: 10.1016/j.eng.2019.07.003

摘要：

本文建立了基于线迹追踪的三维激光吸收模型，用于描述选区激光熔化（SLM）成形纯钨粉末时激光束与粉末层的相互作用，研究了粉末粒径大小对粉末激光吸收率和吸收行为的影响。本文给出了激光吸收率、粉层吸收辐照度及其分布、激光扫描轨迹的表面形貌和几何特征（如接触角、宽度和高度，以及重熔深度）之间的内在关系。模拟结果表明，粉末层的吸收率大大超过单一的粉末颗粒或致密平板材料的吸收率。随着粉末粒径增加，粉末层吸收的激光能量减少。当粒径为5 μm时，纯钨粉末层的吸收率最大达到0.6030。激光辐照度在粉床颗粒表面的分布与粒径大小、方位角和粉末在基板上的位置有关。当粒径从5 μm增加到45 μm时，粉末层中的最大辐照度从1.117 × 10–3 W·μm–2降低到0.85 × 10–3 W·μm–2，并且位于中心辐照区域的辐照度分布轮廓逐渐收缩。对SLM纯钨扫描轨迹的表面形貌和横截面几何特征进行了研究，结果验证了模拟的粉末激光吸收行为。该工作对线迹追踪模型预测SLM扫描轨迹润湿性和铺展性的应用提供了科学依据，从而更好地获得优异的激光成形性能。

关键词： 选区激光熔化     钨     线迹追踪模型     吸收率     激光扫描轨迹    

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Dilution rate and microstructure of TIG arc Ni-Al powder surfacing layer

SHAN Jiguo, DONG Wei, TAN Wenda, ZHANG Di, REN Jialie

《机械工程前沿（英文）》 2007年 第2卷 第1期   页码 20-24 doi: 10.1007/s11465-007-0003-0

摘要： Surfacing beads are prepared by a direct current tungsten inert gas arc nickel-aluminum (Ni-Al) powder surfacing process. With the aim of controlling the dilution rate and obtaining surfacing beads rich in intermetallic compounds, the effects of surfacing parameters on geometric parameters, dilution rate, composition, and microstructure of the bead are investigated. An assistant cooler, which can potentially reduce the temperature of the base metal, is used in the surfacing process and its effect on dilution rate and microstructure is studied. The result indicates that with the surfacing parameter combination of low current and speed, the width and penetration of the bead decrease, reinforcement increases, and dilution rate drops markedly. With the reduction of the parameter combination, the intergranular phase ?-(Fe, Ni) is formed in the grain boundaries of Ni-Al intermetallic matrix instead of the intergranular phase ?-Fe, and large amount of intermetallics are obtained. With the use of an assistant cooler on a selected operation condition during the surfacing process, the reinforcement of the bead increases, penetration decreases, and dilution rate declines. The use of an assistant cooler helps obtain a surfacing bead composed of only intermetallics.

关键词： decrease     Ni-Al     surfacing parameter     temperature     surfacing process    

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Laser sintering of Cu nanoparticles on PET polymer substrate for printed electronics at different wavelengthsand process conditions

Juan Carlos HERNANDEZ-CASTANEDA, Boon Keng LOK, Hongyu ZHENG

《机械工程前沿（英文）》 2020年 第15卷 第2期   页码 303-318 doi: 10.1007/s11465-019-0562-x

摘要： This study explores the feasibility of different laser systems to sinter screen-printed lines from nonconductive copper nanoparticles (Cu NPs) on polyethylene terephthalate polymer film. These materials are commonly used in manufacturing functional printed electronics for large-area applications. Here, optical and thermal characterization of the materials is conducted to identify suitable laser sources and process conditions. Direct diode (808 nm), Nd:YAG (1064 nm and second harmonic of 532 nm), and ytterbium fiber (1070 nm) lasers are explored. Optimal parameters for sintering the Cu NPs are identified for each laser system, which targets low resistivity and high processing speed. Finally, the quality of the sintered tracks is quantified, and the laser sintering mechanisms observed under different wavelengths are analyzed. Practical considerations are discussed to improve the laser sintering process of Cu NPs.

关键词： laser sintering     copper nanoparticles     printed electronics    

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高功率固体激光装置的发展与工程科学问题

彭翰生,张小民,范滇元,朱健强

《中国工程科学》 2001年 第3卷 第3期   页码 1-8

摘要：

在激光聚变需求牵引下，高功率固体激光技术走过了30多年的发展历程。在世界范围内，美、日、法、中、英、俄等国先后建造了20多台大型装置，输出能量初期仅百焦耳级，后来增大到数万焦耳，固体激光技术得到长足发展。近几年来，几个大国都在建造巨型激光装置，如美国和法国正分别建造国家点火装置NIF和兆焦耳激光器LMJ，我国在研制神光-Ⅲ激光装置，俄国也在计划建造Iskra-6激光装置。这一代激光装置的研制不但在科学技术上提出了许多新需求，从而把激光科学技术发展推向新的历史阶段，而且就其规模、投入、周期和风险而言，是前所未有的大光学科学工程。从工程科学的角度去研究如何才能建造出性能优良和效费比高的巨型激光装置是需要回答的具有挑战性的新课题。

关键词： 激光聚变     高功率固体激光     发展趋势     工程科学     创新    

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标题 作者 时间 类型 操作

Development of lunar regolith composite and structure via laser-assisted sintering

期刊论文

Advances in polishing of internal structures on parts made by laser-based powder bed fusion

期刊论文

Orientation effect of electropolishing characteristics of 316L stainless steel fabricated by laser powderbed fusion

期刊论文

alloying of CoCrFeMnNi high-entropy alloy from elemental feedstock toward high-throughput synthesis via laserpowder bed fusion

期刊论文

Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

Omotoyosi H. FAMODIMU, Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG

期刊论文

一种新型激光打印压缩诱导扭转柔顺机构的成型过程和力学变形行为

高捷, 顾冬冬, 马成龙, 戴冬华, 席丽霞, 林开杰, 高彤, 朱继宏, 杜月欣

期刊论文

Two-dimensional modeling of sintering of a powder layer on top of nonporous substrate

Tiebing CHEN, Yuwen ZHANG,

期刊论文

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal

期刊论文

Review on mechanism and process of surface polishing using lasers

Arun KRISHNAN, Fengzhou FANG

期刊论文

Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Zilin HUANG,Gang WANG,Shaopeng WEI,Changhong LI,Yiming RONG

期刊论文

微观选择性激光熔化技术发展的现状及未来展望

Balasubramanian Nagarajan, Zhiheng Hu, Xu Song, Wei Zhai, Jun Wei

期刊论文

选区激光熔化纯钨——粉末粒径对激光吸收的影响和扫描轨迹形成机理研究

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