21 research outputs found
Metal Wire Additive Manufacturing: A Comparison between Arc Laser and Laser/Arc Heat Sources
No full textIn this paper, the authors introduce the reader to the state of the art of Metal Wire Additive Manufacturing (MWAM) and provide a comparison between Wire Arc Additive Manufacturing (WAAM), Wire Laser Additive Manufacturing (WLAM), and Laser Arc Hybrid Wire Deposition (LAHWD) based on their characteristics and potential future applications, since MWAM is expected to have a promising future in various areas, such as aerospace, automotive, biomedical, and energy fields. A detailed discussion of the benefits and drawbacks of each Metal Wire Additive Manufacturing process can help to improve our understanding of the unique characteristics of metal wire application. Therefore, this paper offers a comprehensive analysis that can serve as a reference for upcoming industrial projects and research initiatives, with the aim of helping industries choose the most appropriate WAM technique for their specific applications
Statistical modeling and characterization of laser marking on AISI 301LN stainless steel using short-pulsed fiber laser
No full textThis study explores the effects of nanosecond short-pulsed fiber laser processing on AISI 301LN stainless steel, focusing on optimizing surface characteristics through precise parameter control. Using a Design of Experiments (DOE) approach combined with response surface methodology (RSM), the influence of laser power (30–60 W) and the number of laser passes (5–15 times) was systematically investigated. The results demonstrate that increasing the laser power and passes significantly affected the surface properties. The highest surface roughness of 16.8 µm and engraving width of 51 µm were achieved with 60 W power and 15 passes, whereas the lowest roughness of 13.8 µm and width of 35 µm were observed with 30 W power and 5 passes. Wettability measurements revealed an inverse correlation with roughness, with contact angles ranging from 86.4° for rougher surfaces to 92.4° for smoother textures. The findings demonstrate the capability of short-pulsed fiber laser processing to tailor surface properties effectively, with potential applications in manufacturing and surface engineering where controlled roughness and wettability are critical.This work is part of Maria de Maeztu Units of Excellence Programme CEX2023-001300-M/funded by MCIN/AEI/10.13039/501100011033. Mohammad Rezayat acknowledges the financial support provided via an AGAUR Fellowship [(FI-SDUR-2020)] from the Generalitat de Catalunya.Peer ReviewedPostprint (published version
Capability Enhancing of CO2 Laser Cutting for PMMA Sheet Using Statistical Modeling and Optimization
No full textOverview of Surface Modification Strategies for Improving the Properties of Metastable Austenitic Stainless Steels
No full textMetastable austenitic stainless steels (MASS) are widely used in various industrial applications due to their exceptional compromise between mechanical properties and corrosion resistance. However, the mechanical properties of these materials can be further enhanced by surface treatments. This paper reviews various surface treatment methodologies used to improve the mechanical properties of MASS, with particular attention to laser treatments. The effects of these surface treatments on the microstructure and chemical composition in the thermal affected zone of the MASS are discussed, and their impact on the material’s mechanical properties, such as hardness, tensile strength, and fatigue life, are investigated in detail. Additionally, the paper highlights the limitations of these surface treatments and points out some areas where further research is needed. The findings presented can be used to guide the selection of appropriate surface treatment techniques for specific applications, ultimately improving the performance and lifespan of MASS in various industrial settings
Characterization and Optimization of Cu-Al2O3 Nanocomposites Synthesized via High Energy Planetary Milling: A Morphological and Structural Study
No full textThis study examines the synthesis and characterization of a copper–alumina nanocomposite powder. Mechanical milling is employed to synthesize the powder, and a holistic analysis is conducted to evaluate its morphological and structural properties. TEM analysis reveals the presence of alumina particles within the copper matrix, indicating the formation of both coarse and fine particles at different stages of synthesis. XRD analysis demonstrates a reduction in copper’s crystallite size with increasing milling time, attributed to defects generated within the crystal lattice during milling. Additionally, statistical analysis is utilized to determine the significance of different factors influencing the synthesis process. ANOVA analysis reveals that milling time has a significant impact on the particle size of the nanocomposite powder, while temperature and their interaction do not exhibit significant effects. Optimization techniques are utilized to identify solutions that meet the specified constraints for milling time, temperature, particle size, and differential thermal response, resulting in favorable solutions within the desired ranges. The study highlights the efficacy of mechanical milling for producing nanocomposite powders with enhanced mechanical properties, offering promising prospects for advanced materials in various industries. Additionally, the characterization results provide valuable insights into the microstructure and phase distribution of the nanocomposite powder. The application of the Williamson–Hall method proves to be effective in determining the crystallite size of the synthesized powder.Peer ReviewedPostprint (published version
Correlation between infill percentages, layer width, and mechanical properties in fused deposition modelling of poly-lactic acid 3D printing
No full textThe field of additive manufacturing (AM) has seen a transformation in the production of intricate and complex parts for various applications. Fused Deposition Modelling (FDM), among AM techniques, has garnered significant attention, particularly in fields like fibre-reinforced composites (FRC). In this study, the world of FDM-printed Polylactic Acid (PLA) components is explored, with a focus on how mechanical properties are influenced by infill percentages and layer widths. Through the utilisation of Response Surface Methodology (RSM), the optimisation of FDM-PLA 3D printing for a wide range of biomaterial applications is achieved, along with the unveiling of the potential for remarkable improvements in mechanical performance. Notably, a remarkable 91% reduction in surface roughness for PLA composites was achieved, accompanied by an impressive 25.6% and 34.1% enhancement in the tensile strength and Young’s modulus of fibre-reinforced PLA composites, respectively. This work, positioned at the crossroads of FDM, lays the groundwork for substantial advancements in the realm of additive manufacturing.Peer ReviewedPostprint (published version
Mathematical modelling of fused deposition modeling (FDM) 3D printing of poly vinyl alcohol parts through statistical design of experiments approach
No full textThis paper explores the 3D printing of poly vinyl alcohol (PVA) using the fused deposition modeling (FDM) process by conducting statistical modeling and optimization. This study focuses on varying the infill percentage (10–50%) and patterns (Cubic, Gyroid, tri-hexagon and triangle, Grid) as input parameters for the response surface methodology (DOE) while measuring modulus, elongation at break, and weight as experimental responses. To determine the optimal parameters, a regression equation analysis was conducted to identify the most significant parameters. The results indicate that both input parameters significantly impact the output responses. The Design Expert software was utilized to create surface and residual plots, and the interaction between the two input parameters shows that increasing the infill percentage (IP) leads to printing heavier samples, while the patterns do not affect the weight of the parts due to close printing structures. On the contrary, the discrepancy between the predicted and actual responses for the optimal samples is below 15%. This level of error is deemed acceptable for the DOE experiments
Enhancing mechanical properties of 3D-printed PLAs via optimization process and statistical modeling
No full textThis paper investigates the optimization of 3D printing by 1.75 mm filaments of poly-lactic acid (PLA) materials. The samples are printed separately and glued together to join the tensile device for the failure load and checking the surface roughness. The printing method in this research is Fused Deposition Modeling (FDM), in which the parameters of Infill Percentage (IP), Extruder Temperature (ET), and Layer Thickness (LT) are considered variable parameters for the 3D printer, and according to the Design of Experiments (DOE), a total of 20 experiments are designed. The parametric range is considered to be 15–55% for IP, 190–250 °C for ET, and 0.15–0.35 mm for LT. The optimization model is conducted according to the Response Surface Method (RSM), in which the ANOVA and plot tables are examined. Moreover, the samples’ maximum failure load, weight, fabrication time, and surface roughness are considered output responses. Statistical modeling shows that by increasing the IP and setting the ET at 220 °C, the failure load of the samples increases, and the maximum failure load reaches 1218 N. The weight and fabrication time of the specimen are optimized at the same time to achieve maximum failure load with less surface roughness. By comparing the predicted and actual output for the optimum samples, the percentage error for all results is less than 5%. The developed optimization method is revealed to be accurate and reliable for FDM 3D printing of PLAs
A comparative investigation of different overlaps of the diode laser hardening in low-Carbon steel and stainless steel
No full textIn this paper, the effect of laser overlap on the low-carbon and stainless steel are investigated. The analyzed samples are made of AISI 4130 low-Carbon steel and AISI 410 stainless steel with 50% overlap. The used laser is an industrial high-power diode laser with a continuous wave and a maximum power of 2kW. Samples are fabricated using optimized levels for laser power, focal plane position, and laser scanning speed, and the heat-treatment process is done after that. The parameters and conditions for the laser hardening process of both samples are the same situation. Then, the microstructure analysis is done using OM and SEM. Besides, the hardness of the samples is tested in the hardening depth and width. The study shows that the hardness is improved for both samples at the overlap area, up to 762 hv for AISI 4130 and 675 hv for AISI 410. Also, in both samples the amount of ferrite phase has decreased
Statistical analysis of experimental factors for synthesis of copper oxide and tin oxide for antibacterial applications
No full textThis research explores the impact of Cu composition, heating temperature, and milling time on the production of copper-tin alloy nanoparticles. By employing design of experiments techniques, the study systematically evaluates these input variables and their effects on particle size, optical density, and number of colonies. The identification of new Cu3Sn phases in the nanoparticle structure contributes to the novelty of this research. The findings highlight the potential for optimizing copper-tin alloy nanoparticle synthesis and enhancing their antibacterial properties. Mechanical alloying is found to produce nanoparticles up to 15 nm in size. Increasing the percentage of copper leads to improved antibacterial properties. This work provides insights into the synthesis process of copper-tin mechanical alloying and their potential for antibacterial applications.Peer ReviewedPostprint (published version
