In recent years, in addition to the commonly known wire-based processes of Directed Energy Deposition using lasers, a process variant using the electron beam has also developed to industrial market maturity. The process offers particular potential for processing highly conductive, reflective or oxidation-prone materials. However, for industrial usage there is a lack of comprehensive data on performance, process limits and possible applications. The present study deals with this problem using the example of the high-strength aluminum bronze CuAl8Ni6. Multi-stage test welds are used to determine the physically possible process limits and draw conclusions about the suitability of the parameters for additive manufacturing. For this purpose, optimal ranges for energy input, possible welding speeds and the scalability of the process were investigated. Finally, additive test specimens in the form of cylinders and walls are produced and the hardness profile, microstructure and mechanical properties are investigated. It is found that the material CuAl8Ni6 can be well processed by wire electron beam additive manufacturing. The microstructure is similar to a cast structure, the hardness profile over the height of the specimens is constant and the tensile strength and elongation at fracture values achieved correspond to the specification of the raw material.

To obtain a given structure in 3D building-up modes, it is necessary to use optimal surfacing modes that determine the amount of heat input in local areas. For this purpose, aluminum bronze was surfacing onto a deformed base and the structure and its characteristics in the surfacing and heat-affected zones were studied by the EBSD method. The heterogeneity of the formation of the structure in each selected zone is established, which indicates the heterogeneity of heat input in local areas of the material in one mode of surfacing. For typical cases of crystallization, a molecular dynamics simulation of crystallization processes with different heat input to the base with characteristics specified based on experimental data was carried out. It has been established that the amount of heat input determines the degree of melting and the inherited defectiveness of growing crystals. The formation of misorientation boundaries and crystallization centers of new grains is determined by the conditions of joint growth of grains with given crystallographic parameters of the computational model. Numerical calculations agree with the experimentally observed results.

Keywords: friction stir processing; additive manufacturing; wire; titanium alloy; material transfer; microstructure; microhardness

This study investigates the potential benefits of integrating coarser particle size distributions (PSDs) of 45-106 µm into laser-based powder bed fusion of metals (PBF-LB/M), aiming to reduce costs while maintaining quality standards. Despite the considerable advantages of PBF-LB/M in producing intricate geometries with high precision, the high cost of metal powders remains a barrier to widespread adoption. By exploring the use of coarser PSDs, particularly from electron beam-based powder bed fusion of metals (PBF-EB/M), significant cost-saving opportunities are identified. Through comprehensive powder characterization, process analysis, and mechanical property evaluation, this study demonstrates that PBF-LB/M can effectively utilize coarser powders while achieving comparable mechanical properties to those produced with 20-53 µm PSD. Adaptations in process parameters enable the successful processing of coarser powders, maintaining high-relative density components with minimal porosity. Additionally, market surveys reveal substantial cost differentials between PBF-LB/M and PBF-EB/M powders, indicating 40 % cost reduction potential by integrating coarser PSDs into PBF-LB/M. Overall, this study provides valuable insights into the economic and technical feasibility of printing with coarser powders in PBF-LB/M, offering promising avenues for cost reduction without compromising quality, thus enhancing competitiveness and adoption of the technology in manufacturing applications.

This literature review provides an in-depth exploration of the research conducted on the investigation and measurement of residual stress (RS) in Wire Arc Additive Manufacturing (WAAM) products, particularly focusing on how process parameters influence the phenomenon. RS plays a crucial role in determining the mechanical behavior and structural integrity of WAAM components. This review article gives an understanding of the relationship between process parameters and RS to optimize the WAAM processes and ensure the durability of the final products. It also summarizes key findings, measurement techniques, challenges, and future directions in this evolving field. The review also analyzes a measurement of RS in the products of WAAM as a function of process parameters depending on examining various research studies, techniques, and methodologies employed in their studies. Experimental measuring techniques and numerical analysis of RS to determine the impacts of RS in mechanical response in products of WAAM were discussed. By offering a comprehensive overview of current research trends and insights, this review serves as a valuable resource to guide future investigations, fostering the advancement of WAAM as a robust and efficient manufacturing technology.

Titanium-based metal-matrix composites manufactured by additive manufacturing offer tremendous lightweighting opportunities. However, processing high reinforcement content remains challenging. This study reports an improved manufacturing process for Ti-TiC enabling high reinforcement content and significant fracture strain concurrently: mechanical blending, followed by laser powder bed fusion and a single heat treatment. As-built microstructure shows both un-melted TiC particles and sub-stoichiometric TiC dendrites resulting from a partial dissolution of TiC particles. The heat treatment is shown to fully convert TiC dendrites into equiaxed TiC grains. Reduction of the C/Ti ratio in TiC during the process results in an increase in the reinforcement content, from a nominal 12 vol% to an effective 21.5 vol%. Ti-TiC tensile samples reached fracture strains of up to 1.7%, Young’s moduli of up to 149 GPa and ultimate tensile strengths of up to 827 MPa. Lower TiC initial powder size distributions displayed the best mechanical performance.

This study outlines a 3-step production process for Ti-TiC Metal Matrix Composite (MMC) employing powder Mechanical Blending, Laser Powder Bed Fusion (LPBF), and a heat treatment. A TiC fraction of more than 20 vol% was formed in-situ through the reaction of titanium with carbon during the LPBF process. The manufactured MMC pieces showed a record stiffness and fracture strain combination. The LPBF energy density impacted strongly porosity type. The as-built microstructure displayed an homogeneous distribution of sub-stoichiometric TiC dendrites which were fully converted into equiaxed TiC grains during the heat treatment. The TiC C/Ti ratio was found to be close to 0.5, resulting in an effective reinforcement content nearly twice the one expected for stoichiometric TiC, leading to stronger reinforcement. The mechanical analysis revealed a Young’s modulus of up to 149 GPa and an ultimate tensile strength of up to 770 MPa, indicating a 27% and 34% improvement, respectively, compared to commercially pure Titanium produced by LPBF and heat treated in the same conditions. A fracture strain of up to 2.8% was achieved. The combination of in-situ formation of defect-free TiC reinforcement and subsequent heat treatment enables to reach an exceptional ductility, considering the 20 vol% reinforcement content.

Three-dimensional (3D) printing technology, also known as additive manufacturing (AM), has emerged as an attractive state-of-the-art tool for precisely fabricating functional materials with complex geometries, championing several advancements in tissue engineering, regenerative medicine, and therapeutics. However, this technology has an untapped potential for biotechnological applications, such as sensor and biosensor development. By exploring these avenues, the scope of 3D printing technology can be expanded and pave the way for groundbreaking innovations in the biotechnology field. Indeed, new printing materials and printers would offer new possibilities for seamlessly incorporating biological functionalities within the growing 3D scaffolds. Herein, we review the extrusion-based 3D printing modalities emphasizing biosensor applications. We highlighted the application of natural, synthetic, and composite biomaterials as 3D-printed soft hydrogels. Emphasis was placed on the approach by which the sensing molecules were introduced during the fabrication process. Finally, the future perspective was provided.

This paper proposes an innovative approach to address the challenge of softening deformation of thermal-curable thermosets during additive manufacturing. This approach involves the development of a composite powder composed of thermosetting materials with distinct curing temperatures, the utilization of Cold Spray Additive Manufacturing (CSAM) technology for 3D printing, and the application of a stepwise isothermal curing process. The corresponding effectiveness is validated by case studies. The results demonstrate that samples printed via CSAM maintain a solid state without deformation. During the post-curing process, each component of the composite material cures independently while the other components remain in a solid state, providing structural support for the whole material, thereby effectively reducing the softening deformation during the post-curing process. This approach offers a novel perspective for the additive manufacturing of thermal-curable thermosets.

Chromium (Cr) metal has garnered significant attention in alloy systems owing to its exceptional properties, such as high melting point, low density, and superior oxidation and corrosion resistance. However, its processing capabilities are hindered by the high Ductile-Brittle Transition Temperature (DBTT). Recently, powder bed fusion-laser beam for metals (PBF-LB/M) has emerged as a promising technique, offering the fabrication of net shapes and precise control over crystallographic texture. Nevertheless, research investigating the mechanism underlying crystallographic texture development in pure Cr via PBF-LB/M still needs to be conducted. This study explores the impact of scan speed on relative density and crystallographic texture. At the optimal scan speed, an increase in grain size attributed to epitaxial growth was observed, resulting in the formation of cubic texture. Consequently, a reduction in High Angle Grain Boundaries (HAGB) was achieved, suppressing defects such as cracks and enhancing relative density up to 98.1%. Furthermore, with increasing densification, Vickers hardness also exhibited a corresponding increase. These findings underscore the efficacy of PBF-LB/M for processing metals with high DBTT properties.

Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineering (ICME) approach for a graded alloy formed by mixing P91 steel and Inconel 740H superalloy. An alloy derived from a mixture of 26 wt.% P91 steel and 74 wt.% Inconel 740H, with high configurational and total entropy, was fabricated using wire-arc additive manufacturing. Microstructure characterization revealed intergranular solidification cracks, which increased in length along with the build height. With inputs from experiments, such as secondary dendrite arm spacing, the DICTRA (diffusion-controlled transformations) module within the Thermo-Calc software was used to model location-specific solidification cracking susceptibility. The top region, with the highest cooling rate, has the highest solidification cracking susceptibility and is in good agreement with the experimentally observed crack length. From Scheil simulations, it was deduced that pronounced segregation of Nb and Cu within the cracks increased the solidification range by suppressing the solidus temperature. The overall solidification cracking susceptibility and freezing range was highest for the 26 wt.% P91 alloy amongst the mixed compositions between P91 steel and 740H superalloy, proving that solidification characteristics play a major role in alloy design for additive manufacturing.

Sustainability in Additive Manufacturing (AM) is an emerging area of research that examines the environmental impacts and potential benefits of AM processes compared to traditional manufacturing methods. This paper analyzes the environmental footprint of additive manufacturing technologies, including material usage, energy consumption, and waste production. AM techniques, such as fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS), are evaluated for their efficiency and sustainability. Key factors such as resource utilization, lifecycle emissions, and recyclability are assessed to determine how AM can contribute to a more sustainable manufacturing paradigm. The study highlights that while AM offers advantages such as reduced material waste and the potential for localized production, it also poses challenges, including high energy consumption and limited material options. The paper concludes with recommendations for improving the environmental performance of AM, including advancements in material science, energy-efficient technologies, and the integration of circular economy principles. By addressing these aspects, AM can play a significant role in achieving sustainability goals in manufacturing.

A time-sequential working, spatially multiplexed autostereoscopic 3D display design consisting of a fast switchable RGB-color filter array is presented. The wavelength-selective filter barrier emits the light from a display over a larger active area than common autostereoscopic barrier displays. An optical modelling of wavelength-selective barriers has been used for instance to calculate the light ray distribution properties of that arrangement. To find well working display designs, automated searches by simulation and computational evaluation has been proceeded. Wavelength-selective filter barrier arrangements exhibit characteristics different from common barrier displays with similar barrier pitch and ascent. In particular, these constructions show strong angular luminance dependency under barrier inclination specified by correspondent slant angle. In time-sequential implementation it is important to avoid that quick eye or eyelid movement lead to visible color artifacts. In the millisecond regime tunable liquid crystal Fabry-Pérot color filters for the colors red, green and blue are presented. They consist of a sub-micrometer thick nematic layer sandwiched between dielectric mirrors and ITO-electrodes. These cells shall switch narrow-banding light of red, green or blue. An array for a glasses-free 3D display has to be equipped with several thousand switchable filter elements having different color apertures. The newly introduced design is usable as a multi user display as well as a single user system with user adaptive control.

The aim of the study was the comparison of conventional sintering versus additive manufacturing techniques for β-TCP bioceramics, focusing on mechanical properties and biocompatibility. A "critical" bone defect requires surgical intervention beyond simple stabilization. Autologous bone grafting is the gold standard treatment for such defects but it has its limitations. Alloplastic bone grafting using synthetic materials is becoming increasingly popular. The use of bone graft substitutes has increased significantly and current research was focused on optimizing these substitutes, whereas this study compares two existing manufacturing techniques and the thereby produced β-TCP implants. The 3D-printed β-TCP hybrid structure implant was fabricated using two components, a column structure and a freeze-foam, which were sintered together. The conventionally manufactured ceramics were made by pouring. Both scaffolds were characterized according to porosity, mechanical properties and biocompatibility. The hybrid structure had a total porosity of 74.4 ± 0.5%. Microporous β-TCP implants had a porosity of 43.5 ± 2.4%, while macroporous β-TCP implants had a porosity of 61.81%. Mechanical testing revealed that the hybrid structure had a compressive strength of 10.4 ± 6 MPa, significantly lower than the microporous β-TCP implant’s with 32.9 ± 8.7 MPa. Biocompatibility evaluations showed a steady increase in cell proliferation over time for all β-TCP implants, with minimal cytotoxicity. This study provides valuable insight into the potential of additive manufacturing for β-TCP bioceramics in the treatment of bone defects.

The field of polymer additive manufacturing (AM) has experienced rapid evolution, marked by significant advancements in materials science and technology. This paper reviews recent innovations in polymer materials tailored for additive manufacturing processes, focusing on enhancements in mechanical properties, functionalization, and processability. Key developments include the introduction of high-performance thermoplastics, composite materials incorporating fibers or nanoparticles, and novel photocurable resins. These materials offer improved strength, durability, and versatility compared to traditional polymers. Furthermore, research into bio-based and recyclable polymers highlights a growing trend towards sustainable manufacturing practices. Advances in material formulations, including self-healing and shape-memory polymers, are also examined for their potential to transform applications across various industries. This review synthesizes current research trends and provides a comprehensive overview of the state-of-the-art in polymer AM materials, emphasizing the impact of these innovations on the future of manufacturing technologies.

Metal additive manufacturing (AM), commonly referred to as 3D printing with metals, is an innovative technology with significant potential to transform industries such as aerospace, automotive, and healthcare. Despite its promise, the field faces several challenges that impact both its technical feasibility and economic viability. This paper explores the primary technical challenges, including material properties and processing complexities, such as the need for precise control of thermal gradients and the mitigation of defects like porosity and residual stresses. Additionally, it addresses the economic barriers, including high initial equipment costs, the need for specialized knowledge, and the relatively slow build speeds compared to traditional manufacturing methods. By examining these challenges, this paper aims to provide a comprehensive overview of the current state of metal additive manufacturing and suggest potential pathways for overcoming these obstacles to facilitate wider adoption and technological advancement in the field.

Additive Manufacturing (AM) has been proving suitable to support or even replace traditional manufacturing in several industries, offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and greenhouse gas (GHG) emissions. This study aimed to carry out a comparative assessment of the life cycle, from gate to gate, in the production of a low alloy carbon steel flange part using ER-90 wire. The methods utilized were Wire and Arc Additive Manufacturing (WAAM) and conventional manufacturing (CM) by forging, and comparative factors were energy demands, GHG emissions and generated solid waste. The total energy consumption in WAAM was 10,239.40 MJ, total carbon footprint in CO2 equivalent (CO2e) was 714.1 kgCO2e kg-1, and generated solid waste was 68.6 kg, respectively, 90%, 95% and 76% lower than consumption calculated in conventional manufacturing.

This review examines additive manufacturing for refractory tungsten (W) and its alloys. It emphasizes the primary challenges and determining factors involved in additive manufacturing pure W, W alloys, and composites. Our focus in this regard extends to both process and alloying strategies designed to address critical issues such as densification, micro-cracking, and mechanical properties in tungsten-based components produced through additive techniques. Throughout the review, we organize existing knowledge and insights into convenient tables, serving as valuable resources for researchers embarking on a deeper exploration of these topics.

Additive manufacturing (AM), commonly known as 3D printing, has revolutionized the production of complex geometries that were once challenging or impossible to achieve through traditional manufacturing techniques. This paper investigates the capabilities of additive manufacturing in producing intricate designs, focusing on the unique advantages and potential applications across various industries. Additive manufacturing enables the creation of complex geometries by adding material layer by layer, allowing for greater design freedom and the ability to produce structures with intricate internal features, complex curves, and lightweight lattice structures. This capability is particularly advantageous in fields such as aerospace, biomedical, and automotive, where weight reduction, customization, and the integration of complex internal channels are critical. The study explores various additive manufacturing technologies, including stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM), highlighting their specific strengths and limitations in producing complex geometries. Factors such as material properties, resolution, surface finish, and build size are analyzed to determine the suitability of different AM processes for specific applications. Additionally, the research delves into the design considerations and software tools that facilitate the creation of complex geometries in AM, including generative design and topology optimization. These tools leverage the design freedom offered by AM to optimize structures for weight, strength, and functionality, pushing the boundaries of what is possible in product design. The paper concludes with an examination of the challenges and future directions in the field, such as improving material properties, reducing production costs, and enhancing the accuracy and reliability of AM processes. The potential of additive manufacturing to revolutionize the production of complex geometries is underscored, emphasizing its growing importance in modern manufacturing and its role in enabling innovative solutions across various industries. This abstract provides an overview of the potential and challenges of additive manufacturing for producing complex geometries, suitable for an academic paper or report. If you need more specific information or have a different focus, feel free to ask!

Additive Manufacturing (AM), commonly known as 3D printing, has revolutionized various industries, including the medical field. This technology enables the creation of complex structures layer by layer, offering unprecedented customization and precision. In medical applications, AM has proven transformative in producing patient-specific implants, prosthetics, and anatomical models, facilitating better surgical planning and outcomes. Additionally, it has shown promise in bioprinting, where cells and biomaterials are used to create tissue-like structures for regenerative medicine. The ability to rapidly prototype and manufacture medical devices reduces time and costs, and enhances personalized patient care. This abstract explores the diverse applications, benefits, and challenges of AM in the medical sector, highlighting its potential to revolutionize healthcare and improve patient outcomes.

Automobile industry is recognized as one of the most influential sectors shaping the global economies, societies, and individual lifestyles. Therefore, fierce competitions among different companies are continuously undergoing, and innovations deserve special attention to improve the competitiveness. In the past several years, additive manufacturing (AM) is emerging as an innovative technology in the applications of automobile industry with significant advantages over traditional techniques. As a result, increasing attention has been attracted to combining AM technology with the development of automobile industry. Currently, many automobile players are optimizing their industrial layout by incorporating with innovative AM techniques, and meanwhile, many research progresses have been achieved to meet the market demand. This article aims at presenting a timely review to conclude the recent advances in the application of AM techniques in automobile industry, focusing on the available AM techniques, printable materials, and the industry applications. The future research opportunities and challenges are also outlooked. Hopefully, this work can be useful to the related researchers, as well as the game players in the industry of this field.

Laser Powder Bed Fusion (L-PBF)-based manufacturing is a growing area of research, with a particular focus on evaluating constraints in printed products. This research emphasises the importance of considering various factors—including mechanical properties and support structures—that influence the final product during the design phase. Specifically, the design of microchannel heat exchangers is highlighted, where all constraints are critical. This article will present a method for analysing channel pressure limitations and report findings about mechanical properties loss from examining tube porosity. This includes a summary of results and the establishment of an experimental device system.

This study explores the potential to reach a circular economy for post-consumer recycled polyethylene terephthalate (rPET) packaging and bottles by using it as a distributed recycling for additive manufacturing (DRAM) feedstock. Specifically, rPET is processed using only an open source toolchain with fused particle fabrication (FPF) or fused granular fabrication (FGF) processing. In this study, first the impact of granulation, sifting and heating (and their combination) is quantified on the shape and size distribution of the rPET flakes. Then feeding studies were performed to see if they could be printed through an external feeder or needed to be direct printed with a hopper using two Gigabot X machines, one with extended part cooling and one without. Print settings were optimized based on thermal characterization and for the latter which was shown to print rPET directly from shredded water bottles mechanical testing is performed. The results showed that geometry was important for extended feeding tubes and direct printed using a hopper. Further there is a wide disparity in the physical properties of rPET from water bottles depending on source and the history of the material. Future work is needed to enable water bottles to be used as a widespread DRAM feedstock.

The paper delves into an extensive exploration of the integration of the circular economy paradigm within the realm of additive manufacturing (AM). The objective is to comprehensively investigate existing methodologies for structuring the symbiotic relationship between circular economy and additive manufacturing, while meticulously analyzing the current research gap concerning the implementation of circular economy principles in additive manufacturing practices. A thorough review focusing on the sustainability of additive manufacturing within the circular economy framework was conducted. This review aims to recognize and delineate pertinent aspects related to post-use material valuation in AM, recyclability of materials, and the environmental footprint associated with these processes. Emphasis was placed on the significance of examining circular economy facets concerning additive manufacturing processes to establish a holistic understanding. The overarching goal of this review is to augment knowledge regarding the potential advantages and benefits derived from the seamless integration of circular economy principles within AM. By elucidating the activities essential to attain compliance with the Sustainable Development Goals, this study endeavors to illuminate the pathway toward promoting sustainable development through the harmonious marriage of additive manufacturing and the circular economy.

Due to the manufacturing process of Additive Manufacturing (AM) Parts the mechanical properties cannot be predicted. The scope of the present work is to propose a predictive tool for the mechanical properties of AM parts through the use of Adaptive Neuro-Fuzzy Inference System (ANFIS). The Adaptive Neuro-Fuzzy Inference System (ANFIS) combines neural networks with fuzzy logic to generate a mapping between the inputs and the output. Real data experiments from different AM technologies and materials compose the initial dataset so a detailed investigation is conducted to gain knowledge of how different parameters affect the UTS, the elongation and the Young modulus of each experiment. Experimental data were also use to train, check and verify the methodology. The method is tested for FFF technology, PLA material and 3 point bending stress, with interesting results.

The 70/30 copper–nickel alloy is mainly used in critical parts with more demanding conditions in marine settings. There is a need for innovative methods that offer fast production and cost-effectiveness to supplement current copper–nickel alloy manufacturing processes. In this study, we employ wire-arc additive manufacturing (WAAM) to fabricate the 70/30 copper–nickel alloy. The as-built microstructure is characterized by columnar grains with prominent dendrites and chemical segregation in the inter-dendritic area. The aspect ratio of the columnar grain increases with increasing travel speed (TS) at the same wire feed speed (WFS). This is in contrast to an equiaxed grain structure with a more random orientation of conventional sample. The sample built with a WFS of 8 m/min, TS of 1000 mm/min, and a track distance of 3.85 mm exhibits superior corrosion properties in the 3.5 wt% NaCl solution compared to the conventional one, as evidenced by a higher film resistance and breakdown potential, along with a lower passive current density of the WAAM sample. The corrosion morphology reveals the critical roles played by the nickel element unevenly distributed between the dendrite core and inter-dendritic area.

In this study composite with alternate layers of 5056 and 1580 alloys was manufactured by wire arc additive manufacturing technology. It is shown that increased strength characteristics of composite material can be obtained due to deformation treatment by high-pressure torsion (HPT) technique. The microstructure and mechanical properties of the HPT-processed material in different structural states were investigated. The HPT-processed material exhibits high value of ultimate tensile strength (~ 770 MPa) but low ductility. Short-term annealing at 250 oС and additional deformation by HPT to 0.25 of revolution at room temperature resulted in a slight decrease in material’s strength to ~ 700 MPa but provided ductility ∼ 9%. Physical mechanisms to improve plasticity in correlation with microstructure evolution is discussed.

Additive manufacturing processes offer various options to fabricate metal parts, which show numerous ecological and technological advantages compared to formative and subtractive manufacturing methods. Due to quick availability and high accuracy, they are particularly suitable to produce complex prototypes. Metal fused deposition modeling is a relatively new material extrusion additive manufacturing technique based on the widely used fused filament deposition process. This study focuses on the Inconel 625 metal filament from Markforged Inc., it consists of a mixture of metal powder and a binder system, the latter being removed during washing and sintering. In this article, the mechanical properties of printed and sintered Inconel were investigated using tensile testing specimens with three different infill patterns, solid, triangular, and gyroid, printed in flatwise and upright direction. In addition, investigations into the dimensional accuracy of the printed specimens and the sintering shrinkage were carried out. The results showed that neither the dimensional accuracy nor the sintering shrinkage was significantly influenced by the printing orientation. In the context of lightweight engineering, the structures proofed beneficial especially within the elastic region. Generally, triangular infill patterns resulted in higher stiffness, while gyroids led to more ductile specimens. A mass-related evaluation of tensile testing elucidates that with aid of the infill structures weight savings of 40 % resulted in mechanical performance decreased by only 20 % on average.

Plasma electrolytic polishing (PeP) is mainly used to improve the surface quality and thus the performance of electrically conductive parts. It is usually used as an anodic process, i.e. the workpiece is negatively charged. However, the process is susceptible to high current peaks during the formation of the vapour skin especially when polishing workpieces with a large surface area. In this study, the critical influence of workpiece submerging velocity on the current peaks and the average power during the initialisation of the PeP process is investigated for a workpiece size of microreactor mould insert. Through systematic experimentation and analysis, this work provides insights into the control of the initialisation process by modulating the workpiece submerging velocity. The results clarify the relationship between submerging velocity, peak current and average power and provide a novel approach to improve process efficiency in PeP. The highest peak current and average power occur when the electrolyte splashes over the top of the workpiece and not, as expected, when the workpiece touches the electrolyte. By submerging the workpiece while the voltage is applied to the workpiece and counter electrode, the reduction in both parameters is over 80 %.

The convergence of digital twin technology with additive manufacturing (AM) represents a transformative advancement in the fields of design, simulation, and production. Digital twins—virtual replicas of physical assets—enable real-time monitoring, simulation, and optimization of manufacturing processes by mirroring their physical counterparts. When integrated with additive manufacturing, which allows for the creation of complex geometries and rapid prototyping, digital twins enhance the ability to design, test, and refine products with unprecedented precision and efficiency. This integration facilitates iterative design improvements, predictive maintenance, and real-time process adjustments, leading to more accurate simulations and optimized production workflows. By leveraging data from digital twins, manufacturers can anticipate issues, reduce material waste, and shorten development cycles. This abstract explores how the fusion of digital twin technology with AM not only refines traditional manufacturing paradigms but also paves the way for more innovative and adaptive manufacturing practices.

The integration of additive manufacturing (AM), commonly known as 3D printing, has revolutionized aerospace engineering by enabling the creation of complex, lightweight, and high-performance components. This paper explores the transformative impact of AM technologies on the design, production, and maintenance of aerospace systems. The aerospace industry demands high precision, reduced weight, and enhanced performance, all of which are facilitated by AM's ability to produce intricate geometries and optimize material usage. Key applications of AM in aerospace include the fabrication of engine components, structural parts, and customized tooling. The technology's capability to produce parts with complex internal structures, such as lattice designs, leads to significant weight reductions without compromising strength and durability. Furthermore, AM allows for rapid prototyping, enabling faster iteration and development cycles, which is crucial in the highly competitive aerospace sector.

This paper provides an overview of the new CPAM Project on Additive Manufacturing (AM) in design and simulation, focusing on topology & lattice structure optimization for a light-weighting advantage. This industry/academia collaboration project aims to utilize existing hardware and software tools, and investigate the practical limits of the technologies, providing eventual guidelines for general use. This will provide a solid foundation for the practical use of metal AM optimized solid and latticed structures especially for Ti6Al4V parts. Two case studies are demonstrated here, one a purely topology optimized design, and one also incorporating lattice optimized design, both from Ti6Al4V and load-bearing components, to be utilized in the Nelson Mandela University (NMU) Eco-Car Project in competition, late in 2018. This paper presents the Design for Additive Manufacturing (DfAM) process, the challenges met iro applying a DfAM design mindset, and a unique final voxel-based smoothing step finishing off the design process. Detailed structural integrity assessment of these parts are included - the question remains: can Additive Manufacturing help win the race?

In this work SiC-Ti3AlC2 and TiC-Ti3AlC2 composites produced by additive manufacturing are investigated. The fused granules fabrication (FGF) method as one of the material extrusion additive manufacturing (MEAM) technology is used to obtain composite samples. Composites with different ratios between components and different powder:polymer ratios are investigated. The technological features of the additive formation of composites are investigated, as well as their structure and properties. The optimal sintering temperature to form the best mechanical properties for both composites is 1300 °C. The composites have a regulatable porosity. Ti3AlC2 content, sintering temperature, and polymer content in the feedstock are the main parameters that regulates the porosity of FGF samples.

Direct Energy Deposition (DED) is a versatile and efficient method in metal additive manufacturing. However, humping, caused by abnormal dynamics in the melt pool (MP), poses a significant threat to the geometric integrity of manufactured products. Current state-of-the-art (SOTA) methods primarily detect humping by analyzing late-stage spatial abnormalities, such as MP detachment. This approach is fundamentally reactive, leading to a tendency to miss early humping spatiotemporal dynamics, like cyclic elongation of the MP. This study introduces a novel, proactive indicator named VIMPS (Variability of Instantaneous MP Solidification-Front Speed), a physics-based tool designed to quantify early abnormal fluctuations in MP solidification speed. The experiments demonstrate VIMPS correlation with humping-induced geometric inaccuracies. By capturing early spatiotemporal dynamics of the MP, VIMPS reduces detection latency by 30 seconds compared to existing SOTAs that focus solely on spatial abnormalities. This significant improvement transforms detection from reactive to proactive, providing the time needed for corrective actions to enhance the overall productivity and quality of the DED process.

Responding to changing value creation processes in the sheet metal working sec-tor, where the complexity and interchangeability of products challenge traditional dif-ferentiation strategies, this empirical analysis explores integrating service-oriented and data-driven business models as new paths to ensure competitiveness, especially for small and medium-sized enterprises (SMEs). This study aims to capture the current state and challenges associated with the implementation of these business models in this sector. The research was conducted through semi-structured interviews with SMEs in the industry. The findings indicate that service-oriented and data-driven business models are not yet widely adopted and that manufacturing companies re-quire support in their implementation. Fields of action were identified for the industry. These are "Creating awareness and understanding", "Recognizing added value", "In-creasing company maturity" and "Understanding the change process". Cooperation between science and industry is essential in tackling these fields of action to ensure the successful integration of such business models in manufacturing companies. This pa-per identifies challenges in the fields of action that companies must address through a structured approach promoting awareness, recognizing value, improving organiza-tional maturity, and understanding the change process to successfully implement ser-vice-oriented and data-driven business models.

The purpose of this paper is to describe a feature selection algorithm and its application to enhance the accuracy of the reconstruction of phylogenetic trees by improving the efficiency of tree construction. Applying machine learning models for Arabic and Aramaic scripts such as Deep Neural Networks (DNN), Support Vector Machines (SVM) and Random Forests (RF) each model was used to compare the phylogenies. The methodology was utilized with a dataset containing Arabic and Aramaic scripts, demonstrating its relevance in a range of phylogenetic analyses. Results emphasize the essential role of feature selection by DNNs is outperforming other models in terms of Area Under the Curve (AUC) and Equal Error Rate (EER) across various datasets and fold sizes. Additionally, SVM and RF models show important understandings, advantages and limits of each approach within the context of phylogenetic analysis. This method not only simplifies the tree structures but also enhances their Consistency Index. Therefore offering a robust framework for evolutionary studies. The findings highlight the applications of machine learning in phylogenetics suggesting a path toward accurate and efficient evolutionary analyses and adding a deeper understanding of evolutionary relationships.

Over the past two decades, covalent organic frameworks (COFs) have become the most widely studied porous crystalline materials. Its specific physical and chemical properties are determined by the arrangement of atoms (crystal structure). Therefore, the determination of its structure is arguably the most important characterization step for COFs. Although single crystal X-ray diffraction (SCXRD) is the most widely used method for structure determination, the size of COF crystals is too small, or their crystal quality is so poor that confirmation of their structure is limited to lattice fringes by transmission electron microscopy (TEM). At present, many 2D-COFs have clear PXRD patterns, but not all 2D-COFs can obtain specific lattice fringes. This severely hinders the development of the COF field. Here, we discover the lattice shrinkage behavior of COFs under electron beam irradiation by comparing the lattice fringes of 2D-COFs under different conditions. By comparing the lattice fringes of TAPT-TFPT COF at room temperature and under liquid nitrogen freezing conditions, we found that the lattice fringes are in good agreement with the Powder X-ray diffraction (PXRD) and theoretical values of COF (2.213 nm) under freezing conditions, however, the lattice fringe spacing is only 1.656 nm at room temperature. The discovery not only provides new insights into the TEM characterization of COFs, but also further expands the range of crystalline COF materials.

The emergence of prosumers, who actively participate in designing and producing goods, has generated interest in domestically manufactured products. Factors such as innovation, design methods, component reuse, prototyping, and digital fabrication empower prosumer designers to realize their ideas and enhance products to meet their specific design requirements. This article presents a case that combines bioinspired design methods with prosumer characteristics from the perspective of a designer who uses biological research results acting as a prosumer. By analyzing prosumer needs, bioinspired design, and domestic fabrication requirements, designers define the methods that best suit their possibilities. As a result of using biological information, the geometry of Samara seeds, propeller sizing, wind tunnel tests, and subsequent improvements, the custom design of a bioinspired microgenerator has been refined to the final design of a bicycle flashlight. The aim is to popularize a working approach that facilitates the interaction of design methods and reinforces domestic manufacturing processes. Implementing bioinspired design methods within the prosumer context offers a methodological alternative to transform the current economic model, promoting systemic sustainability and the development of proprietary technologies.

Additive manufacturing (AM), commonly known as 3D printing, has emerged as a transformative technology in supply chain management (SCM). This abstract explores how AM influences various aspects of SCM, including inventory management, production processes, and logistics. By enabling on-demand production and reducing reliance on traditional manufacturing methods, AM minimizes inventory costs and enhances customization capabilities. It also facilitates localized production, which can reduce lead times and transportation costs. The integration of AM into SCM fosters greater flexibility and resilience, allowing businesses to respond more swiftly to market changes and disruptions. This study highlights both the opportunities and challenges associated with adopting AM, emphasizing the need for strategic adjustments to fully leverage its potential in modern supply chains.

In this article, metallic additive manufacturing (AM) processes were classified and demonstrated. AM technology can be applied to a wide range of industrial areas because of its great feasibility in the design and manufacturing of various complex parts. The main factor that distinguishes various metallic AM processes from each other is the deposition method. Deposited metal can be imported in the form of melt or semi-solid. AM technology also covers a wide range of materials like aluminum, titanium, and many other alloys. Some of the common applications of metallic AM processes are the quick manufacturing of the parts which utilized in various industries like medical, automotive, aerospace, and jewelry industries. AM can help to fabricate parts that are impossible to be manufactured by other processes.

Additive Manufacturing and nanotechnology have been used as basic tools for the manufacture of nanostructured parts with magnetic properties to expand the variety of applications in additive processes by tank photopolymerization. Magnetic cobalt ferrite (CoFe2O4) and barium ferrite (BaFe12O19) nanoparticles with the size distribution of average value DTEM of 12 ± 2.95 nm and 37 ± 12.78 nm, respectively were generat-ed by hydroxide precipitation method. The dispersion of the nanoparticles on commercial resins (Anycubic Green and IRIX White resin) was obtained by mechanochemical reactions carried out in an agate mortar for 20 minutes, at room temperature and with limited exposure to light. The product of each reaction was placed in amber vials, also being kept in a box, to avoid contact with light. The photopolymerization process was carried out only at low concentrations (w/w % nanoparticles/resin) since, at high concentrations, there is no for-mation of pieces due to the high refractive index of ferrites. Raman shift spectroscopy of the final pieces showed that they contain the magnetic nanoparticles, with no apparent chemical changes. The EPR results of the pieces maintain the magnetic properties and apparently, they are not modified during the photopolymer-ization. Although significant differences were found in the dispersion process of the nanoparticles in each piece, we determined that the photopolymerization did not influence the structure and superparamagnetic behavior of ferrite nanoparticles during processing, and the magnetic properties were successfully transferred to the final 3D-printed magnetic obtained piece.

Additive manufacturing (AM) provides opportunities to design objects differently than traditional manufacturing methods allow, but only if designers understand the possibilities AM presents. In this study, we examined whether an AM workshop combined with an idea generation session could inspire engineering professionals to use AM solutions to solve current technical problems they face. All subjects were employees at an organization that will be referred to as Company X, a multinational commercial organization based in North America. During the study, we collected ideas for 24 projects generated before and after a training workshop focused on design for AM. In the workshop, we provided three hours of instruction about design for two metal-based AM processes. The participants’ ideas were assessed using four specific metrics: (1) cost, (2) time,(3) completeness of solution, and (4) quality, which was a function of feasibility, usefulness, and novelty. Using these data, we explored whether the workshop was effective in inspiring the participants to use AM methods and techniques from AM research in their concept generation and whether participants’ AM solutions showed improvement in cost, implementation time, and quality over non-AM designs generated before the workshop.

In the past few years, cloud-based additive manufacturing has shown its application and potential in industries. For this reason, when the demand for cloud-based additive products increases, efficient scheduling of related tasks becomes more important to achieve optimized duration. This research proposes a Heuristic Scheduling Algorithm (HSA) for use in Cloud-Based Additive Manufacturing (CBAM) with an approach to Critical Chain Buffer Management (CC/BM). This research aims to schedule and optimize the time in cloud-based additive manufacturing, in addition to the parts production process, it also includes the steps of receiving online orders and informing the manufacturing unit and sending them to the customer. The HSA proposed in this research consists of three phases 1- Buffer sizing, 2- Additive manufacturing and logistics scheduling, and 3- Buffer controlling. To evaluate, the performance of the algorithm is simulated. The finding shows that the proposed HAS can effectively solve the CBAM scheduling problem.

We discuss the implementation of a suite of virtual diagnostics at the FACET-II facility currently under commissioning at SLAC National Accelerator Laboratory. The diagnostics will be used for prediction of the longitudinal phase space along the linac, spectral reconstruction of the bunch profile and non-destructive inference of transverse beam quality (emittance) using edge radiation at the injector dogleg and bunch compressor locations. These measurements will be folded in to adaptive feedbacks and ML-based reinforcement learning controls to improve the stability and optimize the performance of the machine for different experimental configurations. In this paper we describe each of these diagnostics with expected measurement results based on simulation data and discuss progress towards implementation in regular operations.

Electromobility promises to efficiently mitigate consequences of increasing traffic volume and its accompanied greenhouse gas emissions. On an individual level, electrified bikes allow emission free electrified mobility at moderate costs and consequently their stock has increased significantly in recent years. This simultaneously increases the demand for spare parts, which are often manufacturer or application-specific, and due to many variants, challenging to provide for the market. This article evaluates powder-based and extrusion-based metal additive manufacturing of a typical electrified bike component to demonstrate an alternative spare parts supply. The investigation demonstrates how these parts can be additively manufactured function equivalent and with sufficient mechanical properties, also taking economical aspects into account. Furthermore, the needed resources and related environmental consequences for metal-based additive manufacturing spare-part production are compared for both process routes. The results show that both routes are capable of producing spare-parts at comparatively same mechanical performance and resource costs, while needed resources such as energy, gases and manufacturing time are significantly lower for powder-based, respectively machine costs for extrusion-based additive manufacturing. Therefore, additive manufacturing offers a promising opportunity to produce parts in small quantities resource efficient and rapidly.

In order to study the effects of irradiation on the physicochemical properties and digestion behavior of chickpea protein, chickpea protein concentrate (CPC) was treated with electron beam irradiation (EBI) at doses of 5, 10, 15 and 20 kGy, respectively. After irradiation, protein solubility first increased at 10 kGy and 15 kGy, and then decreased at higher dose of 20 kGy. This was supported by SDS-PAGE where the intensity of major protein bands first increased and then decreased. Increased does of EBI generally led to greater oxidative modification of proteins in CPC, indicated by reduced sulfhydryls and increased carbonyls. In addition, protein structure was modified by EBI shown by Fourier transform infrared spectroscopy analysis where α-helix generally decreased and β-sheet increased. Although the protein digestibility was not significantly affected by EBI, the peptidomic analysis of the digests revealed significant difference among CPC irradiated with varying doses. A total of 337 peptides were identified from CPC irradiated with 0 kGy, 10 kGy and 20 kGy, respectively, with 18 overlapping peptides and 60, 29 and 40 peptides specific to the groups of 0, 10 and 20 kGy respectively. Theoretical calculation showed that the distribution of peptide length, hydrophobicity, net charge, and C-terminal residues were affected by irradiation. The 2, 2'-azino-bis (3-ethylbenzothiazoline-6-sulfonic acid) (ABTS) radical scavenging activity showed a marginal decrease with increasing dose of irradiation. In conclusion, EBI led to oxidative modification and structural changes of the chickpea protein, which subsequently affected the physicochemical properties of peptides obtained from in-vitro digestion of CPC despite of similar digestibility.

Additive manufacturing (AM) has revolutionized the field of biopolymers by providing a range of opportunities to create complex and intricate structures. Here we provide an overview of developments in biopolymer AM, first in the context of how natural systems have impacted the synthetic processes of AM, and secondly in the context of how synthetically derived structures can be used for biomedical applications. In particular, we explore the range of biopolymers developed for AM, AM techniques for biopolymers, and potential biocompatible medical applications with a focus on four categories of tissue in the human body: skin, bone, heart, and nerve. Despite the current challenges of the technology, exciting results in tissue regeneration, synthetic replacements for natural grafts, and complex dynamic organoids have already come to pass - with many more possible in the future.

The recent decade has witnessed the evolution of a novel paradigm of alloying which is based on utilising multiple elements to design compositionally complex alloys also known as high entropy alloys (HEAs). Conventional manufacturing of HEAs has a number of drawbacks, especially in terms of mechanical properties and design complexities. This has been addressed by additive manufacturing (AM), which has not only led to the fabrication of complex-shaped HEA components but has also enabled both ex-situ and in-situ tailoring of alloy microstructures. Considering the increasing interest in AM-based fabrication of HEAs in the last ten years, the present chapter is aimed at highlighting the present status and challenges in the avenue of AM of HEAs. This has been followed by a discussion on the recent trends in the avenue of AM-based fabrication of HEAs from the viewpoints of (i) microstructure evolution and mechanical properties, and (ii) alloy fabrication techniques. The chapter ends with a discussion on the future prospects in the aforementioned avenue.

Background: Advances in additive manufacturing and the development of antimicrobial biopolymers facilitate the production of critical medical devices with strong and safe biocidal properties. The purpose of this study was to assess the antimicrobial efficacy, safety, and longevity of a polylactic acid-based biopolymer supplemented with a copper-based composite additive. Methods: An antimicrobial polylactic acid-based biopolymer was tested against several inoculants including Staphylococcus Aureus, MRSA, E. coli, Listeria, HCoV-229E (a SARS-CoV-2 surrogate), and HIV-1. Material safety was evaluated according to international testing standards for in vitro cytotoxicity. Results: The main findings of the present investigation showed a strong and long-lasting biocidal effect of a polylactic acid-based biopolymer embedded with a copper-based composite additive against Staphylococcus Aureus, MRSA, E. coli, Listeria, HCoV-229E (a SARS-CoV-2 surrogate), and HIV-1. Furthermore, the cytotoxicity and safety assessment of the antimicrobial biopolymer was found to be “non-toxic” and safe for human skin contact. Conclusions: The present investigation showed that the antimicrobial biopolymer exhibits strong and long-lasting biocidal properties against an array of viral and bacterial inoculants.

Metal Additive Manufacturing (MAM) has emerged as a promising technology in the aerospace industry, enabling the production of complex components with enhanced design flexibility and reduced lead times. Concurrently, Industry 4.0 has gained significant attention for its potential to revolutionize aerospace manufacturing processes. The paper aims to cluster and review the literature on MAM in the aerospace industry, specifically focusing on its relevance to Industry 4.0 and its applicability throughout the various stages of the product life cycle for the chief purpose of matching supply with demand. Identified gaps and challenges are analyzed, highlighting the need for further research and outlining research agenda aimed at advancing the integration of MAM for Industry 4.0 in the aerospace sector. By addressing these research areas, the aerospace industry can unlock the value of MAM within an Industry 4.0 framework, leading to improved efficiency, productivity, and competitiveness.

Porous structured metallic implants are preferable as bone graft substitutes due to their faster tissue integration mediated by bone in-growth and vascularization. The porous scaffolds/ implants should also mimic the graded structure of natural bone to ensure a match of mechanical properties. This article presents a method to design graded porous structured acetabular implant and identifies the suitable parameters for manufacturing the model through additive manufacturing. The design method is based on slice-wise modification to ensure continuity of gradation. Modification of the slices was achieved through the binary image processing route. A geodesic dome type design was adopted for developing the acetabular cup model from the graded porous structure. The model had a solid shell with the target porosity and pore size gradually changing from 65% and 950 µm, respectively, in the inner side to 75% and 650 µm, respectively, towards the periphery. The required dimensions of the unit structures, and the combinations of pore structure and strut diameter to obtain the target porosity and pore size were determined analytically. Suitable process parameters were identified to manufacture the model by Direct Metal Laser Sintering (DMLS) using Ti6Al4V powder after carrying out a detailed experimental study to minimize the variation of surface roughness and warping over different build angles of the strut structures. A dual contour scanning was implemented to simplify the scan strategy. The minimum diameter of struts that could be manufactured using the selected scanning strategy and scanning parameters was found to be 375 µm. Finally, the model was built and from the micro-CT data, the porosities and pore sizes were found to be closely conforming to the designed values. The stiffness of the structures, as found from compression testing, was also found to be well matching with that of human trabecular bone. Further, the structure exhibited compliant bending-dominated behavior under compressive loading.

Additive manufacturing has already been established as a highly versatile manufacturing technique with demonstrated potential to completely transform conventional manufacturing in the future. The objective of this paper is to review the latest progress and challenges associated with the fabrication of multi-material parts using additive manufacturing technologies. Various manufacturing processes and materials used to produce functional components were investigated and summarized. The latest applications of multi-material additive manufacturing (MMAM) in automotive, aerospace, biomedical and dentistry field were demonstrated. Investigation on the current challenges were also carried out to predict the future direction of MMAM processes. It is concluded that the further research and development needed in the design of multi-material interfaces, manufacturing processes and material compatibility of MMAM parts are necessary.

(1) In recent ten years, with the fast development of digital and engineering manufacturing technology, additive manufacturing has already been more and more widely used in the field of dentistry, from the first personalized surgical guides to the latest personalized restoration crowns and root implants. (2) Especially, the bioprinting of teeth and tissue is of great potential to realize organ regeneration and finally improve the life quality. (3) In this review paper, we firstly presented the workflow of additive manufacturing technology. Then we summarized main applications and recent research progresses of additive manufacturing in dentistry. (4) Lastly, we sketched out some challenges and future directions of additive manufacturing technology in dentistry.

In this study, additive manufacturing of reinforced parts using metallic wire as both a reinforcement component and a shape memory stimulus through Fused Deposition Modeling (FDM) was investigated. A Shape Memory Polymer (SMP) restores its original shape and recovers it upon specific stimuli. This research employed chromium-nickel metal wire as a reinforcing component to enhance mechanical properties and introduce the capability for thermal stimulation of polylactic acid (PLA) via electrical current using the "in-situ impregnation" method within FDM process. Reinforced specimens were fabricated with wire with two diameters of 0.1 and 0.15 mm, along with two volume percentages of 5 and 10. Comprehensive evaluations encompassing mechanical (tensile and flexural) and thermal properties of the printed specimens were conducted. The outcomes revealed a significant enhancement in both tensile and flexural properties of the polymer matrix due to the embedding metallic wire, even under elevated temperatures during bending test. Furthermore, the thermal properties of the reinforced specimens were examined by subjecting them to various voltages, resulting in temperature ranging from 36.4 to 150.1°C. These findings highlight the ability to tailor a wide range of mechanical properties and shape recovery in the reinforced specimens by carefully selecting the wire volume fraction, voltage, and wire diameter, thus regulating the materials properties with specific application requirements.

The Food and Drug Administration’s 2011 Process Validation Guidance and International Council for Harmonization Quality Guidelines recommend continued process verification (CPV) as a mandatory requirement for pharmaceutical, biopharmaceutical, and other regulated industries. As a part of product life cycle management, after process characterization in stage 1 and process qualification and validation in stage-2, CPV is performed as stage-3 validation during commercial manufacturing. CPV ensures that the process continues to remain within a validated state. CPV requires the collection and analysis of data related to critical quality attributes, critical material attributes, and critical process parameters on a minimum basis. Data is then used to elucidate process control regarding the capability to meet predefined specifications and stability via statistical process control tools. In statistical process control, control charts and Nelson rules are commonly used throughout the industry to monitor and trend data to ensure that a process remains in control. In the control chart, the mean value is taken as the center line, and 3σ limits are placed on either side of the center line. In CPV, manufactured lots are summarized, trended, and discussed at a cross-functional level at pre-defined intervals (either weekly, bi-weekly, or even monthly) based on the batch run rate. A cross-functional team assesses details regarding 1) violation frequency, 2) statistical strength of the signal, 3) violation magnitude and its impact on process or quality, and 4) any potential root causes for out-of-expectation or out-of-trend signals. The cross-functional team must analyze whether any signal identified by the control chart is reliable and must determine whether corrective action should be taken and justify the decision in the CPV meeting minutes based on statistical strength and reliability of the signal. However, basic control charts are susceptible to false alarms and nuisance alarms. Therefore, it is imperative to understand the assumptions behind control charts and the inherent false alarm rates for different Nelson rules. In this article, the authors have detailed the assumptions behind the usage of control charts, the rate of false alarms for different Nelson rules, the impact of skewness and kurtosis of a data distribution on the false alarm rate, and methods for optimizing control chart design by reducing false alarm rates and nuisance signals.

The main aspects of material research: material synthesis, material structure, and material properties, are interrelated. Acquiring atomic structure information of electron beam sensitive materials by electron microscope, such as porous zeolites, organic-inorganic hybrid perovskites, metal-organic frameworks, is an important and challenging task. The difficulties in characterization of the structures will inevitably limit the optimization of their synthesis methods and further improve their performance. The emergence of integrated differential phase contrast scanning transmission electron microscopy (iDPC-STEM), a STEM characterization technique capable of obtaining images with high signal-to-noise ratio under lower doses, has made great breakthroughs in the atomic structure characterization of these materials. This article reviews the developments and applications of iDPC-STEM in electron beam sensitive materials, and provides an outlook on its capabilities and development.

A new approach to fabricate TiNi surfaces combining the advantages of both monolithic and porous materials for implants is used in this work. New materials were obtained by depositing a porous TiNi powder onto monolithic TiNi plates followed by sintering at 1200°C. Then, further modification of the material surface with a high-current-pulsed electron beam (HCPEB) was carried out. Three materials obtained (one after sintering and two after subsequent beam treatment by 20 and 30 pulses, respectively) were studied by XRD, SEM, EDX, EIS methods, profilometry and OCP measurements. Structural and compositional changes caused by HCPEB treatment were investigated. Surface properties of the samples during their storage in saline for 10 days were studied and a model experiment with cell growth (MCF-7) was carried out for the sample unmodified with electron beam to detect cell appearance on different surface locations.

Yttria stabilized zirconia (Y-TZP) ceramics with drastically reduced yttria content have been introduced by different manufacturers aiming at improving the damage tolerance of ceramic components. In this study an alumina doped 1.5Y-TZP was axially pressed, pressureless sintered in air at 1250–1400 °C for 2 h and characterized with respect to mechanical properties, microstructure and phase composition. The material exhibits a combination of high strength of 1000 MPa and a high toughness of 8.5–10 MPa√m. The measured fracture toughness is, however, extremely depending on measurement protocol. Direct crack length measurements overestimate toughness due to trapping effects. The initially purely tetragonal material has a high transformability of > 80 %, the transformation behavior is predominantly dilatoric, measured R-curve related toughness increments are in good agreement with transformation toughness increments derived from XRD data.

Yttria stabilized zirconia materials are frequently used in mechanical engineering and biomedical applications. Demanding loading conditions require materials combining a high level of strength and fracture toughness. A ready to press alumina doped 2 mol% yttria stabilized zirconia powder was shaped by axial pressing and sintering in air at 1250 - 1500 °C for 2 h. The best combination of strength and toughness value of 7.8 MPa√m. Materials sintered in the middle of the chosen temperature range combine fully density, high transformability and small grain size. Toughness measurements by direct crack length measurements delivered unrealistically high fracture toughness values.

Nowadays, rotor-stator mixers are widely used in the chemical process industry to carry out the dispersion and de-agglomeration processes for manufacturing the homogenous electrode slurries. Development of the process simulation models for the turbulent mixing of these slurries helps to optimize the mixing parameters such as rotational speed and dispersion time. In this work, computational fluid dynamics (CFD) approach through ANSYS Fluent are explored to determine and analyze the flow patterns, velocity fields and viscosity distribution during the dispersion of anode slurries. It utilizes a non-homogeneous Eulerian multiphase approach and the typical k-ε model to create turbulence fields and compute the mixing rate. This work significantly improves our understanding of the relationship between rotor speed, dispersion time, viscosity distribution, and mixer geometry in rotor-stator mixers.

In this paper, based on the cumulated damage generated by the cyclical application of the testing vibration profile, a methodology to determine the reliability index of the analyzed component is given. In the analysis, the testing time, component geometry, applied weight, and material resonant frequency are all of them considered by using a dynamic, and amplitude factor. Then, from the generated vibration response data of the analysis, the corresponding bending stress is determined for each one of the rows of the testing profile. And by the cyclical application of the whole testing profile, the corresponding damage is cumulated to each profile cycle until the cumulated damage is D=1. Finally, the reliability that each one of the cumulated blocks (cyclical profile application) is determined by considering, the random vibration is a stress variable. Thus, we use the cumulative damage model with the inverse power law stress/life relationship to determine the two parameter Weibull distribution used to estimate the reliability index of each cumulated block. As a numerical application, we analyze a cantilever aluminum beam Al 6061-T6.

The paper presents the conceptualization and realization of a novel platform for additive manu-facturing, an industrial robot arm-based system for additive manufacturing applications. Tradi-tional 3D printers, especially those employing fused deposition modelling (FDM) processes, are restricted to depositing material in a single toolpath plane (e.g. x-y plane). The focus of this study was to explore the feasibility of integrating commercial off the shelf (COTS) additive manufac-turing technologies with a six degree of freedom industrial robot arm to yield a 3D additive manufacturing system with the capability to perform free-form six degree of freedom fused deposition modelling. The present paper presents the development of a platform from stage 0, i.e. materials to its use, and finally a printed product with the developed extruder.

The potential of the Additive Manufacturing technologies is impeded by the surface finish obtained on the as-manufactured material. Therefore, the influence of various surface treatments, commonly applied to space hardware, on the mechanical properties of three selected metallic alloys (SS316L, AlSi10Mg, Ti6Al4V) prepared by using Selective Laser Melting (SLM) and Electron Beam Melting (EBM) additive manufacturing processes have been investigated. Within this study, SLM using EOS M400 and EOS M280 equipment and in addition EBM using an ARCAM Q20 machine have been applied for sample manufacturing. A half-automated shot-peening process followed by a chemical and/or electrochemical polishing or Hirtisation® process has been applied in order to obtain lower surface roughness compared to their as-received states. Special emphasize has been taken on their tensile, fatigue, and fracture toughness properties. In addition, their stress corrosion cracking (SCC) behaviour including microstructural analysis using HR-SEM have been investigated.

Intermetallic alloys like e.g. Iron-Aluminides, Titanium-Aluminides or Molybdenum- Silizides are prospective materials for high-temperature applications. For additive manufacturing (AM) intermetallic structural materials are particularly challenging due to their high melting points, oxygen susceptibility and low temperature brittleness. The feasibility of manufacturing intermetallic Mo-Si-B alloys with the laser additive manufacturing process of direct energy deposition (DED) is demonstrated and recent results in characterizing rapidly solidified material with respect to correlations between process, composition and microstructures are presented. The possibility to dope the material with Yttrium oxide (Y2O3) for dispersion is successfully demonstrated. Current challenges, e.g. homogenous distribution of alloying elements and applicability are addressed.

This work investigates the influence of strain rate on the stress/strain behaviour of Scalmalloy. This material is an aluminium-scandium-magnesium alloy, specifically developed for additive manufacturing. The bulk yield stress of the material processed by Selective Laser Melting is approximately 340 MPa which can be increased by heat-treating to approximately 530 MPa. These numbers, combined with the low mass density of 2.7 g/cm3, make Scalmalloy an interesting candidate for lightweight crash-absorbing structures. As this application is inherently dynamic, it is of interest to study the loading rate sensitivity, which is difficult to predict: Al-Sc alloys exhibit classic strain rate sensitivity with an increased yield stress at elevated strain rates. However, Al-Mg alloys are known to show the contrary effect, they exhibit less strength as strain rate is increased. To answer the question how these effects combine, we study the dynamic behaviour at four different strain rates ranging from 10−3 /s to 1000 /s using servo-hydraulic and Split-Hopkinson testing methods. The resulting data is analysed in terms of strain rate sensitivity of tensile strength and failure strain. A constitutive model based on a simplified Johnson-Cook approach is employed to simulate the tensile tests and provides good agreement with the experimental observations.

Fabrication of a true-3D inorganic ceramic with resolution down to nanoscale using sol-gel resist precursor is demonstrated. The method has an unrestricted free-form capability, control of the fill-factor, and high fabrication throughput. A systematic study of the proposed approach based on ultrafast laser 3D lithography of organic-inorganic hybrid sol-gel resin followed by a heat treatment enabled formation of inorganic amorphous and crystalline composites guided by the composition of the initial resin. The achieved resolution of 100 nm was obtained for 3D patterns of complex free-form architectures. Fabrication throughput of 50×10³ voxels/s is achieved; voxel - a single volume element was recorded by a single pulse exposure. After a subsequent thermal treatment, ceramic phase was formed depending on the temperature and duration of the heat treatment as validated by Raman micro-spectroscopy. The X-ray diffraction (XRD) revealed a gradual emergence of the crystalline phases at higher temperatures with a signature of cristobalite SiO₂, a high-temperature polymorph. Also, the tetragonal ZrO₂ phase known for its high fracture strength was observed. This 3D nano-sintering technique is scalable from nano- to millimeter dimensions and opens a conceptually novel route for optical 3D nano-printing of various crystalline inorganic materials defined by an initial composition for diverse applications for microdevices in harsh physical and chemical environments and high temperatures.

The use of digital twin and shadow concepts for industrial material processes have promoted new notions to bridge the gap between physical and cyber manufacturing processes. Hence, many multi-disciplinary areas like advanced sensor technologies, material science, data analytics, and machine learning algorithms are employed to create such hybrid systems. On the other hand, new additive manufacturing (AM) processes for metals and polymers based on novel emerging technologies have already shown a promising horizon for manufacturing of sophisticated parts with complex geometries. These processes are going through a major transformation with the emergence of digital technology, hybrid physical-data driven modelling and fast reduced models. This paper presents a fresh look at the hybrid physical-data driven and reduced order modelling (ROM) techniques for digitalization of AM processes within a digital-twin concept. The main contribution is to show the benefits of ROM and machine learning (ML) technology for process data handling, optimization\controlling and their integration into the real-time assessment of AM processes. Hence, a novel combination of efficient data solver technology and architecturally designed neural network (NN) module has been developed for the transient manufacturing processes with high heating\cooling rates. Furthermore, a real-world case study has been presented where the combination of hybrid modelling along with ROM and ML schemes are used for an industrial wire arc AM (WAAM) process.

Additive manufacturing, commonly referred to as 3D printing, is an exciting and versatile manufacturing technology that is gaining traction and interest in both academic and industrial settings. Polymeric materials are essential components in a majority of the “inks” used across the various 3D printing technologies. As the environmental ramifications of sole or primary reliance on petrochemicals as a resource for industrial polymers continue to manifest themselves at a global scale, a transition to more sustainable bioderived alternatives could offer solutions. In particular, cellulose is promising due to its global abundance, biodegradability, excellent thermal and mechanical properties, and ability to be chemically modified to suit various applications. Thus far, cellulose has typically been incorporated in additive manufacturing applications as a substrate, filler, or reinforcement for other materials. However, due to its versatility and desirable properties, the exploration of all-cellulose 3D printing materials and associated methodologies is increasing. This review will discuss the progress and status of all-cellulose 3D printing approaches, associated challenges, and their potential as a key player in a more sustainable industrial future.

Magnesium and Aluminum alloys continue to be important in the context of modern and lightweight technologies. With the advancement of additive manufacturing (AM), components can be produced directly in a net shape, widen up the usage of magnesium and aluminum alloys as well as holding new ideas for the application of unique physical structures made feasible by 3D printing. Laser-based approach, one of the metal additive manufacturing (AM) methods, enables the formation of arbitrary 3D structures. With promising findings, research in this area is advancing quickly, bringing up a variety of potential applications in both the scientific and industrial sectors. Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives like reduced part numbers, greater functionality, and lightweight, among others. AM has the ability to meet demands by lowering costs and speeding up the manufacturing process. Due to their popularity in numerous high-value applications, aluminum, and magnesium alloys are one of the key material systems being researched in the laser-based additive manufacturing approaches. The review here aims to comprehensively examine the additive manufacturing of magnesium and aluminum alloys, highlighting the influence of the laser-based additive manufacturing approach on the mechanical characteristics, microstructure, and tribological performance of magnesium and aluminum alloys.

Fatigue remains a challenge especially for high end metal AM parts and materials. From a design perspective, the fatigue limit of an AM solution can be improved upon by optimizing the manufacturing process for a certain material and part. In addition, improved accuracy of design methodologies aids in capturing the features critical for fatigue and quantifies their significance to desired part lifetime as well as providing a basis for their avoidance. In current work we present an overall concept merging thermomechanical process and powder bed solidification modeling to micromechanical analysis of fatigue of the resulting material microstructure. Material features critical to fatigue, particularly surface roughness, internal defects such as porosity and cracks and on the other hand inclusions, can be assessed directly on the basis of AM part microstructure with respect to the resulting fatigue limit. Case analyses consist of maraging steel and nickel alloys. The overall scheme provides a basis for optimization of metal AM solutions against fatigue and multiscale modeling founded basis for fatigue design.

The design complexity of the new generation of civil aero-engines results in higher demands on engines’ components, higher component temperature, higher heat generation, and, finally, critical thermal management issues. This paper will propose a methodological approach to create physics-based models for heat loads developed by sources as well as a systematic sensitivity analysis to identify the effects of design parameters on the thermal behaviour of civil aero-engines. The ranges and levels of heat loads generated by heat sources (e.g., accessory gearbox, bearing, pumps, etc.) and heat absorption capacity of heat sinks (e.g., engine fuel, oil, and air) are discussed systematically. The practical research challenges for thermal management system design and development for the new and next generation of turbofan engines will then be addressed through a sensitivity analysis of the heat load values as well as the heat sinks flow rates. The potential solutions for thermal performance enhancements of propulsion systems will be proposed and discussed accordingly.

We have investigated the effect of electron-beam irradiation by a forevacuum-pressure plasma-cathode electron source on the surface roughness and hardness of Al2O3- and AlN-based ceramics. The roughness increases with increasing temperature of the processed surface, while the hardness slightly decreases. For aluminum nitride ceramic, we find that the thermal conductivity increases by a factor of 1.5 to 2 depending on the electron-beam irradiation regime.

Powerful emitters of the ultraviolet C (UVC) light in the wavelength range of 230-280nm are necessary for the development of effective and safe optical disinfection technologies, high-sensitive optical spectroscopy and non-line-of-sight optical communication. This review considers such UVC-emitters with electron-beam pumping of heterostructures with quantum wells in the (Al,Ga)N material system. The important advantages of these emitters include the absence of the critical problem of p-type doping and the possibility of achieving record (up to several tens of watts for peak values) output optical power values in the UVC range. The review consistently considers about a decade of world experience in the implementation of various UV emitters with various types of thermionic, field-emission, and plasma-cathode electron guns (sources) used to excite various designs of active (light-emitting) regions in heterostructures with quantum wells AlxGa1-xN/AlyGa1-yN (x = 0 − 0.5, y = 0.6 − 1) fabricated either by metal-organic chemical vapor deposition or by plasma-activated molecular beam epitaxy. Special attention is paid to the production of heterostructures with multiple quantum wells/two-dimensional(2D) quantum disks GaN/AlN with a monolayer (1ML ~ 0.25nm) thickness, which ensures a high internal quantum efficiency of radiative recombination in the UVC range, low elastic stresses in heterostructures, and a high output UVC-optical powers.

Driven by the growing interest of the scientific community and the proliferation of research in this field, cranial implants have seen significant advancements in recent years regarding design techniques, structural optimisation, appropriate material selection and fixation system method. Custom implants not only enhance aesthetics and functionality but are also crucial for achieving proper biological integration and optimal blood irrigation, critical aspects in bone regeneration and tissue health. This research aims to optimize the properties of implants designed from triply periodic minimal surface structures. The gyroid architecture is employed for its balance between mechanical and biological properties. Experimental samples were designed varying three parameters of the surface model: cell size, isovalue and shape factor. Computational simulation tools were used for determining the relationship between those parameters and the response variables: the surface area, permeability, porosity and Young modulus. These tools include computer aided design, finite element method and computational fluid dynamics. With the simulated values, the corresponding regression models were fitted. Using the NSGA-II, a multi-objective optimisation was carried out, finding the Pareto set which includes surface area and permeability as targets, and fulfil the constraints related with the porosity and Young modulus. From these non-dominated solutions, the most convenient for a given application was chosen, and an optimal implant was designed, from a patient computed tomography scan. An implant prototype was additively manufactured for validating the proposed approach.

This study presents a novel approach combining computer vision with topology optimization for additive manufacturing. Using specialized photogrammetry software, we capture high-resolution images of the design domain to create precise 3D models through detailed scanning. These models are converted into STL file format and remeshed using an adaptive algorithm within COMSOL 5.3 Multiphysics, managed by a custom MATLAB 2023. This integration allows optimal mesh resolution and accuracy in analyses. We applied this method to design a concrete pillar for 3D printing, aiming for a 75% volume reduction to enhance material efficiency and stability, crucial for extraterrestrial environments. The design, scanned with a 360-degree camera array, informed the MATLAB-based topology optimization process. Combining MATLAB’s optimization algorithms with COMSOL’s meshing and finite element solver solver, we explored material-efficient configurations. The results show significant volume reduction, particularly in the central design area, optimizing material use while maintaining structural stability. The optimization algorithm demonstrated rapid, stable convergence to near-optimal solutions within about 20 iterations, highlighting the method’s efficiency and robustness in complex design optimization.

One century ago, ferroelectricity and then piezoelectricity were discovered using Rochelle salt crystals. Today, modern societies are invited to switch towards a resilient and circular economy model. In this context, this work proposes a method to manufacture piezoelectric devices made from agro-resources such as tartric acid and polylactide significantly reducing the energy budget without requiring any sophisticated equipement. These piezoelectric devices are manufactured by liquid phase epitaxy grown Rochelle salt (RS) crystals into a 3D printed poly(Lactic acid) (PLA) matrix being the artificial squared meshes which mimic the natural wood anatomy. This composite material can easily be produced in any fablab with renewable materials and at low processsing temperatures, reducing then the total energy consumed. Manufactured biodegradable samples are fully recyclable and have good piezoelectric properties without any pooling step. The measured piezoelectric coefficients of manufactured samples are higher than many piezoelectric polymers such as PVDF-TrFE.

The critical systems, which the failure and malfunction may result in human, environment and financial severe damages, are essential components in various sectors and particularly in energy domains. Although unwished, integration error problems in supervision of critical systems occurs, incurring significant expenses because of operator’s subjective analysis and on hardware topology failures. In this work, a malleable model design approach is proposed to formulate and solve the integration error problem in the critical systems supervision in terms of reliability. A real Hybrid Power Plant (HPP) case is considered as a requirement for a study case with simulated data. A method framework with informal approach (C4 diagram) and formal approach (Hierarchical Coloured Petri Nets) in radial spectrum is applied to the HPP supervision design. Using formal methods, a formulation and solution to this problem through structured, scalable and compact mathematical representations are possible. This malleable model intends to guarantee functional correctness and then reliability of the plant supervision system based on system software architecture. Outcomes suggest corroboration that the malleable model is appropriate for energy domain, and can be used for other types of critical systems, bringing all the benefits of this methodology to the context in which it will be applied.

CAD-CAE software companies have introduced numerous tools aimed at facilitating topology optimization through Finite Element Simulation, thereby enhancing accessibility for designers via user-friendly interfaces. However, the imposition of intricate constraint conditions or additional restrictions during calculations may introduce instability into the resultant outcomes. In this paper, an algorithm for updating the design variables called Adaptive Variable Design is proposed to keep the final design space volume of the optimized part always under the target value while giving the main algorithm multiple chances to update the optimization parameters and search for a valid design. This algorithm aims to producing results that are more conducive to manufacturability and potentially more straightforward in interpretation. A comparison between several commercial software and the proposed algorithm, implemented in MATLAB, is carried out to prove the robustness of the latter. By simulating identical parts under similar conditions, we seek to generate comparable results and underscore the advantages stemming from the adoption and comprehension of the proposed topology optimization methodology. Our findings reveal that the integrated enhancements within MATLAB pertaining to the topology optimization process yield favourable outcomes with respect to discretization, and the manufacturability of resultant geometries. Furthermore, we assert that the methodology evaluated within MATLAB holds promise for potential integration into commercial packages, thereby enhancing the efficiency of topology optimization processes.

This paper presents the use of Graph Neural Networks (GNNs) to predict the tensile strength of Fused Deposition Modeling (FDM) specimens. In the present work, there are four main input parameters i.e. Infill percentage, Layer height, Print speed and Extrusion temperature while the Tensile Strength is an output parameter were considered. This study includes use of central composite design based response surface methodology to finalize the experimental layout. 3D printed specimen were manufactured as per the ASTM E8 standard on FDM printer using Polylactic Acid (PLA) as filament. Micro-tensile test were performed on the printed specimen as per ASTM E8 standard. The GNN algorithm was trained on a dataset of FDM specimens, achieving a mean squared error (MSE) of 2.47, mean absolute error (MAE) of 1.14, and R-squared value of 0.78. An adjacency matrix, which shows the connections between nodes in a graph. The obtained plot for nodes and weights in a GNN provide valuable information about the model and its performance. The results show the potential of using GNNs in predicting the mechanical properties of additively manufactured specimens and provide a promising direction for further research in this field.

The presented research article shows a functionally graded lattice as an infill structure in designing a 3D printed mechanical element—a bicycle crank arm. The authors want to answer the fundamental question: whether the functionally graded lattice structures can efficiently improve structural performance and how they can be implemented in real complex components. Intuitively, everyone senses that using such elements must bring profit. A good example might be nature, which commonly reaches for such a solution in the skeletons of animals and humans. Two aspects determine their realisations: the lack of adequate construction and analysis methods and the limitations of existing manufacturing methods. Thus, the authors used relatively simple crank arm design and design exploration methods for structural analysis. The design exploration method enabled us to find the optimum solution efficiently. A developed prototype was created utilising additive manufacturing. One of the 3D printing methods - fused filament fabrication technology for metals, allowed the prototype of a crank arm with the optimised infill to be made. As a result, the authors developed a lightweight and manufacturable crank arm showing the new construction and analysis method implementable in similar 3D printed elements.

Additive Manufacturing (AM) simplifies the fabrication of complex geometries. Its scope has rapidly expanded from the fabrication of pre-production visualization models to the manufacturing of end use parts driving the need for better part quality assurance in the additively manufactured parts. Machine learning (ML) is one of the promising techniques that can be used to achieve this goal. Current research in this field includes the use of supervised and unsupervised ML algorithms for quality control and prediction of mechanical properties of AM parts. This paper explores the applications of supervised learning algorithms - Support Vector Machines and Random Forests. Support vector machines provide high accuracy in classifying the data and is used to decide whether the final parts have the desired properties. Random Forests consist of an ensemble of decision trees capable of both classification and regression. This paper reviews the implementation of both algorithms and analyzes the research carried out on their applications in AM.

Layer-wise 3D surface morphology information is critical for the quality monitoring and control of additive manufacturing (AM) processes. However, most of the existing 3D scan technologies are either contact or time consuming, which are not capable of obtaining the 3D surface morphology data in a real-time manner during the process. Therefore, the objective of this study is to achieve real-time 3D surface data acquisition in AM, which is achieved by a supervised deep learning-based image analysis approach. The key idea of this proposed method is to capture the correlation between 2D image and 3D point cloud, and then quantify this relationship by using a deep learning algorithm, namely, convolutional neural network (CNN). To validate the effectiveness and efficiency of the proposed method, both simulation and real-world case studies were performed. The results demonstrate that this method has strong potential to be applied for real-time surface morphology measurement in AM, as well as other advanced manufacturing processes.

The current paper is focused on the rapidly developing field of nano-/micro three-dimensional production of inorganic materials. The fabrication method includes laserlithography of hybrid organic-inorganic materials with subsequent heat treatment lead-ing to a variety of crystalline phases in 3D structures. In this work, it was examineda series of organometallic polymer precursors with different silicon (Si) and zirconium (Zr) molar ratios, ranging from 9:1 to 5:5, prepared via sol-gel method. All mixtureswere examined for perspective used in 3D laser by manufacturing by fabricating nano-and micro-feature sized structures. Their deformation and surface morphology wereevaluated depending on chemical composition and crystallographic phase. The appear-ance of a crystalline phase was proven using single-crystal X-ray diffraction analysis,which revealed a lower crystallization temperature for microstructures compared tobulk materials. Fabricated 3D objects retain a complex geometry without any distortion after heat treatment up to 1400^oC. Under the proper conditions, a zircon phase (ZrSiO₄ - a highly stable material) can be observed. In addition, the highest newrecord of achieved resolution below 60 nm has been reached. The proposed prepara-tion protocol can be used to manufacture micro/nano-devices with high precision andresistance to high temperature and aggressive environment.

This paper presents the latest developments in microCT, both globally and locally, for supporting the additive manufacturing industry. There are a number of recently developed capabilities which are especially relevant to the non-destructive quality inspection of additive manufactured parts; and also for advanced process optimization. These new capabilities are all locally available but not yet utilized to their full potential, most likely due to a lack of knowledge of these capabilities. The aim of this paper is therefore to fill this gap and provide an overview of these latest capabilities, showcasing numerous local examples.

Additive Manufacturing (AM) provides an opportunity to fundamentally redesign components previously limited by conventional manufacturing techniques. A new process for this workflow of design, manufacture by Powder Bed Fusion (PBF) and validation is presented, to which a case study of a crank for a high performance racing bicycle is applied. Topology optimisation generated conceptually ideal geometry from which a functional design was interpreted. Design for AM considerations were employed to reduce build time, material usage and post-processing labour. PBF was employed to manufacture the parts, and the build quality assessed using Computed Tomography (CT). Static and dynamic functional testing was performed and compared to a Finite Element Analysis (FEA). CT confirmed good build quality of tall, complex geometry with no significant geometrical deviation from CAD over 0.5 mm. Static testing proved performance close to current market leaders, although failure under fatigue occurred after just 2495 ± 125 cycles, the failure mechanism was consistent in both its form and location. These physical results were representative of those simulated, thus validating the FEA. This research demonstrates a complete workflow from design, manufacture, post-treatment and validation of a highly loaded PBF manufactured component, offering practitioners with a validated approach to the application of PBF.

Companies are increasingly focusing on sustainable business practices. Internal and external stakeholders’ expectations manifest in legal requirements, national and international standards, and market and customer expectations, among other things, must be considered. In addition to profit maximization as the usual target for corporate management, management must consider environmental sustainability aspects such as resource efficiency, greenhouse gas intensity, and a company's emissions behavior. In addition, social aspects relating to the company's employees, the immediate urban environment, the situation in the supply chain, and effects on the market environment must increasingly be considered. Specifically, companies are faced with the chal-lenge of dealing with conflicting objectives regarding the various aspects of sustainability and, if necessary, weighing them up against each other. These trade-offs must be made against the company's socio-economic and ecological environment, corporate strategy, and sustainability goals. This paper provides an overview of current approaches and research gaps on this topic through a literature review. It shows a lack of methods and frameworks to specifically deal with trade-offs and conflicts of goals.

Electron beam treatment of ZnS:Cu,Br (Cu activator content 0…0.6%wt.) radioluminescent phosphors as well as charge mixture with the electron energy 900 keV and absorbed dose of 600 kGy resulted in a enhancement of brightness up to 80%. The increased brightness is due to increase of content of wurtzite phase relative to sphalerite one with formation of wurtzite/sphalerite nanocomposite structure. Transformation of crystal structure is accompanied with corresponding change in content of active surface centers characteristic for sphalerite and wurtzite phases. A model describing surface centers of ZnS:Cu,Br radioluminescent phosphor is suggested.

Polymethyl methacrylate (PMMA) is a transparent thermoplastic with excellent optical properties, transparent surface, low moisture absorption, tensile and electrical resistance. In this study, the alloy was prepared through PMMA and cycloolefin copolymer (COC) due to some similar properties. The mechanical test showed that properties such as impact resistance, elongation, tensile, and flexural strength decreased by adding COC by up to 20% due to less incompatibility and miscibility, but mentioned properties improved by adding COC 40% due to sub-phase generation. The DSC and DMTA tests showed improvement in the thermal properties of alloys by adding 40% COC. SEM micrographs exhibited a softer surface and more phase elongation of the alloy. Finally, the sample was selected as the optimal sample in terms of mechanical properties irradiated by electron beam, and amplification results showed that a dose of 50 KGY increased the mechanical and thermal properties relatively.

Focused electron beam induced deposition is a versatile tool for the direct fabrication of complex-shaped nanostructures with unprecedented shape fidelity and resolution. While the technique is well-established for various materials, the direct electron beam writing of silver is still in its infancy. Here, five different silver carboxylates, three fluorinated: [Ag2(µ-O2CCF3)2], [Ag2(µ-O2CC2F5)2], [Ag2(µ-O2CC3F7)2] and two containing hydrogen: [Ag2(µ-O2CCMe2Et)2] and [Ag2(µ-O2CtBu)2] were examined and compared as potential precursors for focused electron beam induced deposition. All of the compounds show high sensitivity to electron dissociation and efficient dissociation of Ag-O bonds. The as-deposited materials showed high silver content from 42 at.% to above 70at.% and silver nano-crystal formation with impurities of carbon and fluorine incorporated between metal grains. A correlation of the number of carbon atoms in the precursor ligands and silver content of the deposited structures was found. The highest silver contents were achieved for compounds with the shortest CF chains. The deposited silver content depends on the balance of electron induced ligand co-deposition and thermal ligand desorption. Low electron flux is advantageous for high silver content. Our findings demonstrate that silver carboxylates constitute a promising group of precursors for focused electron beam nanoprinting of high silver content materials.

The relaxation processes induced by an exposure of the Ar matrices doped with CH4 (0.1 – 10%) to an electron beam were studied with a focus on the dynamics of radiolysis products – H atoms, H2 molecules, CH radicals, and energy transfer processes. Three channels of energy transfer to dopant and radiolysis products were discussed: by free charge carriers, free excitons and photons from the “intrinsic source” provided by emission of the self-trapped excitons. Radiolysis products along with the total yield of desorbing particles were monitored in a correlated manner. Analysis of methane transformation reactions induced by free excitons showed that the CH radical can be considered as a marker of the CH3 species. The competition between exciton self-trapping and energy transfer to the dopant and radiolysis products has been demonstrated. A nonlinear concentration behavior of the H atoms in doped Ar matrices has been established. Real-time correlated monitoring of optical emissions (H atom and CH3 radicals), particle ejection, and temperature revealed a nonmonotonic behavior of optical yields with a strong luminescence flash after almost an hour of exposure, which correlated with explosive pulse of particle ejection and temperature. The connection of this phenomenon with the processes of energy transfer and radical-radical recombination is discussed.

: The paper presents the results of uniaxial tensile tests of samples of hypoeutectic aluminum-silicon alloy A319. According to the results of which the influence of surface treatment by a pulsed electron beam on the mechanical properties of the material was determined. The peculiarities of localization of deformation in the material, caused by grinding of the surface layer material structure due to rapid crystallization during electron beam treatment were revealed. The surface treatment up to 100 µm depth leads to the formation of a fine dendritic columnar structure of silumin and to an increase in the plasticity of the samples. The influence of surface treatment affects the increase of deformation localization in the region of stable concentrator before failure. The largest increase in ductility and localization of deformation occurs during processing with energy density of 15 J/cm2. In the process of specimen deformation, unstable, metastable, and stable areas of plastic deformation localization are formed and replaced, and the formation of stable areas of localized plastic deformation, in which the specimen fails at the end of the test, can be detected at the initial stages of testing. In specimens, during testing in the zone of localized plastic deformation, bands are formed that pass through the entire surface of the specimen at an angle from 35 to 55 degrees to the axis of tension, their evolution leads to the formation of stable zones of localized plastic deformation and to the failure of the specimen.

EIMIs face the challenge of adapting to the Paris Agreement and the European Green Deal to achieve carbon neutrality. This change is being driven by consumer interest in low-carbon products, regulatory requirements from climate agreements and investors prioritizing sustainability. This pressure is pushing companies to go beyond short-term financial gains and integrate sustainability into their business. The growing awareness of the environmental impact of business models (BM) has fueled the development of Sustainable Business Models (SBMs). This study aims to link the discussion on the role of SBMs in the drivers of decarbonization, to improve the understanding of how the drivers can be integrated and enable new BMs for EIMIs. Based on a structured literature review, semi-structured interviews were conducted in the EIMIs. The study identifies BM-components that are influenced by these drivers and require sustainable business model innovation (SBMI). The results show that decarbonization drivers have a significant impact on all BM components. Experts emphasize the importance of collaborative approaches and cooperation throughout the value chain. This research elaborates on the importance of systematic analysis to understand how companies can effectively manage decarbonization drivers and suggests in-depth exploration within BM-research to uncover potential SBM design options.

Making sustainable business models, especially in manufacturing, is a key approach for organizations to adopt in order to create more sustainable processes. New technologies are needed to implement new policies that can minimize the economic, environmental, and social consequences of industrial activity. Sustainable maintenance is decisive to guarantee the availability, reliability, and safety of assets, surpassing traditional maintenance policies and embracing the principles of the circular economy. The main objective of Maintenance 4.0 is to increase the lifespan and availability of the equipment by preventing unplanned downtime, reducing planned shutdowns, and improving safety. This research focuses on the integration of advanced Industry 4.0 tools with conventional monitoring and control techniques in process industries. The article suggests that while complex neural networks might provide good predictions, simpler solutions can generalize well and have lower prediction errors because they can capture the underlying relationships between variables in a specific asset better. The combination of maintenance function, Industry 4.0 tools, and advanced statistical solutions to obtain sustainable processes can facilitate organizational change and aid decision-making in equipment management. These solutions seek to reduce interruptions and expenses through the unnecessary utilization of labor and spare parts. All these considerations improve communication and data processing, resulting in improved maintenance of a hydrogen compressor in the petrochemical industry.

Nowadays, Multi-needle electrospinning has used to be an efficient method for producing nanofiber membranes. But in the process, the fluctuation errors in electrospinning fluid flow rate have directly influence the membrane quality, which bringing instability and still have not been solved yet. For finding out the solution to the inaccurate flow control in multi-needle, it is necessary to develop a multi-stage flow runner spinneret for large-scale production of nanofiber membrane. At first, the paper uses the finite element software COMSOL to numerically simulate the polymer flow in the runner of spinneret. Based on it, the velocity field distribution curve was draw and the velocity instability coefficient of the polymer flow was attained, which are providing theoretical guidance for the optimal design of spinneret. Next, the response surface analysis method (RSM) was used to establish a regression model between the average diameter of the nanofiber membrane and the process parameters. Then, above regression model used to perform variance data processing between the average diameter and the process parameter configuration. After that, the 2D and 3D response surface profiles and the significance analysis were completed. Finally, the stability of the nanofibers production was improved, which attained the optimal adjustment of process configuration in multi-needle electrospinning.

Recent developments in metallic additive manufacturing (AM) processes for the production of high-performance industrial pieces have been hampered by the limited availability of reliably processable or printable alloys. To date, most of the alloys used in AM are commercial grades that have been previously optimized for different manufacturing techniques. This study aims to design new alloys specifically tailored for AM processes, to minimize defects in the final products and optimize their properties. A computational approach is proposed to design novel and optimized austenitic alloy compositions. This method integrates a suite of predictive tools, including machine learning, calculation of phase diagrams (CALPHAD) and physical models, all piloted by a multi-objective genetic algorithm. Within this framework, several material-dependent criteria are examined and their impact on properties and on the occurrence of defects is identified. To validate our approach, experimental tests are performed on a selected alloy composition: powder is produced by gas atomization and samples are fabricated by laser powder bed fusion. The microstructure and mechanical properties of the alloys are evaluated and its printability is compared to a commercial 316L stainless steel taken as a reference.

The limitations of investment casting of cobalt-based alloys are claimed to be less problematic with significant improvements in metal additive manufacturing by selective laser melting (SLM). Despite these advantages, the metallic devices are likely to display mechanical anisotropy in relation to build orientations, which could consequently affect their performance ‘in vivo’. In addition, there are inconclusive evidence concerning the requisite composition and post-processing steps (e.g. heat-treatment to relieve stress) that must be completed prior to the devices being used. In the current paper, we evaluate the microstructure of ternary cobalt-chromium-molybdenum (Co-Cr-Mo) and cobalt-chromium-tungsten (Co-Cr-W) alloys built with Direct Metal Printing and LaserCUSING SLM systems respectively at 0°, 30°, 60° and 90° inclinations (Φ) in as-built (AB) and heat-treated (HT) conditions. The study also examines the tensile properties (Young's modulus, E; yield strength, R_P0.2; elongation at failure, A_t and ultimate tensile strength, R_m), relative density (RD), and micro-hardness (HV5) and macro-hardness (HV20) as relevant physico-mechanical properties of the alloys. Data obtained indicate improved tensile properties and HV values after short and cost-effective heat-treatment cycle of Co-Cr-Mo alloy; however, the process did not homogenize the microstructure of the alloy. Annealing heat-treatment of Co-Cr-W led to significant isotropic characteristics with increased E and A_t (except for Φ = 90º) in contrast to decreased R_P0.2, R_m and HV values, compared to the AB form. Similarly, the interlaced weld-bead structures in AB Co-Cr-W were removed during heat-treatment, which led to a complete recrystallization in the microstructure. Both alloys exhibited defect-free microstructures with RD exceeding 99.5%.

In this paper, a novel microwave catalyst Ni@SiC/CNFs (NSC), C/Ni (NC), and C/SiC (SC) were successfully synthesized by electrostatic spinning method, and proved to degrade methylene blue with high efficiency under microwave irradiation. The results imply that the catalyst Ni@SiC/CNFs with double shell structure gave a 99.99 % removal rate in 90 s for the degradation of methylene blue under microwave irradiation, outperformed the C/Ni and C/SiC and most other reported catalysts in similar studies. On the one hand, the possible mechanism of the methylene blue degradation should be ascribed to that double shell structure increases the polarization source of the material, resulting in excellent microwave absorption properties; and on the other, the in-situ generation of active species OH• and O2 - under microwave radiation and the synergistic coupling effect of metal plasma greatly improved the degradation efficiency of methylene blue. The findings of this study could provide a valuable reference for the green degradation of industrial dye wastewater and its sustainable development process.

Additive manufacturing (AM) is a promising new technology that is having a very fast growth from home workshops to high-tech cutting-edge factories. As any manufacturing technique, adequate metrology services are needed to assure the quality of items manufactured by AM. One of the most widely used instruments to measure the characteristics of surfaces manufactured with AM is the confocal microscope. In this paper, authors present a whole calibration procedure for confocal microscopes designed to be implemented preferably in workshops or industrial environments rather than in research and development departments. Because of that, it is as simple as possible. The procedure is designed without forgetting any of the key aspects that need to be taken into account and based on classical reference material standards. These standards can be easily found in industrial dimensional laboratories and easily calibrated in accredited calibration laboratories.

The present work investigates primarily the morphology evolution of the body-centered-cubic (BCC)/B2 phases in AlxNiCoFeCr high-entropy alloys (HEAs) with increasing Al content, which has been neglected so far. There exist two types of microscopic morphologies of BCC and B2 phases in this HEA series: one is the weave-like morphology induced by the spinodal decomposition, and the other is the microstructure of a spherical disordered BCC precipitation on the ordered B2 matrix that appears in HEAs with a much higher Al content. The shape of coherent precipitates is found to be closely related to the lattice misfit between BCC and B2 phases, which is sensitive to Al. The mechanical properties, including the compressive yielding strength and microhardness of the AlxNiCoFeCr HEAs, are also discussed in light of the concept of the valence electron concentration (VEC).

The study presented hereafter shows a new methodology to reveal traces of polyethylene (the most common microplastic particles, known as a structure of C2H4) in a sample of ocean water by the irradiation of a 50 keV, 1 µA electron beam. This is performed by analyzing the photon (produced by the electrons in water ) fluxes and spectra (i.e. fluxes as a function of photon energy) at different types of contaminated water with an adequate device and in particular looking at the peculiar interactions of electrons/photons with the potential abnormal atomic hydrogen (H), oxygen (O), carbon (C), phosphorus (P) compositions present in the water, as a function of living and not living organic organisms with a PO4 group RNA/DNA strands in a cluster configuration through a volumetric cells grid.