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Laser powder bed fusion (LPBF) holds promise to efficiently produce metal parts. However, LPBF incurs stochastic melt pool (MP) spattering, which would roughen workpiece in-process surface, thus weakening inter-layer bonding and causing…
Numerical simulations of a complete laser powder bed fusion (LPBF) additive manufacturing (AM) process are extremely challenging or even impossible to achieve without a radical model reduction of the complex physical phenomena occurring…
Additive manufacturing technologies enable the production of complex and bioinspired shapes using magneto-responsive materials, which find diverse applications in soft robotics. Particularly, the development of composites with controlled…
Laser powder bed fusion (L-PBF) is a widely recognized additive manufacturing technology for producing intricate metal components with exceptional accuracy. A key challenge in L-PBF is the formation of complex microstructures affecting…
Laser Powder Bed Fusion (L-PBF) is a widely adopted additive manufacturing process for fabricating complex metallic parts layer by layer. Effective thermal management is essential to ensure part quality and structural integrity, as thermal…
Metal additive manufacturing via laser-based powder bed fusion (PBF-LB/M) faces performance-critical challenges due to complex melt pool and vapor dynamics, often oversimplified by computational models that neglect crucial aspects, such as…
Powder Bed Fusion (PBF) is a type of Additive Manufacturing (AM) technology that builds parts in a layer-by-layer fashion out of a bed of metal powder via the selective melting action of a laser or electron beam heat source. The technology…
Additive manufacturing by laser powder bed fusion (LPBF) offers material versatility, capability for complex geometries, and control of mechanical properties and microstructure. However, achieving high-quality output requires process…
This work investigated the effects of aging heat treatments on the microstructure and, consequently, the quasi-static (tensile properties) and dynamic (impact toughness) mechanical behaviour of a 17-4 PH stainless steel produced by powder…
Surface defects in Laser Powder Bed Fusion (LPBF) pose significant risks to the structural integrity of additively manufactured components. This paper introduces TransMatch, a novel framework that merges transfer learning and…
Pore formation during Laser Powder Bed Fusion (LPBF) has long posed challenges in metal 3D printing, significantly affecting the mechanical properties of the final product. Porosity frequently occurs because of an unstable keyhole…
Laser powder bed fusion (L-PBF) of semi-crystalline polymers such as polyamide-12 (PA12) has found increasing use in various industrial applications. However, achieving high dimensional accuracy remains a significant challenge. Despite the…
We present a computational framework for the simulations of powder-bed fusion of metallic alloys, which combines: (1) CalPhaD calculations of temperature-dependent alloy properties and phase diagrams, (2) macroscale finite element (FE)…
The microstructure of Ti-6Al-4V has a decisive impact on its mechanical performance; however, controlling phase composition during Laser Powder Bed Fusion (LPBF) remains difficult because of the inherent localized and cyclic thermal…
The stochastic formation of defects during Laser Powder Bed Fusion (L-PBF) negatively impacts its adoption for high-precision use cases. Optical monitoring techniques can be used to identify defects based on layer-wise imaging, but these…
Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and…
This article proposes a novel high-performance computing approach for the prediction of the temperature field in powder bed fusion (PBF) additive manufacturing processes. In contrast to many existing approaches to part-scale simulations,…
Powder bed additive manufacturing processes such as laser powder bed fusion (LPBF) or binder jetting (BJ) benefit from using fine (D50 $\leq20~\mu m$) powders. However, the increasing level of cohesion with decreasing particle size makes…
Powder bed fusion additive manufacturing (PBFAM) of metals has the potential to enable new paradigms of product design, manufacturing and supply chains while accelerating the realization of new technologies in the medical, aerospace, and…
In this paper, we present the results of single-track experiments conducted for different fractions of standard AlSi10Mg powder, which were sieved to achieve varying mean size of the particles. We observed strong differences in the melting…