Manufacturing of high strength and high conductivity copper with laser powder bed fusion.

Additive manufacturing (AM), known as 3D printing, enables rapid fabrication of geometrically complex copper (Cu) components for electrical conduction and heat management applications. However, pure Cu or Cu alloys produced by 3D printing often suffer from either low strength or low conductivity at room and elevated temperatures. Here, we demonstrate a design strategy for 3D printing of high strength, high conductivity Cu by uniformly dispersing a minor portion of lanthanum hexaboride (LaB) nanoparticles in pure Cu through laser powder bed fusion (L-PBF).

Designing against phase and property heterogeneities in additively manufactured titanium alloys.

Additive manufacturing (AM) creates digitally designed parts by successive addition of material. However, owing to intrinsic thermal cycling, metallic parts produced by AM almost inevitably suffer from spatially dependent heterogeneities in phases and mechanical properties, which may cause unpredictable service failures. Here, we demonstrate a synergistic alloy design approach to overcome this issue in titanium alloys manufactured by laser powder bed fusion.

Mesoscale Process Modeling of a Thick Pultruded Composite with Variability in Fiber Volume Fraction.

Pultruded fiber-reinforced polymer composites are susceptible to microstructural nonuniformity such as variability in fiber volume fraction (Vf), which can have a profound effect on process-induced residual stress. Until now, this effect of non-uniform Vf distribution has been hardly addressed in the process models. In the present study, we characterized the Vf distribution and accompanying nonuniformity in a unidirectional fiber-reinforced pultruded profile using optical light microscopy.

A Review on the Mechanical Modeling of Composite Manufacturing Processes.

The increased usage of fiber reinforced polymer composites in load bearing applications requires a detailed understanding of the process induced residual stresses and their effect on the shape distortions. This is utmost necessary in order to have more reliable composite manufacturing since the residual stresses alter the internal stress level of the composite part during the service life and the residual shape distortions may lead to not meeting the desired geometrical tolerances. The occurrence of residual stresses during the manufacturing process inherently contains diverse interactions between the involved physical phenomena mainly related to material flow, heat transfer and polymerization or crystallization.