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Applied Sciences
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Advancements in Laser Based Additive Manufacturing Technologies
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Advancements in Laser Based Additive Manufacturing Technologies

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Optics and Lasers".

Deadline for manuscript submissions: closed (30 October 2020) | Viewed by 25390

Special Issue Editor

Dr. Guijun Bi

E-Mail Website
Guest Editor
Institute of Intelligent Manufacturing, Guangdong Academy of Sciences, Guangzhou 510070, China
Interests: joining & welding; additive manufacturing; laser material processing; process monitoring and control, simulation and machine learning
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

As a unique and powerful heat source, laser plays very important role in additive manufacturing for surface modification, remanufacturing, and direct fabrication of 3D components. Laser-based additive manufacturing technologies have been attracting more and more interests from both academia and industry for R&D and technology adoptions. Laser-based additive manufacturing is an interdisciplinary research area covering optoelectronics, mechanical engineering, materials science, control, topology design, numerical computing, and more. Various issues need to be addressed to guarantee the metallurgical, mechanical properties, and performance of the additively manufactured components.

This Special Issue aims to provide a platform for researchers to share the latest advancements in laser-based additive manufacturing technologies. It covers the following key areas of laser-based additive manufacturing technologies, in addition to other relevant topics:

  • Analysis of laser-material interaction and fundamentals of the processes;
  • Development of laser-based additive manufacturing processes as well as hybrid processes;
  • Simulation/modeling of process, material, thermal–mechanical–performance relationship;
  • Advanced materials development via laser-based additive manufacturing;
  • Material characterization and performance;
  • Process monitoring and control for quality assurance and enhancement;
  • Design and optimization;
  • Novel systems and industry applications;
  • Post-processing of additively manufactured components.

Dr. Guijun Bi
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • laser-based additive manufacturing
  • simulation and modeling
  • advanced materials
  • material characterization
  • process monitoring and control
  • design for additive manufacturing
  • post-processing

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Published Papers (6 papers)

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Editorial

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2 pages, 157 KiB  
Editorial
Special Issue on Advancements in Laser-Based Additive Manufacturing Technologies
by Guijun Bi
Appl. Sci. 2023, 13(3), 1529; https://doi.org/10.3390/app13031529 - 24 Jan 2023
Viewed by 1254
Abstract
As a unique and powerful heat source, lasers are very important for the surface modification, re-manufacturing, and direct fabrication of 3D components [...] Full article
(This article belongs to the Special Issue Advancements in Laser Based Additive Manufacturing Technologies)

Research

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17 pages, 5175 KiB  
Article
Multiphysics Modeling, Sensitivity Analysis, and Optical Performance Optimization for Optical Laser Head in Additive Manufacturing
by Jiaping Yang, Xiling Yao, Yuxin Cai and Guijun Bi
Appl. Sci. 2021, 11(2), 868; https://doi.org/10.3390/app11020868 - 19 Jan 2021
Cited by 1 | Viewed by 3087
Abstract
Optical laser head is a key component used to shape the laser beam and to deliver higher power laser irradiation onto workpieces for material processing. A focused laser beam size and optical intensity need to be controlled to avoid decreasing beam quality and [...] Read more.
Optical laser head is a key component used to shape the laser beam and to deliver higher power laser irradiation onto workpieces for material processing. A focused laser beam size and optical intensity need to be controlled to avoid decreasing beam quality and loss of intensity in laser material processing. This paper reports the multiphysics modeling of an in-house developed laser head for laser-aided additive manufacturing (LAAM) applications. The design of computer experiments (DoCE) combined with the response surface model was used as an efficient design approach to optimize the optical performance of a high power LAAM head. A coupled structural-thermal-optical-performance (STOP) model was developed to evaluate the influence of thermal effects on the optical performance. A number of experiments with different laser powers, laser beam focal plane positions, and environmental settings were designed and simulated using the STOP model for sensitivity analysis. The response models of the optical performance were constructed using DoCE and regression analysis. Based on the response models, optimal design settings were predicted and validated with the simulations. The results show that the proposed design approach is effective in obtaining optimal solutions for optical performance of the laser head in LAAM. Full article
(This article belongs to the Special Issue Advancements in Laser Based Additive Manufacturing Technologies)
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9 pages, 5177 KiB  
Article
Effect of Laser Remelting on Wear Behavior of HVOF-Sprayed FeCrCoNiTiAl0.6 High Entropy Alloy Coating
by Lijia Chen, Dingyong He, Bing Han, Zhen Guo, Li Zhang, Longxing Lu, Xu Wang, Zhen Tan and Zheng Zhou
Appl. Sci. 2020, 10(20), 7211; https://doi.org/10.3390/app10207211 - 16 Oct 2020
Cited by 10 | Viewed by 2943
Abstract
In this study, a laser remelting process was applied to the FeCrCoNiTiAl0.6 high entropy alloy coating in order to improve the density and the surface quality of the coating. The coating was fabricated by high-velocity-oxygen-fuel (HVOF) technology. The microstructure and phase composition [...] Read more.
In this study, a laser remelting process was applied to the FeCrCoNiTiAl0.6 high entropy alloy coating in order to improve the density and the surface quality of the coating. The coating was fabricated by high-velocity-oxygen-fuel (HVOF) technology. The microstructure and phase composition of the coating were investigated by scanning electron microscopy (SEM), energy dispersive X-ray spectrometer (EDS), X-ray diffractometer (XRD) and confocal scanning laser microscope (CSLM). Moreover, the wear behavior of the coating was evaluated by use of a ball-on-disc test. The coating was denser after laser remelting treatment by eliminating the previous lamellar structure. The microstructure of the laser-remelted coating exhibits two body-centered cubic (BCC) phases, which is different from the HVOF coating. In addition, aluminum oxide formed during laser remelting. Different from the wear mechanism of the HVOF coating, which comprised abrasion and fatigue, the major wear of the laser remelted coating was abrasion. Full article
(This article belongs to the Special Issue Advancements in Laser Based Additive Manufacturing Technologies)
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18 pages, 6245 KiB  
Article
High-Efficient Micro Reacting Pipe with 3D Internal Structure: Design, Flow Simulation, and Metal Additive Manufacturing
by Xiaomin Chen, Di Wang, Jingming Mai, Xiaojun Chen and Wenhao Dou
Appl. Sci. 2020, 10(11), 3779; https://doi.org/10.3390/app10113779 - 29 May 2020
Cited by 1 | Viewed by 2319
Abstract
The micro reacting pipe with 3D internal structure, which is a micromixer with the shape of the pipe, has shown great advantages regarding mass transfer and heat transfer. Since the fluid flow is mostly laminar at the micro-scale, which is unfavorable to the [...] Read more.
The micro reacting pipe with 3D internal structure, which is a micromixer with the shape of the pipe, has shown great advantages regarding mass transfer and heat transfer. Since the fluid flow is mostly laminar at the micro-scale, which is unfavorable to the diffusion of reactants, it is important to understand the influence of the geometry of the microchannel on the fluid flow for improving the diffusion of the reactants and mixing efficiency. On the other hand, it is a convenient method to manufacture a micro reacting pipe in one piece through metal additive manufacturing without many post-processing processes. In this paper, a basis for the design of a micromixer model was provided by combining the metal additive manufacturing process constraints with computational fluid dynamics (CFD) simulation. The effects of microchannel structures on fluid flow and mixing efficiency were studied by CFD simulation whose results showed that the internal micro-structure had a significantly positive effect on the mixing efficiency. Based on the simulation results, the splitting-collision mechanism was discussed, and several design rules were obtained. Two different materials were selected for manufacturing with the laser powder bed fusion (L-PBF) technology. After applying pressure tests to evaluate the quality of the formed parts and comparing the corrosion-resistance of the two materials, one material was picked out for the industrial application. Additionally, the chemical experiment was conducted to evaluate the accuracy of the simulation. The experimental results showed that the mixing efficiency of the micro reacting pipe increased by 56.6%, and the optimal determining size of the micro reacting pipe was 0.2 mm. The study can be widely used in the design and manufacture of a micromixer, which can improve efficiency and reacting stability in this field. Full article
(This article belongs to the Special Issue Advancements in Laser Based Additive Manufacturing Technologies)
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11 pages, 4015 KiB  
Article
Design, Fabrication, and Evaluation of Polyglycolic Acid Modules with Canals as Tissue Elements in Cellular-Assembly Technology
by Jingyuan Ji, Yuan Pang, Stephanie Sutoko, Yohei Horimoto, Wei Sun, Toshiki Niino and Yasuyuki Sakai
Appl. Sci. 2020, 10(11), 3748; https://doi.org/10.3390/app10113748 - 28 May 2020
Cited by 4 | Viewed by 2312
Abstract
The aim of the present study was to design and fabricate polyglycolic acid (PGA) modules on the basis of the Raschig ring as a tissue element for bottom–top tissue engineering to increase the feasibility of cellular-assembly technology. Three types of modules, namely, cylindrical, [...] Read more.
The aim of the present study was to design and fabricate polyglycolic acid (PGA) modules on the basis of the Raschig ring as a tissue element for bottom–top tissue engineering to increase the feasibility of cellular-assembly technology. Three types of modules, namely, cylindrical, Raschig ring, and transverse-pore modules, with different numbers and orientations of canals, were designed and fabricated by modified selective-laser-sintering (SLS) technology. These modules maintained their structure in a flowing culture environment, and degradation did not create an acidic environment, hence promoting their ability to scale up to highly functional tissue. The modules were seeded with human hepatoma Hep G2 cells and cultured for 10 days. The transverse-pore modules were found to have the highest glucose consumption, albumin production, and cell viability among the three tested modules. Our study showed that the proposed module design provided better mass transfer and possessed the required mechanical strength to enable use in the construction of large tissue. Full article
(This article belongs to the Special Issue Advancements in Laser Based Additive Manufacturing Technologies)
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Review

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10 pages, 2561 KiB  
Review
Digital Twins for Additive Manufacturing: A State-of-the-Art Review
by Li Zhang, Xiaoqi Chen, Wei Zhou, Taobo Cheng, Lijia Chen, Zhen Guo, Bing Han and Longxing Lu
Appl. Sci. 2020, 10(23), 8350; https://doi.org/10.3390/app10238350 - 24 Nov 2020
Cited by 74 | Viewed by 12439
Abstract
With the development of Industry 4.0, additive manufacturing will be widely used to produce customized components. However, it is rather time-consuming and expensive to produce components with sound structure and good mechanical properties using additive manufacturing by a trial-and-error approach. To obtain optimal [...] Read more.
With the development of Industry 4.0, additive manufacturing will be widely used to produce customized components. However, it is rather time-consuming and expensive to produce components with sound structure and good mechanical properties using additive manufacturing by a trial-and-error approach. To obtain optimal process conditions, numerous experiments are needed to optimize the process variables within given machines and processes. Digital twins (DT) are defined as a digital representation of a production system or service or just an active unique product characterized by certain properties or conditions. They are the potential solution to assist in overcoming many issues in additive manufacturing, in order to improve part quality and shorten the time to qualify products. The DT system could be very helpful to understand, analyze and improve the product, service system or production. However, the development of genuine DT is still impeded due to lots of factors, such as the lack of a thorough understanding of the DT concept, framework, and development methods. Moreover, the linkage between existing brownfield systems and their data are under development. This paper aims to summarize the current status and issues in DT for additive manufacturing, in order to provide more references for subsequent research on DT systems. Full article
(This article belongs to the Special Issue Advancements in Laser Based Additive Manufacturing Technologies)
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