Research Progress and Prospect of Wire and Arc Additive Manufacture Article

TIAN Gen, WANG Wenyu, CHANG Qing, REN Zhiqiang, WANG Xiaoming, ZHU Sheng

Materials Reports 2021,35(23 ):23131 -23141. DOI:10.11896/cldb.20110244

Abstract （2054）

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Research Progress on Environmental Impact and Life Cycle Assessment of Additive Manufacturing Technology Article

LI Zhuoxin, ZHU Jing, LI Hong

Materials Reports 2021,35(11 ):11173 -11179. DOI:10.11896/cldb.19120078

Abstract （965）

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Save Additive manufacturing (AM) techniques for different material deposition methods have been created to meet the needs of different industrial areas. Among them, wire and arc additive manufacturing(WAAM) is rapidly developing, which is suitable for the molding of large and complex metal parts. It has the advantages of low energy consumption, low carbon footprint and low cost. With the development of new materials, processes, machinery and systems related to additive manufacturing technology, many research issues on sustainability remain unresolved. Due to the great difference in material and energy demands of different manufacturing processes, additive manufacturing technology is generally no better than traditional processes. Therefore, besides studying the flexibility and process performance of additive manufacturing technology, prudent analyses of the environmental impact of different techniques are also necessary. Life cycle assessment (LCA), as an important environmental management tool for the whole process, or so called “cradle to grave”, of industrial products, has found increasing application in the research of different manufacturing techniques. However, the LCA of additive manufacturing technology only acquires moderate attention, most of which mainly focuses on energy and raw materials consumption. There are relatively few conclusions explaining the energy and environmental impacts, especially those based on reliable life cycle inventory, and moreover, fewer environmental impact and evaluation studies on the WAAM. Therefore, tighter integration and deeper interdisciplinary collaboration are worthful.
This paper introduces the definition and technical framework of LCA, and, based on LCA method, summarizes the research status of WAAM’s environmental impact from four aspects, i.e. goal and scope definition, inventory analysis, impact assessment and result interpretation, including all material and energy flows from raw material acquisition to end-of-life treatment. Compared with different process methods, the environmental impact characteristics of the AM are analyzed.

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Mix Proportion Optimization of 3D Printing Concrete for Underwater Intelligent Construction Article

SUN Xiaoyan, CHEN Long, WANG Hailong, ZHANG Jing

Materials Reports 2022,36(4 ):21050230 -9. DOI:10.11896/cldb.21050230

Abstract （894）

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Save With the shortage of land resources, underwater construction has become the necessary way for engineering development. At present, the research on underwater concrete is relatively systematic, but there is seldom report on the research on underwater 3D printing concrete. Underwater intelligent construction can be digital forming without formwork and can promote the development of deep-sea engineering, in which 3D printing concrete is its core construction technology.
Currently, the design methods for underwater concrete and land 3D printed concrete lack technical pertinence to underwater intelligent construction process and service environment. In this paper, the optimization design process of underwater 3D printing concrete mix proportion has been established according to the mechanical properties, printability and underwater working performance. A serials of experimental studies were designed and carried out considering the influences of water binder ratio, mineral powder dosage, sand binder ratio, fine aggregate gradation, flocculant and thixotropic agent content. The results showed that the 28 d compressive strength of printed concrete decreased with the increase of water binder ratio, mineral powder ratio, sand binder ratio and other parameters. The water binder ratio has the most significant effect, followed by the mineral powder ratio, and the change of sand binder ratio and the flocculant agent content have little effect on material strength. Based on the experimental data and Boromir formula, an underwater 3D printing concrete mix proportion design model with high fitting accuracy is proposed.
Considering the strength and underwater non-dispersibility of printed concrete, the optimum dosage of flocculant is 2% of the mass of cementitious material. The fluidity range of 165—190 mm can ensure the construction requirement of underwater printing. The time-varying vertical deformation prediction model is established with consideration of sand binder ratio, thixotropic agent content and fine aggregate gradation as basic variables, which has reliable accuracy and can be used to control the stability of underwater 3D printing concrete construction.
It is first times to systematically study the underwater 3D printing concrete, establish the 3D printed concrete mix proportion optimization design process for underwater intelligent construction, and put forward the underwater 3D printed concrete strength design model and the vertical defor-mation prediction model during construction process, which provides theoretical basis and experimental reference for underwater intelligent construction. The 28 d compressive strength of optimized underwater printed specimen is up to 55 MPa, and the water land strength ratio reaches 93.9%, which can meet the performance requirements of underwater intelligent construction structure.

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Recent Advances in 3D Printed Polymer Nanocomposites Article

YANG Zhaozhe, KONG Zhenwu, WU Guomin, WANG Siqun, XIE Yanjun, FENG Xinhao

Materials Reports 2021,35(13 ):13177 -13185. DOI:10.11896/cldb.19120105

Abstract （1105）

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Save Compared to the traditional manufacturing methods such as extrusion, molding, etc., 3D printing technology can not only rapidly mold the product with complex and fine structure, but also realizes efficient manufacturing with different materials to meet the requirements on the functions and performance. Therefore, 3D printing has been attracted more attention, and more 3D printed products have been applied into people's lives, study, and work. Among all the raw materials used for 3D printing, polymer such as thermoset and thermoplastic polymer, has been mostly 3D printed and applied in the areas ranging from house decorations to micro/nano-electronic devices. However, the 3D printed polymers can only be used in mo-dels and non-structural materials due to their low strength and weak adhesion between printed layers. Nanomaterials such as cellulose nanocrystals, are often used as reinforcement in polymers to prepare high-strength 3D printed nanocomposites, which can be used in structural and functional applications. Cellulose nanocrystal is an ideal nano-enhancement material with wide sources, low price, renewable, and high strength. Hence, the application of nanomaterials in the 3D printed nanocomposites has been researched, meanwhile, the effect of nanomaterials on the properties of 3D-printed polymers was elaborately investigated. Researches were also focused on the modification of nanomaterial and development of new nanomaterials to improve the property of 3D printed nanocomposites and obtain functionality in the printed nanocomposites, and several fruitful results have been achieved. In addition, the structure-property-function relationship of 3D printed nanocomposites produced by stereolithography and fused deposition modeling, respectively, have been evaluated to provide a reliable reference for the extensive application of 3D printed nanocomposites. In this study, the 3D printing technology was briefly introduced. The basic principles and characteristics of 3D printing technology used in thermoset and thermoplastic polymers were introduced. Subsequently, the application of stereolithography and fused deposition modeling in the field of polymer nanocomposites were analyzed. Finally, the performance and applications of the printed nanocomposites were analyzed and summarized to establish a stable foundation for the wide application of 3D printed polymer nanocomposites.

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Research Progress of Copper and Its Alloys Surface Coating Technology and Additive Manufacturing Technology Article

WANG Rongcheng, WANG Wenyu, YIN Fengshi, REN Zhiqiang, CHANG Qing, ZHAO Yang, QIN Zhiyong

Materials Reports 2021,35(19 ):19142 -19152. DOI:10.11896/cldb.20070054

Abstract （1013）

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Save Copper and its alloys have excellent corrosion resistance, electrical and thermal conductivity and mechanical processing properties, and are widely used in electrical, light industry, machinery manufacturing and other fields. With the continuous optimization of production conditions and meeting different application requirements at the same time, people expect to obtain parts with better overall performance or a particular performance, but the traditional manufacturing and processing methods are complex and the material utilization rate in the production process is low, there are great limitations. In order to realize the surface alloying of parts and improve the surface performance defects of parts, surface coating technology has been developed and widely used; in order to realize the forming of complex structural parts, people have developed additive manu-facturing technology. Copper alloy additive manufacturing technology can efficiently and quickly manufacture various types of precision parts through a layer-by-layer accumulation method. It not only has a high utilization rate of alloy materials, but also can meet the forming needs of various complex parts. It is the current copper alloy application research hotspots. In recent years, domestic and foreign researchers have used copper alloy coatings to improve the surface properties of parts with deposition, thermal spraying, cold spraying, etc. The research on copper alloy additive manufacturing technology mainly focuses on laser additive manufacturing technology, from process optimization, the analysis of the organization and performance provides a great theoretical basis for future research, but there is less attention to other additive manufacturing technologies such as electron beam additive and arc additive, and the composition is uniform in the copper alloy additive manufacturing process. The heat treatment process, and the excellent electrical conductivity, thermal conductivity, and density of the additive need to be further studied.
This article summarizes the process principle and research status of copper alloy surface coating and additive manufacturing technology. By comparing various additive manufacturing methods, the influence of various additive manufacturing technology process parameters on the microstructure and mechanical properties of the formed part is analyzed. The advantages and disadvantages of the formed parts obtained by each technology are summarized, and the future focus of copper alloy additive manufacturing is prospected, which lays the foundation for the preparation of copper alloy formed parts with better performance and process applications.

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Antibacterial Principles, Traditional Processing and Additive Manufacturing of Antibacterial Stainless Steel Article

LIU Ying, YANG Junjie, YI Yanliang, ZHANG Zhiguo, WANG Xiaojian, LI Wei, ZHOU Shengfeng

Materials Reports 2021,35(23 ):23097 -23105. DOI:10.11896/cldb.20070008

Abstract （893）

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Save With the frequent occurrence of various public health incidents, the development and application of various antibacterial products have been spawned. Antibacterial materials are classified according to the source of raw materials, including inorganic antibacterial materials, orga-nic antibacterial materials, natural antibacterial materials and synthetic antibacterial materials. As one of the most widely used inorganic metal ma-terials, stainless steel has made some progress in the application of antibacterial materials.
There are two methods to obtain antibacterial properties of stainless steel: surface modification and alloying. However, the surface antibacterial stainless steel after abrasion is easy to lose the antibacterial effect, and the antibacterial ion utilization rate of alloy antibacterial stainless steel is low, which leads to unsatisfactory antibacterial effect of stainless steel. This urges intensive research endeavors to optimize antibacterial stainless steel fabrication process, aiming at improving durability and antibacterial efficiency, and expanding the scope of use of antibacterial stainless steel.
In recent years, in order to improve the service life and antibacterial properties of antibacterial stainless steel, a variety of preparation technologies of antibacterial stainless steel have been developed. Adding antibacterial elements to stainless steel surface by deposition, penetration, implantation and spraying can increase the thickness of antibacterial layer and stabilize the antibacterial effect. At the same time, an appropriate amount of antibacterial metal elements added to stainless steel, after appropriate antibacterial treatment, can be continuously released in the me-dium, which make antibacterial rate greatly improve. In addition, in order to meet the use demand of antibacterial stainless steel in biomedical field and realize the organic combination of antibacterial property and biocompatibility, some biocompatible substances such as hydroxyapatite and poly (L-lactide-caprolactone) are often introduced into the surface, or use advanced preparation technology to control the release concentration of harmful metal ions, which can achieve the organic combination of antibacterial properties and biocompatibility.
This paper summarizes the research status of various antibacterial stainless steels at home and abroad in the past decade. The antibacterial principles, characteristics of surface modified antibacterial stainless steel and alloy antibacterial stainless steel and the related manufacturing met-hods are introduced. In addition, due to the limitations of traditional manufacturing method, such as poor antibacterial durability, long preparation cycle, large material wear, and serious environmental pollution, additive manufacturing is considered as a new technique for producing antibacterial stainless steel. This developed technique exhibits the personalized customization, short time manufacturing, precision machining and other advantages to replace the above shortcomings of subtractive manufacturing. The application of additive manufacturing antibacterial materials in the medical care is also introduced in this paper.

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Research Progress and Prospects of High-entropy Alloys Made by Additive Manufacturing Article

XIA Ming, SUN Bo, WANG Xin, LIANG Xiubing, SHEN Baolong

Materials Reports 2021,35(13 ):13119 -13127. DOI:10.11896/cldb.20030155

Abstract （1257）

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Research Progress of Metal Lattice Porous Materials for Additive Manufacturing Article

YANG Xin, MA Wenjun, WANG Yan, LIU Shifeng, ZHANG Zhaoyang, WANG Wanlin, WANG Ben, TANG Huiping

Materials Reports 2021,35(7 ):7114 -7120. DOI:10.11896/cldb.19110208

Abstract （1808）

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Save Metal lattice porous materials are advanced lightweight and multifunctional materials with complex periodic structure. Due to its excellent specific strength, sound absorption, noise reduction and metamaterials, they has attracted much attention in recent years. These characteristics make the metal lattice porous materials have a wide range of applications in the fields of medical implantation and aerospace. At the same time, the traditional preparation process can only manufacture lattice-like structures, and has many defects, making them difficult to produce complex and fine lattice structures, making the application of metal lattice porous materials encounter a bottleneck. In recent years, the rapid development of additive manufacturing (AM) technology has the characteristics of large design, manufacturing freedom and rapid manufacturing of any complex geometric parts. It is the forefront of metal lattice porous materials preparation technology to regulate and control multiple combinations of grids. However, the additive manufacturing of metal lattice porous materials have problems such as large residual stress, high surface roughness, and local stress concentration, which result in low compression brittleness and low fatigue strength. Therefore, in recent years, in addition to studying the effects of additive manufacturing process parameters on the performance of lattice structures, researchers have continued to try from the perspective of topology optimization and post-processing, and have achieved fruitful results. Combined with topology optimization design, it can make the stress distribution more uniform and better serve in different loading environments; the compressive strength and energy absorption of the gradient lattice structure are more than twice that of the uniform lattice structure; it can be reduced by heat treatment and chemical etching. The residual stress and surface roughness of the lattice structure greatly increase the fatigue strength of the lattice structure. By controlling the hierarchical porosity distribution of the unit cell structure and appropriate post-treatment, it is expected to achieve high porosity, high fatigue strength and high energy absorption at the same time. This article first states the advantages and forming criteria of additively manufactured metal lattice porous materials, and then introduces the influence of the unit cell shape, unit cell size, pillar diameter, volume porosity and other factors on the lattice structure dimensional accuracy and surface roughness. And summarized the influence of these factors on the yield strength, energy absorption rate and fatigue strength of the lattice structure. In addition, the effects of topology optimization and post-processing of the lattice structure on its performance are summarized. Finally, the obstacles of the metal lattice structure of additive manufacturing are introduced, and the future research trends are prospected.

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Status of Metal Additive Manufacturing and Its Application Research in the Field of Civil Aviation Article

CHANG Kun, LIANG Enquan, ZHANG Ren, ZHENG Min, WEI Lei, HUANG Wenjing, LIN Xin

Materials Reports 2021,35(3 ):3176 -3182. DOI:10.11896/cldb.19100153

Abstract （1296）

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Save The metal additive manufacturing technology, which is based on the primary principle of layer-by-layer rapid melting/consolidation and stacking the metal or alloy materials, can forms any shape components in a manner of “addition” manufacturing. The main advantages of additive manufacturing include high forming efficiency, high material utilization rate, low cost, the ability of manufacturing complex structure and high-melting point material. Moreover, the additive manufacturing has the technical advantages unmatched by traditional processing in the weight reduction, rapid configuration change and the integrate manufacturing of civil aviation components.
The metal raw materials and forming processes for additive manufacturing technology are rich and varied, providing much more choices for manufacturing components with different requirements in sizes, shapes, operating environments and a new path for weight reduction, efficiency improvement and cost control. Therefore, the world countries are actively formulating relevant strategic plans to seize the opportunities of additive manufacturing technologies and promote the transformation and upgrading of manufacturing industry. Global manufacturers, universities and other institutions have carried out a large amount of application researches on raw materials, processing and performances of additive manufacturing, among which the most typical example is the utilization in the cutting-edge manufacturing field of civil aviation. Different from other fields, the application of metal components in civil aircraft requires a strict airworthiness verification procedure to establish the standard specification and technical system, achieving stable and controllable manufacturing process and product quality. Then, the additive manufactured productions are allowed for being installed on airplane.
This paper introduces the domestic and international policy overview, the classification of raw materials and processing, the type of non-destructive testing, the application research status of metal additive manufacturing on civil aircraft, and points out the research and development trend of expanding the application of metal additive manufacturing in civil aviation.

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Research Status and Prospect of On-orbit Additive Manufacturing Technology for Large Space Truss Article

YANG Jie, LI Jing, WU Wenjie, YU Ning

Materials Reports 2021,35(3 ):3159 -3167. DOI:10.11896/cldb.20090363

Abstract （1467）

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Save Space truss is widely used in deep space exploration, high-resolution earth observation and other space missions. Nowadays, spacecraft and its attachments are developing into large-scale and light-weight. However, due to the constraints of space-earth carrying capacity and cost, the conventional on-site manufacturing technology cannot be satisfied by the space application requirements of large-scale, high-performance and complex structures. The on-orbit additive manufacturing (on-orbit 3D printing) technology could break the technical bottleneck of on-ground manufacturing technologies to solve the space fabrication problems, and realize the low-cost construction.
On-orbit additive manufacturing is a new fabrication technology of implement in extreme environment such as micro/zero gravity, high alternating temperature and strong radiation. Due to the short development time and low technology maturity, many scientific problems and key technical problems still need to be verified and solved. The on-orbit additive manufacturing of large space truss is an extension of the ground additive manufacturing technology. Up to now, in the field of basic research, the fused deposition modeling (FDM) technology in zero-g environment have been carried out successfully and verified the feasibility of additive manufacturing technology in microgravity. In the field of additive manufacturing equipment, the prototype of FDM aboard the space station has been developed by China, USA and Europe. However, the device applied for the ono-rbit additive manufacturing of large space truss outboard the space station is still on the concept situation. In the field of forming process research, there are few studies on the performances of on-orbit fused deposition modeling due to the restriction of equipment development. In the field of additive manufacturing in simulated microgravity environment, the anisotropy of mechanical properties of large-size, long-axial-diameter ratio polymers and their composites by melt deposition has been improved by material modification and heat control of interlayer bonding.
This paper summarizes the research status and prospect of on-orbit additive manufacturing technology for large space truss. For the on-orbit FDM technology, it views the research status of the bottleneck technique such as microgravity effects, on-orbit equipment and forming process.The challenges and development trend of large space truss fabricated by on-orbit additive manufacturing are discussed. It could provide theoretical basics and technical references for the large structure of on-orbit fabrication research.

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Influence of Processing Parameters on Microstructure and Mechanical Property of Pulsed Plasma Arc Additive Manufactured IN738LC Superalloy Article

WANG Kaibo, LIU Yuxin, LYU Yaohui, XU Binshi

Materials Reports 2021,35(2 ):2086 -2091. DOI:10.11896/cldb.19110077

Abstract （779）

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Effect of HB-CSA and Expansion Agent on Shrinkage and Cracking Performance of 3D Printing Concrete Article

CUI Tianlong, WANG Li, MA Guowei, LI Zhijian, BAI Mingke

Materials Reports 2022,36(2 ):20120078 -7. DOI:10.11896/cldb.20120078

Abstract （774）

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