Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 - part I: the effects of the process parameters

The sustainable energy transition has spurred the development of technologies that minimize material and energy waste, such as additive manufacturing (AM). Laser metal deposition (LMD) is a promising AM technique, but its complexity and limited automation hinder its implementation in production chains. To enhance productivity, the high deposition rate LMD (HDR-LMD) technology has been developed, requiring advanced equipment and powerful laser sources. In contrast, the conventional LMD (C-LMD) process is simpler and less expensive to implement. This study aims to optimize the productivity and efficiency of C-LMD by adjusting laser power, scan speed, powder feed rate, and standoff distance on Inconel 718 single tracks. An innovative approach eliminates the need for cutting specimens to evaluate single tracks, allowing comprehensive geometric and performance characterization with limited operator involvement, making the analysis quicker and more robust. An extensive experimental campaign was conducted to examine the influence of process parameters on track geometry, productivity, and efficiency. A multi-objective optimization procedure identified parameter combinations maximizing productivity while maintaining high efficiency and desirable clad shape. The study attained deposition rates ranging from 700 to 800 g/h, with powder catchment efficiency ranging between 75 and 90%. These results were achieved using parameters including 1775 W of laser power, scan speeds ranging from 960 to 1140 mm/min, powder feed rates between 810 and 1080 g/h, and standoff distance of 9 mm. The study also clearly indicated that further potential for improving C-LMD process performance may be possible. The findings gathered in this paper are the base for the further optimization presented in the second part of the work, which is focused on multi-pass multi-layer and reaches deposition rates of 1500 g/h, promoting the implementation of C-LMD process at industrial level

Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 – Part II: advancing the process performance

This paper is the second part of a work focused on optimizing the performance of conventional Laser Metal Deposition (C-LMD) process for Inconel 718 (IN718). In Part I, through an extensive experimental campaign on single tracks, the interplay between process parameters and their impact on the deposition rate, powder catchment efficiency, and clad geometry is examined. The parameters investigated include laser power, scan speed, powder feed rate, and standoff distance. By systematically adjusting these parameters, the aim is to identify optimal conditions that maximize productivity while maintaining a favorable clad shape for multi-pass multi-layer depositions. Part II starts from the findings and results of Part I by continuing the optimization on thick wall structures. These are utilized to assess the effect of 3D geometrical process parameters, specifically hatch spacing and Z-step, on process performance and stability. Based on the findings, further optimization procedure is presented, pushing the boundaries of the C-LMD process for IN718. By fine-tuning the process parameters, the capability of the C-LMD process to deposit fully dense IN718 with a productivity of 1500 g/h and a powder catchment efficiency of 70% is demonstrated. These results highlight the potential of C-LMD as a viable manufacturing technique for efficiently fabricating large components. Overall, this study contributes to a deeper understanding of the relationship between process parameters and performance in C-LMD for IN718. The insights gained from this research can guide the development of efficient and cost-effective LMD strategies, facilitating the practical implementation of this process in various industries

Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Featured Application: Laser metal deposition of large axisymmetric components. Laser metal deposition (LMD) is an additive manufacturing (AM) process capable of producing large components for the aerospace and oil and gas industries. This is achieved by mounting the deposition head on a motion system, such as an articulated robot or a gantry computer numerical control (CNC) machine, which can scan large volumes. Articulated robots are more flexible and less expensive than CNC machines, which on the other hand, are more accurate. This study compares two LMD systems with different motion architectures (i.e., an eight-axis articulated robot and a five-axis CNC gantry machine) in producing a large gas turbine axisymmetric component. The same process parameters were applied to both machines. The deposited components show no significant differences in geometry, indicating that the different performances in terms of accuracy of the two machines do not influence the outcome. The findings indicate that LMD can consistently produce large-scale axisymmetric metal components with both types of equipment. For such an application, the user has the option of using an articulated robot when flexibility and cost are essential, such as in a research context, or a CNC machine where ease of programming and process standardization are important elements, such as in an industrial environment

Lightweight error correction technique in industrial IEEE802.15.4 networks

Industrial Wireless Sensor Networks (IWSNs) are nowadays becoming more and more popular thanks to their flexibility and pervasive monitoring capabilities to support process automation and remote maintenance applications. In such a scenario, channel errors due to the wireless medium can result in data packet losses, and consequently in unreliable IWSN services. To mitigate the above reported problem, this paper presents a lightweight error correction scheme specially developed for IEEE802.15.4-based IWSNs. By adding error correction and detection information inside the IEEE802.15.4 MAC data frame, the proposed FEC scheme is able to guarantee a backward compatibility with the standard while providing advanced capabilities in recovering data packets affected by bit errors. In the paper the benefits of the proposed technique are first evaluated through simulated loss traces, then they are validated in a real environment by considering real loss traces collected in an electricity power plant. The proposed error correction scheme is able to recover around 50% of the data packets that would be lost in case of a standard communication without any error correction capability

Isocitrate dehydrogenase 1 mutations (IDH1) and p16/CDKN2A copy number change in conventional chondrosarcomas.

To determine whether IDH1 mutations are present in primary and relapsed (local and distal) conventional central chondrosarcomas; and secondly, to assess if loss of p16/CDKN2A is associated with tumour grade progression, 102 tumour samples from 37 patients, including material from presenting and relapse events, were assessed. All wild-type cases for IDH1 R132 substitutions were also tested for IDH2 R172 and R140 alterations. The primary tumour and the most recent relapse sample were tested for p16/CDKN2A by interphase fluorescence in situ hybridisation. An additional 120 central cartilaginous tumours from different patients were also tested for p16/CDKN2A copy number. The study shows that if an IDH1 mutation were detected in a primary central chondrosarcoma, it is always detected at the time of presentation, and the same mutation is detected in local recurrences and metastatic events. We show that p16/CDKN2A copy number variation occurs subsequent to the IDH1 mutation, and confirm that p16/CDKN2A copy number variation occurs in 75 % of high grade central chondrosarcomas, and not in low grade cartilaginous tumours. Finally, p16/CDKN2A copy number variation is seen in both the IDH1 wild-type and mutant cartilaginous central tumours

Cellular Angiofibroma of Oral Mucosa: Report of Two Cases

Cellular angiofibroma is a benign vascular neoplasm that typically arises in the vulva, perineal, and paratesticular region. Microscopically the lesions exhibit multiple small, non-dilated capillary channels, many of which contain erythrocytes. The endothelial lining cells are prominent, with monomorphic oval nuclei. Interposed among the vessels are both delicate and mature collagen fibers with fibroblastic hypercellularity that is variable in older lesions where sclerosis is prominent. The lesions usually do not recur following simple excision. Recent evidence indicates that cellular angiofibromas may be cytogenetically related to spindle cell lipoma. This represents the first reported instances of cellular angiofibroma in the oral cavity

Osteopathy students profile in Italy: A cross sectional census

Introduction: The Osteopathy Students Analysis (OSA) aims to profile osteopathy students in Italy as a target population in terms of sociodemographic characteristics, geographical distribution, health status, and previous and ongoing education specifications. Materials and methods: The OSA used a cross-sectional design. A Web-based survey was distributed to the Italian Osteopathic Education Institutions (OEIs). The OSA survey was composed of items organised into four sections: 1. Sociodemographic characteristics (11 items); 2. Geographical distribution (5 items); 3. Health status (3 items); 4. Previous and ongoing education specifications (16 items). A descriptive sample population analysis was performed. Dichotomous and categorical variables were presented as frequencies and percentages, and continuous variables were displayed as means and standard deviations. Some variables were analysed using a pentenary distribution. Results: 49 out of the 61 OEIs identified matched the inclusion criteria, and among these, 22 accepted to propose the enrolment of their students into the study. The survey was administered to 4,720 students from all the participant OEIs. A total of 3,762 students responded to the survey, accounting for an estimated response rate of 53.7%. The majority of respondents were men (54%), with an average age of 26.9 ± 6.5 years. Almost the totality of the sample was composed of the European ethnic group (99.1%). Respondents were predominantly born in Italy (97.2%). The majority of the sample reported being in good (49.5%) to excellent (38.6%) health. To date, osteopathy students are almost evenly distributed between the two types of curricula (T1 = 46.6%; T2 = 53.4%). Conclusions: The OSA is the first study that aims to profile Italian osteopathy students as a target population in terms of sociodemographic characteristics, geographical distribution, health status, and previous and ongoing education specifications. Future studies should focus on investigating the correlation between the sociodemographic characteristics of students and their academic performance