Investigation on the effect of the gas-to-metal ratio on powder properties and PBF-LB/M processability

Metal powders for the laser powder bed fusion process are usually produced via gas atomization. However, due to the tight particle size distribution required for this application, the yield of the atomization process is low, resulting in a high-powder cost. In this work, atomization process parameters were varied to increase the gas-to-metal ratio to reduce the particle size distribution produced, and therefore increase the yield of the process. As a result, eight powders were produced starting from scrap AISI 136L material at different gas-to-metal ratio values, and the atomization process yield was successfully increased by 50%. First, the eight powders were characterized in terms of powder size, shape distributions, and flowability. Later, all powders were used to produce tensile specimens. The powders produced at higher yield exhibited a larger number of fine particles but slightly lower circularity, particularly in the coarse fraction. Furthermore, powders produced at a high gas-to-metal ratio demonstrated enhanced flowing properties and higher packing density. Consequently, these powders exhibited superior tensile performance, with ultimate tensile strength (UTS) ranging from 651 to 673 MPa and elongation values between 63 and 66%

Improvement of surface flatness in high precision milling

The use of high precision micro components has increased in various industrial fields in recent years. Repeatable techniques are needed to face very tight tolerances and make micro fabrication processes industrially feasible against current micro machining limitation. Improving surface flatness in high precision milling is the main target of the present research. Critical issues such as machining strategy, spindle thermal transient management and tool wear compensation were considered for machining operations on a representative part

Mathematical Models for Minimizing Total Tardiness on Parallel Additive Manufacturing Machines

In this research we tackle the scheduling problem in additive manufacturing for unrelated parallel machines. Both the nesting and scheduling aspects are considered. Parts have several alternative build orientations. The goal is to minimize the total tardiness of parts. We propose a mixed-integer linear programming model which considers the nesting subproblem as a 2D bin-packing problem, as well as a model which simplifies the nesting subproblem to a 1D bin-packing problem. The computational efficiency and properties of the proposed models are investigated by numerical experiments. Results show that the total tardiness optimization significantly increases the complexity of the problem, only the simple instances are solved optimally, whereas the makespan variant is able to solve all testing instances. Using the 1D bin-packing simplification allows for solving more instances to optimality, but with a risk of obtaining nesting-infeasibility. We also observed the compromise between the total tardiness and makespan objectives, which originates from the dilemma of “packing more parts to benefit from the common machine setup/recoating time” or “packing less parts to maintain the flexibility for handling distributed duedates”

A techno-economic approach for decision-making in metal additive manufacturing: metal extrusion versus single and multiple laser powder bed fusion

This work presents a decision-making methodology that allows the merging of quantitative and qualitative decision variables for selecting the optimal metal Additive Manufacturing (AM) technology. The approach is applied on two competing technologies in the field of metal AM industry, i.e., the metal extrusion AM process (metal FFF) and the Laser Powder Bed Fusion process (LPBF) with single and multiple lasers, which represent the benchmark solution currently on the market. A comprehensive techno-economical comparison is presented where the two processes are analysed in terms of process capabilities (quality, easiness of use, setup time, range of possible materials, etc.) and costs, considering two different production scenarios and different parts’ geometries. In the first scenario, the AM system is assumed to be dedicated to one single part production while in this second scenario, the AM system is assumed to be saturated, as devoted to producing a wide mix of part types. For each scenario, two different part types made of 17–4 PH stainless steel are considered as a reference to investigate the effect of shape complexity, part size and production times to select the best technology when metal FFF and LPBF must be considered. The first part type refers to an extrusion die, to represent typical shapes of interest in the tooling industry, while the second part type is an impeller which can be used in many different industrial sectors, ranging from oil and gas to aerospace. In order to include quantitative and qualitative criteria, a decision-making model based on Analytic Hierarchy Process (AHP) is proposed as the enabler tool for decision making. The proposed approach allows to determine the most effective solution depending on the different production configurations and part types and can be used as a guideline and extended to include other technologies in the field of metal AM. On the other side, the critical discussion of the criteria selected, and the results achieved allow to highlight the pros and cons of the competing technologies, thus defining the existing limits to define directions for future research

Optimization of cutting conditions using an evolutive online procedure

This paper proposes an online evolutive procedure to optimize the Material Removal Rate in a turning process considering a stochastic constraint. The usual industrial approach in finishing operations is to change the tool insert at the end of each machining feature to avoid defective parts. Consequently, all parts are produced at highly conservative conditions (low levels of feed and speed), and therefore, at low productivity. In this work, a framework to estimate the stochastic constraint of tool wear during the production of a batch is proposed. A simulation campaign was carried out to evaluate the performances of the proposed procedure. The results showed that it was possible to improve the Material Removal Rate during the production of the batch and keeping the probability of defective parts under a desired level

Geometrical quality improvement of high aspect ratio micromilled pins

Mechanical micromachining is a reference process for producing 3D complex microparts and specifically tools for other processes as molds for micro injection molding and males for microextrus ion. High aspect ratio features as bars , ribs , pins , etc. are very common in these cases and their quality strongly affects the final plastic part quality. This paper focuses on high aspect ratio steel pins, since they are one of the most challenging features to be manufactured on microextrusion males. The pin geometrical quality has been defined according to the standards and a suitable measurement procedure has been set up with the aim to study the micromilling process parameters effects on the most representative pin quality characteristics . The statistical analysis results point out some criteria for selecting the best process parameters

Applicability of an orthogonal cutting slip-line field model for the microscale

Mechanical micromachining is a very flexible and widely exploited process, but its knowledge should still be improved since several incompletely explained phenomena affect the microscale chip removal. Several models have been developed to describe the machining process, but only some of them consider a rounded edge tool, which is a typical condition in micromachining. Among these models, the Waldorf’s slip-line field model for the macroscale allows to separately evaluate shearing and ploughing force components in orthogonal cutting conditions; therefore, it is suitable to predict cutting forces when a large ploughing action occurs, as in micromachining. This study aims at demonstrating how this model is suitable also for micromachining conditions. To achieve this goal, a clear and repeatable procedure has been developed for objectively validating its force prediction performance at low uncut chip thickness (less than 50 mm) and relatively higher cutting edge radius. The proposed procedure makes the model generally applicable after a suitable and nonextensive calibration campaign. This article shows how calibration experiments can be selected among the available cutting trial database based on the model force prediction capability. Final validation experiments have been used to show how the model is robust to a cutting speed variation even if the cutting speed is not among the model quantities. A suitable set-up, especially designed for microturning conditions, has been used to measure forces and chip thickness. Tests have been performed on 6082-T6 Aluminum alloy with different cutting speeds and different ratios between uncut chip thickness and cutting edge radius

Workpiece surface flatness improvement by tool length compensation in micromilling

Micromilling quality improvement requires an accurate management of all the involved resources (machine tool, tool, fixture, workpiece). Specific attention has to be paid, comparing to macro operations, also to machining strategies and tool and workpiece measuring strategies. The extreme workpiece accuracy requires to reinterpret some procedures, already applied in the macro world, with the purpose to minimize errors. It is the case of the tool length compensation, which plays a strong role on the micromilling overall performance. In order to demonstrate the importance of factors affecting tool length, as machine spindle thermal transients and tool wear assessment, the present paper takes the workpiece flatness deviation as a case study and presents a manufacturing and measuring strategy able to meet a challenging flatness constraint

OFF-ON-OFF Fluorescence Switch with T-Latch Function

A novel molecular system with characteristics of an OFF-ON-OFF fluorescence switch was designed to integrate the function of a T-latch. In detail, a receptor(1)-fluorophore-receptor(2) architecture was adopted to achieve fluorescence switching upon addition of protons

Neutrophil Extracellular Traps in Breast Cancer and Beyond: Current Perspectives on NET Stimuli, Thrombosis and Metastasis, and Clinical Utility for Diagnosis and Treatment

Abstract The formation of neutrophil extracellular traps (NETs), known as NETosis, was first observed as a novel immune response to bacterial infection, but has since been found to occur abnormally in a variety of other inflammatory disease states including cancer. Breast cancer is the most commonly diagnosed malignancy in women. In breast cancer, NETosis has been linked to increased disease progression, metastasis, and complications such as venous thromboembolism. NET-targeted therapies have shown success in preclinical cancer models and may prove valuable clinical targets in slowing or halting tumor progression in breast cancer patients. We will briefly outline the mechanisms by which NETs may form in the tumor microenvironment and circulation, including the crosstalk between neutrophils, tumor cells, endothelial cells, and platelets as well as the role of cancer-associated extracellular vesicles in modulating neutrophil behavior and NET extrusion. The prognostic implications of cancer-associated NETosis will be explored in addition to development of novel therapeutics aimed at targeting NET interactions to improve outcomes in patients with breast cancer