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Towards digital metal additive manufacturing via high-temperature drop-on-demand jetting (2019)
Journal Article
Simonelli, M., Aboulkhair, N., Rasa, M., East, M., Tuck, C., Wildman, R., …Hague, R. (2019). Towards digital metal additive manufacturing via high-temperature drop-on-demand jetting. Additive Manufacturing, https://doi.org/10.1016/j.addma.2019.100930

Drop-on-demand jetting of metals offers a fully digital manufacturing approach to surpass the limitations of the current generation powder-based additive manufacturing technologies. However, research on this topic has been restricted mainly to near-n... Read More about Towards digital metal additive manufacturing via high-temperature drop-on-demand jetting.

Evolution of carbon nanotubes and their metallurgical reactions in Al-based composites in response to laser irradiation during selective laser melting (2019)
Journal Article
Aboulkhair, N. T., Simonelli, M., Salama, E., Rance, G., Neate, N. C., Tuck, C. J., …Hague, R. J. (2019). Evolution of carbon nanotubes and their metallurgical reactions in Al-based composites in response to laser irradiation during selective laser melting. Materials Science and Engineering: A, 765, doi:10.1016/j.msea.2019.138307

Aluminium-based composites reinforced with carbon nanotubes are widely sought for their outstanding metallurgical and structural properties that largely depend on the manufacturing route. In this work, the process-structure-property relationship for... Read More about Evolution of carbon nanotubes and their metallurgical reactions in Al-based composites in response to laser irradiation during selective laser melting.

A comparison of Ti-6Al-4V in-situ alloying in Selective Laser Melting using simply-mixed and satellited powder blend feedstocks (2018)
Journal Article
Simonelli, M., Aboulkhair, N. T., Cohen, P., Murray, J. W., Clare, A. T., Tuck, C., & Hague, R. J. (in press). A comparison of Ti-6Al-4V in-situ alloying in Selective Laser Melting using simply-mixed and satellited powder blend feedstocks. Materials Characterization, doi:10.1016/j.matchar.2018.05.039

In-situ alloying within laser powder-bed fusion, specifically Selective Laser Melting (SLM), has been investigated for the formulation of novel alloys from elemental powders to extend the benefits offered by these technologies. Inadequate preparation... Read More about A comparison of Ti-6Al-4V in-situ alloying in Selective Laser Melting using simply-mixed and satellited powder blend feedstocks.

Compressive failure modes and energy absorption in additively manufactured double gyroid lattices (2018)
Journal Article
Maskery, I., Aboulkhair, N. T., Aremu, A., Tuck, C., & Ashcroft, I. (in press). Compressive failure modes and energy absorption in additively manufactured double gyroid lattices. Additive Manufacturing, 16, doi:10.1016/j.addma.2017.04.003

Lattice structures are excellent candidates for lightweight, energy absorbing applications such as personal protective equipment. In this paper we explore several important aspects of lattice design and production by metal additive manufacturing, inc... Read More about Compressive failure modes and energy absorption in additively manufactured double gyroid lattices.

The application of composite through-thickness assessment to additively manufactured structures (2017)
Conference Proceeding
Bitar, I., Aboulkhair, N., & Leach, R. (2017). The application of composite through-thickness assessment to additively manufactured structures. In Solid Freeform Fabrication 2017: Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference, 616-632

This study looks into the applicability of through-thickness assessment to additive manufacturing (AM) carbon-fibre reinforced polymers (CFRPs). The study utilised a material extrusion printer that uses fused filament fabrication and composite filame... Read More about The application of composite through-thickness assessment to additively manufactured structures.

A Tripropylene Glycol Diacrylate-based Polymeric Support Ink for Material Jetting (2017)
Journal Article
Aboulkhair, N., He, Y., Zhang, F., Saleh, E., Vaithilingam, J., Aboulkhair, N. T., …Wildman, R. D. (2017). A Tripropylene Glycol Diacrylate-based Polymeric Support Ink for Material Jetting. Additive Manufacturing, 16, 153-161. https://doi.org/10.1016/j.addma.2017.06.001

© 2017 Support structures and materials are indispensable components in many Additive Manufacturing (AM) systems in order to fabricate complex 3D structures. For inkjet-based AM techniques (known as Material Jetting), there is a paucity of studies o... Read More about A Tripropylene Glycol Diacrylate-based Polymeric Support Ink for Material Jetting.

Selective laser melting of aluminium alloys (2017)
Journal Article
Aboulkhair, N. T., Everitt, N. M., Maskery, I., Ashcroft, I., & Tuck, C. (2017). Selective laser melting of aluminium alloys. MRS Bulletin, 42(4), 311-319. https://doi.org/10.1557/mrs.2017.63

Metal additive manufacturing (AM) processes, such as selective laser melting, enable powdered metals to be formed into arbitrary 3D shapes. For aluminium alloys, which are desirable in many high-value applications for their low density and good mecha... Read More about Selective laser melting of aluminium alloys.

Fractal scan strategies for selective laser melting of ‘unweldable’ nickel superalloys (2017)
Journal Article
Catchpole-Smith, S., Aboulkhair, N., Parry, L., Tuck, C., Ashcroft, I., & Clare, A. (in press). Fractal scan strategies for selective laser melting of ‘unweldable’ nickel superalloys. Additive Manufacturing, doi:10.1016/j.addma.2017.02.002

The high thermal gradients experienced during manufacture via selective laser melting commonly result in cracking of high γ/γ′ Nickel based superalloys. Such defects cannot be tolerated in applications where component integrity is of paramount import... Read More about Fractal scan strategies for selective laser melting of ‘unweldable’ nickel superalloys.

Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality (2016)
Journal Article
Aboulkhair, N. T., Maskery, I., Tuck, C., Ashcroft, I., & Everitt, N. M. (2016). Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality. Materials and Design, 104, 174-182. https://doi.org/10.1016/j.matdes.2016.05.041

Selective laser melting (SLM) is being widely utilised to fabricate intricate structures used in various industries. Widening the range of applications that can benefit from such promising technology requires validating SLM parts in load bearing appl... Read More about Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality.

The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment (2016)
Journal Article
Aboulkhair, N. T., Maskery, I., Tuck, C., Ashcroft, I., & Everitt, N. M. (2016). The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment. Materials Science and Engineering: A, 667, 139-146. https://doi.org/10.1016/j.msea.2016.04.092

Selective laser melting (SLM) of aluminium is of research interest because of its potential benefits to high value manufacturing applications in the aerospace and automotive industries. In order to demonstrate the credibility of SLM Al parts, their m... Read More about The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment.

Nanoindentation shows uniform local mechanical properties across melt pools and layers produced by selective laser melting of AlSi10Mg alloy (2016)
Journal Article
Everitt, N. M., Aboulkhair, N. T., Maskery, I., Tuck, C., & Ashcroft, I. (2016). Nanoindentation shows uniform local mechanical properties across melt pools and layers produced by selective laser melting of AlSi10Mg alloy. doi:10.5185/amlett.2016.6171

Single track and single layer AlSi10Mg has been produced by selective laser melting (SLM) of alloy powder on a AlSi12 cast substrate. The SLM technique produced a cellular-dendritic ultra-fined grained microstructure. Chemical composition mapping an... Read More about Nanoindentation shows uniform local mechanical properties across melt pools and layers produced by selective laser melting of AlSi10Mg alloy.

On the formation of AlSi10Mg single tracks and layers in selective laser melting: Microstructure and nano-mechanical properties (2015)
Journal Article
Tuck, C., Aboulkhair, N. T., Maskery, I., Tuck, C., Ashcroft, I., & Everitt, N. M. (2016). On the formation of AlSi10Mg single tracks and layers in selective laser melting: Microstructure and nano-mechanical properties. Journal of Materials Processing Technology, 230, 88-98. https://doi.org/10.1016/j.jmatprotec.2015.11.016

Selective laser melting (SLM) is a relatively new manufacturing technique that can be used to process a range of materials. Aluminum alloys are potential candidates for SLM but are more difficult to process than the titanium alloys more commonly used... Read More about On the formation of AlSi10Mg single tracks and layers in selective laser melting: Microstructure and nano-mechanical properties.

On the Precipitation Hardening of Selective Laser Melted AlSi10Mg (2015)
Journal Article
Tuck, C., Aboulkhair, N. T., Tuck, C., Ashcroft, I., Maskery, I., & Everitt, N. M. (2015). On the Precipitation Hardening of Selective Laser Melted AlSi10Mg. Metallurgical and Materials Transactions A, 46(8), 3337-3341. https://doi.org/10.1007/s11661-015-2980-7

Precipitation hardening of selective laser melted AlSi10Mg was investigated in terms of solution heat treatment and aging duration. The influence on the microstructure and hardness was established, as was the effect on the size and density of Si part... Read More about On the Precipitation Hardening of Selective Laser Melted AlSi10Mg.

Nano-hardness and microstructure of selective laser melted AlSi10Mg scan tracks (2015)
Conference Proceeding
Aboulkhair, N. T., Tuck, C., Maskery, I., Ashcroft, I., & Everitt, N. (2015). Nano-hardness and microstructure of selective laser melted AlSi10Mg scan tracks. In Industrial Laser Applications Symposium (ILAS 2015)doi:10.1117/12.2190015

Selective laser melting (SLM) of aluminium alloys faces more challenges than other ongoing alloys such as stainless steels and titanium alloys because of the material’s properties. It is important to study single scan tracks if high density large par... Read More about Nano-hardness and microstructure of selective laser melted AlSi10Mg scan tracks.

Reducing porosity in AlSi10Mg parts processed by selective laser melting (2014)
Journal Article
Aboulkhair, N. T., Everitt, N. M., Ashcroft, I., & Tuck, C. (2014). Reducing porosity in AlSi10Mg parts processed by selective laser melting. Additive Manufacturing, 1-4, 77-86. https://doi.org/10.1016/j.addma.2014.08.001

Selective laser melting (SLM) is widely gaining popularity as an alternative manufacturing technique for complex and customized parts. SLM is a near net shape process with minimal post processing machining required dependent upon final application. T... Read More about Reducing porosity in AlSi10Mg parts processed by selective laser melting.