A Study on the Laser Spatter and the Oxidation Reactions During Selective Laser Melting of 316L Stainless Steel, Al-Si10-Mg, and Ti-6Al-4V

Hague, Richard; Tuck, Chris; Simonelli, Marco; Tuck, Christopher; Aboulkhair, Nesma T.; Maskery, Ian; Ashcroft, Ian; Wildman, Ricky D.; Hague, Richard J.M.

doi:10.1007/s11661-015-2882-8

A voxel-based method of constructing and skinning conformal and functionally graded lattice structures suitable for additive manufacturing (2016)
Journal Article
Aremu, A., Brennan-Craddock, J., Panesar, A., Ashcroft, I., Hague, R. J., Wildman, R. D., & Tuck, C. (in press). A voxel-based method of constructing and skinning conformal and functionally graded lattice structures suitable for additive manufacturing. Additive Manufacturing, 13, https://doi.org/10.1016/j.addma.2016.10.006

Additive Manufacturing (AM) enables the production of geometrically complex parts that are difficult to manufacture by other means. However, conventional CAD systems are limited in the representation of such parts. This issue is exacerbated when latt... Read More about A voxel-based method of constructing and skinning conformal and functionally graded lattice structures suitable for additive manufacturing.

A combined inverse finite element – elastoplastic modelling method to simulate the size-effect in nanoindentation and characterise materials from the nano to micro-scale (2016)
Journal Article
Chen, X., Ashcroft, I., Wildman, R. D., & Tuck, C. (2017). A combined inverse finite element – elastoplastic modelling method to simulate the size-effect in nanoindentation and characterise materials from the nano to micro-scale. International Journal of Solids and Structures, 104-105, 25-34. https://doi.org/10.1016/j.ijsolstr.2016.11.004

Material properties such as hardness can be dependent on the size of the indentation load when that load is small, a phenomenon known as the indentation size effect (ISE). In this work an inverse finite element method (IFEM) is used to investigate th... Read More about A combined inverse finite element – elastoplastic modelling method to simulate the size-effect in nanoindentation and characterise materials from the nano to micro-scale.

3D inkjet-printed UV-curable inks for multi-functional electromagnetic applications (2016)
Journal Article
Saleh, E., Woolliams, P., Clarke, B., Gregory, A., Greedy, S., Smartt, C., …Tuck, C. (2017). 3D inkjet-printed UV-curable inks for multi-functional electromagnetic applications. Additive Manufacturing, 13, 143-148. https://doi.org/10.1016/j.addma.2016.10.002

Inkjet printing of multiple materials is usually processed in multiple steps due to various jetting and curing/sintering conditions. In this paper we report on the development of all inkjet-printed UV-curable electromagnetic responsive inks in a sing... Read More about 3D inkjet-printed UV-curable inks for multi-functional electromagnetic applications.

A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting (2016)
Journal Article
Maskery, I., Aboulkhair, N., Aremu, A., Tuck, C., Ashcroft, I., Wildman, R., & Hague, R. (2016). A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting. Materials Science and Engineering: A, 670, 264-274. https://doi.org/10.1016/j.msea.2016.06.013

Metal components with applications across a range of industrial sectors can be manufactured by selective laser melting (SLM). A particular strength of SLM is its ability to manufacture components incorporating periodic lattice structures not realisab... Read More about A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting.

Understanding the effect of laser scan strategy on residual stress in selective laser melting through thermo-mechanical simulation (2016)
Journal Article
Parry, L., Ashcroft, I., & Wildman, R. D. (2016). Understanding the effect of laser scan strategy on residual stress in selective laser melting through thermo-mechanical simulation. Additive Manufacturing, 12(A), https://doi.org/10.1016/j.addma.2016.05.014

Selective laser melting (SLM) is an attractive technology, enabling the manufacture of customised, complex metallic designs, with minimal wastage. However, uptake by industry is currently impeded by several technical barriers, such as the control of... Read More about Understanding the effect of laser scan strategy on residual stress in selective laser melting through thermo-mechanical simulation.

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.

Metallurgy of high-silicon steel parts produced using selective laser melting (2016)
Journal Article
Garibaldi, M., Ashcroft, I., Simonelli, M., & Hague, R. (2016). Metallurgy of high-silicon steel parts produced using selective laser melting. Acta Materialia, 110, https://doi.org/10.1016/j.actamat.2016.03.037

The metallurgy of high-silicon steel (6.9%wt.Si) processed using Selective Laser Melting (SLM) is presented for the first time in this study. High-silicon steel has great potential as a soft magnetic alloy, but its employment has been limited due to... Read More about Metallurgy of high-silicon steel parts produced using selective laser melting.

An investigation into reinforced and functionally graded lattice structures (2016)
Journal Article
Maskery, I., Hussey, A., Panesar, A., Aremu, A., Tuck, C., Ashcroft, I., & Hague, R. J. (in press). An investigation into reinforced and functionally graded lattice structures. Journal of Cellular Plastics, https://doi.org/10.1177/0021955X16639035

Lattice structures are regarded as excellent candidates for use in lightweight energy absorbing applications, such as crash protection. In this paper we investigate the crushing behaviour, mechanical properties and energy absorption of lattices made... Read More about An investigation into reinforced and functionally graded lattice structures.

The thermo-mechanical degradation of ethylene vinyl acetate used as a solar panel adhesive and encapsulant (2016)
Journal Article
Badiee, A., Ashcroft, I., & Wildman, R. D. (2016). The thermo-mechanical degradation of ethylene vinyl acetate used as a solar panel adhesive and encapsulant. International Journal of Adhesion and Adhesives, 68, 212-218. https://doi.org/10.1016/j.ijadhadh.2016.03.008

© 2016 The Authors. Published by Elsevier Ltd. The thermal ageing of an ethylene-vinyl acetate (EVA) polymer used as an adhesive and encapsulant in a photovoltaic module has been investigated. The EVA is used to bond the silicon solar cells to the fr... Read More about The thermo-mechanical degradation of ethylene vinyl acetate used as a solar panel adhesive and encapsulant.

Surface microstructuring to modify wettability for 3D printing of nano-filled inks (2016)
Journal Article
Vafaei, S., Tuck, C., Ashcroft, I., & Wildman, R. D. (2016). Surface microstructuring to modify wettability for 3D printing of nano-filled inks. Chemical Engineering Research and Design, 109, https://doi.org/10.1016/j.cherd.2016.02.004

This paper investigates the effect of surface wettability on the cross-sectional profiles of printed nanofluid inks which can have a significant role on conductivity of printed lines that are used in the production of printed electronics. Glass subst... Read More about Surface microstructuring to modify wettability for 3D printing of nano-filled inks.

Shape complexity and process energy consumption in electron beam melting: a case of something for nothing in additive manufacturing? (2016)
Journal Article
Baumers, M., Tuck, C., Wildman, R. D., Ashcroft, I., & Hague, R. J. (in press). Shape complexity and process energy consumption in electron beam melting: a case of something for nothing in additive manufacturing?. Journal of Industrial Ecology, https://doi.org/10.1111/jiec.12397

Additive manufacturing (AM) technology is capable of building up component geometry in a layer-by-layer process, entirely without tools, molds, or dies. One advantage of the approach is that it is capable of efficiently creating complex product geome... Read More about Shape complexity and process energy consumption in electron beam melting: a case of something for nothing in additive manufacturing?.

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. https://doi.org/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.

Quantification and characterisation of porosity in selectively laser melted Al–Si10–Mg using x-ray computed tomography (2016)
Journal Article
Maskery, I., Aboulkhair, N., Corfield, M., Tuck, C., Clare, A., Leach, R. K., …Hague, R. J. (2016). Quantification and characterisation of porosity in selectively laser melted Al–Si10–Mg using x-ray computed tomography. Materials Characterization, 111, https://doi.org/10.1016/j.matchar.2015.12.001

We used X-ray computed tomography (CT), microscopy and hardness measurements to study Al–Si10–Mg produced by selective laser melting (SLM). Specimens were subject to a series of heat treatments including annealing and precipitation hardening. The spe... Read More about Quantification and characterisation of porosity in selectively laser melted Al–Si10–Mg using x-ray computed tomography.

On the formation of AlSi10Mg single tracks and layers in selective laser melting: Microstructure and nano-mechanical properties (2015)
Journal Article
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.

Design Framework for Multifunctional Additive Manufacturing: Placement and Routing of Three-Dimensional Printed Circuit Volumes (2015)
Journal Article
Panesar, A., Brackett, D., Ashcroft, I., Wildman, R. D., & Hague, R. J. (2015). Design Framework for Multifunctional Additive Manufacturing: Placement and Routing of Three-Dimensional Printed Circuit Volumes. Journal of Mechanical Design, 137(11), Article 111414. https://doi.org/10.1115/1.4030996

© 2015 by ASME. A framework for the design of additively manufactured (AM) multimaterial parts with embedded functional systems is presented (e.g., structure with electronic/electrical components and associated conductive paths). Two of the key stran... Read More about Design Framework for Multifunctional Additive Manufacturing: Placement and Routing of Three-Dimensional Printed Circuit Volumes.

Fibre architecture design of 3D woven composite with genetic algorithms: a unit cell based optimisation framework and performance assessment (2015)
Conference Proceeding
Zeng, X., Long, A. C., Ashcroft, I., & Potluri, P. (2015). Fibre architecture design of 3D woven composite with genetic algorithms: a unit cell based optimisation framework and performance assessment.

There are vast possibilities in fibre architecture design of 3D woven reinforcement. This paper considers the application of Genetic Algorithm (GA) in 3D woven composites optimisation. A set of real and integral variables, representing 3D fibre archi... Read More about Fibre architecture design of 3D woven composite with genetic algorithms: a unit cell based optimisation framework and performance assessment.

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.

Mechanical Properties of Ti-6Al-4V Selectively Laser Melted Parts with Body-Centred-Cubic Lattices of Varying cell size (2015)
Journal Article
Maskery, I., Aremu, A., Simonelli, M., Tuck, C., Wildman, R., Ashcroft, I., & Hague, R. (2015). Mechanical Properties of Ti-6Al-4V Selectively Laser Melted Parts with Body-Centred-Cubic Lattices of Varying cell size. Experimental Mechanics, 55(7), 1261-1272. https://doi.org/10.1007/s11340-015-0021-5

Significant weight savings in parts can be made through the use of additive manufacture (AM), a process which enables the construction of more complex geometries, such as functionally graded lattices, than can be achieved conventionally. The existing... Read More about Mechanical Properties of Ti-6Al-4V Selectively Laser Melted Parts with Body-Centred-Cubic Lattices of Varying cell size.

A Study on the Laser Spatter and the Oxidation Reactions During Selective Laser Melting of 316L Stainless Steel, Al-Si10-Mg, and Ti-6Al-4V (2015)
Journal Article
Hague, R., Tuck, C., Simonelli, M., Tuck, C., Aboulkhair, N. T., Maskery, I., …Hague, R. J. (2015). A Study on the Laser Spatter and the Oxidation Reactions During Selective Laser Melting of 316L Stainless Steel, Al-Si10-Mg, and Ti-6Al-4V. Metallurgical and Materials Transactions A, 46(9), 3842-3851. https://doi.org/10.1007/s11661-015-2882-8

The creation of an object by selective laser melting (SLM) occurs by melting contiguous areas of a powder bed according to a corresponding digital model. It is therefore clear that the success of this metal Additive Manufacturing (AM) technology reli... Read More about A Study on the Laser Spatter and the Oxidation Reactions During Selective Laser Melting of 316L Stainless Steel, Al-Si10-Mg, and Ti-6Al-4V.

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