Deposits of clastic carbonate-dominated (calciclastic) sedimentary slope systems in the rock record have been identified mostly as linearly-consistent carbonate apron deposits, even though most ancient clastic carbonate slope deposits fit the submarine fan systems better. Calciclastic submarine fans are consequently rarely described and are poorly understood. Subsequently, very little is known especially in mud-dominated calciclastic submarine fan systems. Presented in this study are a sedimentological core and petrographic characterisation of samples from eleven boreholes from the Lower Carboniferous of Bowland Basin (Northwest England) that reveals a >250 m thick calciturbidite complex deposited in a calciclastic submarine fan setting. Seven facies are recognised from core and thin section characterisation and are grouped into three carbonate turbidite sequences. They include: 1) Calciturbidites, comprising mostly of highto low-density, wavy-laminated bioclast-rich facies; 2) low-density densite mudstones which are characterised by planar laminated and unlaminated muddominated facies; and 3) Calcidebrites which are muddy or hyper-concentrated debrisflow deposits occurring as poorly-sorted, chaotic, mud-supported floatstones. These

Phd by thesis

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

In the present study, we examined changes in the microstructure and mechanical properties of AlSi10Mg alloy, initially fabricated using selective laser melting (SLM) combined with a powder-bed system, by applying heat treatments at temperatures of either 300 or 530 °C. The as-fabricated samples exhibited a characteristic microstructural morphology and {001} texture. Melt pools corresponding to the locally melted and rapidly solidified regions were found to be composed of several columnar α-Al grains surrounded by fine eutectic Si particles. A fine dislocation substructure consisting of low-angle boundaries is present within the columnar α-Al grains. At elevated temperatures, fine Si phase precipitates within the columnar α-Al phase and coarsening of the eutectic Si particles occurs. These fine Si particles inhibit grain growth in the α-Al matrix, resulting in the microstructural morphology and [001] texture observed in the heat-treated samples. The dislocation substructure disappears in the columnar α-Al grains. Furthermore, the formation of a stable intermetallic phase occurs, reaching microstructural equilibrium after long-term exposure. The as-fabricated specimen exhibits a high tensile strength of approximately 480 MPa. The strength is independent of the tensile direction, that is, normal and parallel to the building direction. In contrast, the tensile ductility is found to be direction-dependent, and is therefore responsible for a fracture preferentially occurring at a melt pool boundary. The direction-dependence of the tensile ductility was not found in the specimen that had been heat-treated at 530 °C. The present results provide new insights into the control of the direction-dependence of the tensile properties of AlSi10Mg alloys fabricated by SLM.

Change in microstructure of selectively laser melted AlSi10Mg alloy with heat treatments

• Common defects and anomalies in powder bed fusion metal additive manufacturing. • Formation mechanism and practical mitigation strategies are discussed. • Defects/anomalies are classified as powder-related, processing-related, and post-processing related issues. • Properties such as mechanical behavior and corrosion resistance of defective parts are discussed. • Current challenges, gaps, and future trends are discussed. Metal additive manufacturing is a disruptive technology that is revolutionizing the manufacturing industry. Despite its unrivaled capability for directly fabricating metal parts with complex geometries, the wide realization of the technology is currently limited by microstructural defects and anomalies, which could significantly degrade the structural integrity and service performance of the product. Accurate detection, characterization, and prediction of these defects and anomalies have an important and immediate impact in manufacturing fully-dense and defect-free builds. This review seeks to elucidate common defects/anomalies and their formation mechanisms in powder bed fusion additive manufacturing processes. They could arise from raw materials, processing conditions, and post-processing. While defects/anomalies in laser welding have been studied extensively, their formation and evolution remain unclear. Additionally, the existence of powder in powder bed fusion techniques may generate new types of defects, e.g., porosity transferring from powder to builds. Practical strategies to mitigate defects are also addressed through fundamental understanding of their formation. Such explorations enable the validation and calibration of models and ease the process qualification without costly trial-and-error experimentation. 

Defects and anomalies in powder bed fusion metal additive manufacturing

Evaluation of compressive properties of SLM-fabricated multi-layer lattice structures by experimental test and μ-CT-based finite element analysis

Direction and location dependency of selective laser melted AlSi10Mg specimens

Powder-bed based additive manufacturing techniques, such as selective laser melting (SLM), are gaining in importance due to the opportunity to produce highly complex shapes. This offer new construction possibilities in the design. However, the surface of the produced SLM parts exhibit a high roughness which can affect the integrity and geometric tolerance. To reduce the surface roughness and to improve the mechanical properties of the outmost layer, laser polishing by re-melting the surface can be used. The present paper focus on the laser polishing of additive manufactured parts. This investigation contains measurement results of the initial and laser polished surfaces out of AlSi10Mg. The surfaces have been analyzed by roughness spectroscopy and white light interferometry. By utilizing a disk laser with a maximum power of 4 kW in combination with a 1-D scanner system, the initial surface roughness was reduced up to 92 %.

Laser Polishing of Additive Manufactured AlSi10Mg Parts with an Oscillating Laser Beam

Lab scale additive manufacturing of Fe-Nd-B based powders was performed to realize bulk nanocrystalline Fe-Nd-B based permanent magnets. For fabrication a special inert gas process chamber for laser powder bed fusion was used. Inspired by the nanocrystalline ribbon structures, well-known from melt-spinning, the concept was successfully transferred to the additive manufactured parts. For example, for Nd16.5-Pr1.5-Zr2.6-Ti2.5-Co2.2-Fe65.9-B8.8 (excess rare earth (RE) = Nd, Pr; the amount of additives was chosen following Magnequench (MQ) powder composition) a maximum coercivity of µ0Hc = 1.16 T, remanence Jr = 0.58 T and maximum energy density of (BH)max = 62.3 kJ/m3 have been achieved. The most important prerequisite to develop nanocrystalline printed parts with good magnetic properties is to enable rapid solidification during selective laser melting. This is made possible by a shallow melt pool during laser melting. Melt pool depths as low as 20 to 40 µm have been achieved. The printed bulk nanocrystalline Fe-Nd-B based permanent magnets have the potential to realize magnets known so far as polymer bonded magnets without polymer.

https://www.mdpi.com/2072-666X/12/5/538/pdf

Additive Manufacturing of Bulk Nanocrystalline FeNdB Based Permanent Magnets.

Selective laser melting is gaining importance to manufacture reliable and highly complex parts. However, the surfaces of the selective laser melted parts exhibit for many applications an insufficient high roughness, thus require subsequent post processing steps. A relatively new way to reduce the surface roughness is the laser polishing technique. In the present paper, additively manufactured AlSi10Mg samples were polished with different laser intensities and laser modes. The investigations contain the potential of roughness reduction and enhancement of the surface appearances, which can be achieved by laser polishing of the as-built surfaces. An initial arithmetic mean roughness of 8.43 μm was remarkably reduced up to 98 %. The compositions of the polished surfaces were detected and the surface appearances were examined. Reasons and mechanisms were explained and depicted for the occurred shade formations on the polished surfaces. High laser intensity led to segregation of silicon and magnesium on the surface. A higher laser intensity enabled an increased melt depth within the conture layer of the selective laser melting structure. Through increasing melt depth, a porosity of max. 1.7 % was detected in the remolten area. Hardness investigations of the initial and laser remolten cross section revealed no significant reduction in hardness.

Metallurgical investigations of laser remelted additively manufactured AlSi10Mg parts

Process parameter dependencies of continuous and pulsed laser modes on surface polishing of additive manufactured aluminium AlSi10Mg parts

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