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This study aims to comprehensively investigate the electron beam powder bed fusion (EB-PBF) process for copper, offering validated estimations of melt pool temperature and morphology through numerical and analytical approaches. This work also assesses how process parameters influence the temperature fluctuations and the morphological changes of the melt pool.

Two distinct methods, an analytical model and a numerical simulation, were used to assess temperature profiles, melt pool morphology and associated heat transfer mechanisms, including conduction and keyhole mode. The analytical model considers conduction as the dominant heat transfer mechanism; the numerical model also includes convection and radiation, incorporating specific parameters such as beam power, scan speed, thermophysical material properties and powder interactions.

Both the analytical model and numerical simulations are highly correlated. Results indicated that the analytical model, emphasising material conduction, exhibited exceptional precision, although at substantially reduced cost. Statistical analysis of numerical outcomes underscored the substantial impact of beam power and scan speed on melt pool morphology and temperature in EB-PBF of copper.

This numerical simulation of copper in EB-PBF is the first high-fidelity model to consider the interaction between powder and substrate comprehensively. It accurately captures material properties, powder size distribution, thermal dynamics (including heat transfer between powder and substrate), phase changes and fluid dynamics. The model also integrates advanced computational methods such as computational fluid dynamics and discrete element method. The proposed model and simulation offer a valuable predictive tool for melt pool temperature, heat transfer processes and morphology. These insights are critical for ensuring the bonding quality of subsequent layers and, consequently, influencing the overall quality of the printed parts.

Metal additive manufacturing is an inherently thermal process, with intense localised heating and for sparse lattice structures, often rapid uneven cooling. Thermal effects influence manufactured geometry through residual stresses and may also result in non-isotropic material properties. This paper aims to increase understanding of the evolution of the temperature field during fabrication of lattice structures through numerical simulation.

This paper uses a reduced order numerical analysis based on “best-practice” compromise found in literature to explore design permutations for lattice structures and provide first-order insight into the effect of these design variables on the temperature field.

Instantaneous and peak temperatures are examined to discover trends at select lattice locations. Insights include the presence of vertical struts reduces overall lattice temperatures by providing additional heat transfer paths; at a given layer, the lower surface of an inclined strut experiences higher temperatures than the upper surface throughout the fabrication of the lattice; during fabrication of the lower layers of the lattice, isolated regions of material can experience significantly higher temperatures than adjacent regions.

Due to the simplifying assumptions and multi-layer material additions, the findings are qualitative in nature. Future research should incorporate additional heat transfer mechanisms.

These findings point towards thermal differences within the lattice which may manifest as dimensional differences and microstructural changes in the built part.

The paper provides qualitative insights into the effect of local geometry and topology upon the evolution of temperature within lattice structures fabricated in metal additive manufacturing.

Additive manufacturing (AM) enables the fabrication of complex geometries beyond the capability of traditional manufacturing methods. Complex lattice structures have enabled engineering innovation; however, the use of traditional computer-aided design (CAD) methods for the generation of lattice structures is inefficient, time-consuming and can present challenges to process integration. In an effort to improve the implementation of lattice structures into engineering applications, this paper aims to develop a programmatic lattice generator (PLG).

The PLG method is computationally efficient; has direct control over the quality of the stereolithographic (STL) file produced; enables the generation of more complex lattice than traditional methods; is fully programmatic, allowing batch generation and interfacing with process integration and design optimization tools; capable of generating a lattice STL file from a generic input file of node and connectivity data; and can export a beam model for numerical analysis.

This method has been successfully implemented in the generation of uniform, radial and space filling lattices. Case studies were developed which showed a reduction in processing time greater than 60 per cent for a 3,375 cell lattice over traditional CAD software.

The PLG method is a novel design for additive manufacture (DFAM) tool with unique advantages, including full control over the number of facets that represent a lattice strut, allowing optimization of STL data to minimize file size, while maintaining suitable resolution for the implemented AM process; programmatic DFAM capability that overcomes the learning curve of traditional CAD when producing complex lattice structures, therefore is independent of designer proficiency and compatible with process integration; and the capability to output both STL files and associated data for numerical analysis, a unique DFAM capability not previously reported.

Fused deposition modelling (FDM) is increasingly being explored as a commercial fabrication method due to its ability to produce net or near-net shape parts directly from a computer-aided design model. Other benefits of technology compared to conventional manufacturing include lower cost for short runs, reduced product lead times and rapid product design. High-performance polymers such as polyetherimide, have the potential for FDM fabrication and their high-temperature capabilities provide the potential of expanding the applications of FDM parts in automotive and aerospace industries. However, their relatively high glass transition temperature (215 °C) causes challenges during manufacturing due to the requirement of high-temperature build chambers and controlled cooling rates. The purpose of this study is to investigate the mechanical properties of ULTEM 1010, an unfilled polyetherimide grade.

In this research, mechanical properties were evaluated through tensile and flexural tests. Analysis of variance was used to determine the significance of process parameters to the mechanical properties of the specimens, their main effects and interactions. The fractured surfaces were analysed by scanning electron microscopy and optical microscopy and porosity was assessed by X-ray microcomputed tomography.

A range of mean tensile and flexural strengths, 60–94 MPa and 62–151 MPa, respectively, were obtained highlighting the dependence of performance on process parameters and their interactions. The specimens were found to fracture in a brittle manner. The porosity of tensile samples was measured between 0.18% and 1.09% and that of flexural samples between 0.14% and 1.24% depending on the process parameters. The percentage porosity was found to not directly correlate with mechanical performance, rather the location of those pores in the sample.

This analysis quantifies the significance of the effect of each of the examined process parameters has on the mechanical performance of FDM-fabricated specimens. Further, it provides a better understanding of the effect process parameters and their interactions have on the mechanical properties and porosity of FDM-fabricated polyetherimide specimens. Additionally, the fracture surface of the tested specimens is qualitatively assessed.

This paper aims to present a methodology for the detection and categorisation of metal powder particles that are partially attached to additively manufactured lattice structures. It proposes a software algorithm to process micro computed tomography (µCT) image data, thereby providing a systematic and formal basis for the design and certification of powder bed fusion lattice structures, as is required for the certification of medical implants.

This paper details the design and development of a software algorithm for the analysis of µCT image data. The algorithm was designed to allow statistical probability of results based on key independent variables. Three data sets with a single unique parameter were input through the algorithm to allow for characterisation and analysis of like data sets.

This paper demonstrates the application of the proposed algorithm with three data sets, presenting a detailed visual rendering derived from the input image data, with the partially attached particles highlighted. Histograms for various geometric attributes are output, and a continuous trend between the three different data sets is highlighted based on the single unique parameter.

This paper presents a novel methodology for non-destructive algorithmic detection and categorisation of partially attached metal powder particles, of which no formal methods exist. This material is available to download as a part of a provided GitHub repository.

Biofouling of marine vessels results in significant operational costs, as well as the bio-security risk associated with the transport of marine pests. Biofouling is particularly rapid in sea-chest water intakes due to elevated temperatures and circulating flow. Inspection challenges are exacerbated, as sea chests are difficult to inspect and clean. This paper aims to present a method that utilises the flexibility and low-batch capabilities of additive manufacture to manufacture custom sea-chest inserts that eliminate circulating flow and increase the uniformity of shear stress distributions to enable more constant ablation of anti-biofouling coatings.

An automated design procedure has been developed to optimise sea-chest insert geometry to achieve desirable flow characteristics, while eliminating the necessity for support material in FDM manufacture – thereby significantly reducing build cost and time.

Numerical flow simulation confirms that the fluid-flow approximation is robust for optimising sea-chest insert geometry. Insert geometry can be manipulated to enable support-free additive manufacture; however, as the threshold angle for support-free manufacture increases, the set of feasible sea-chest aspect ratios decreases.

The surface of revolution that defines the optimal insert geometry may result in features that are not compatible with additive manufacture constraints. An alternate geometry is proposed that may be more useful in practice without compromising anti-biofouling properties.

Marine sea-chest biofouling results in significant negative environmental and economic consequence. The method developed in this paper can reduce the negative impact of sea-chest biofouling.

Marine sea-chest biofouling results in significant resource consumption and emissions. The method developed in this paper can reduce the negative impact of sea-chest biofouling.

The method presented in this paper provides an entirely original opportunity to utilise additive manufacture to mitigate the effects of marine biofouling.

Additive manufacture (AM) such as selective laser melting (SLM) provides significant geometric design freedom in comparison with traditional manufacturing methods. Such freedom enables the construction of injection moulding tools with conformal cooling channels that optimize heat transfer while incorporating efficient internal lattice structures that can ground loads and provide thermal insulation. Despite the opportunities enabled by AM, there remain a number of design and processing uncertainties associated with the application of SLM to injection mould tool manufacture, in particular from H13/DIN 1.2344 steel as commonly used in injection moulds. This paper aims to address several associated uncertainties.

A number of physical and numerical experimental studies are conducted to quantify SLM-manufactured H13 material properties, part manufacturability and part characteristics.

Findings are presented which quantify the effect of SLM processing parameters on the density of H13 steel components; the manufacturability of standard and self-supporting conformal cooling channels, as well as structural lattices in H13; the surface roughness of SLM-manufactured cooling channels; the effect of cooling channel layout on the associated stress concentration factor and cooling uniformity; and the structural and thermal insulating properties of a number of structural lattices.

The contributions of this work with regards to SLM manufacture of H13 of injection mould tooling can be applied in the design of conformal cooling channels and lattice structures for increased thermal performance.

The purpose of this paper is to demonstrate the preliminary work on using laser cladding technology for the restoration of structural integrity.

The primary methodology used in this research is to develop a laser cladding‐based metal deposition technique to articulate restoration of structural geometry affected by corrosion damages. Following from this method, it is planned to undertake further work to use the laser cladding process to restore geometry and the associated static/fatigue strength.

This work has found that it is possible to use laser cladding as a repair technology to improve structural integrity in aluminium alloy aircraft structures in terms of corrosion reduction and geometrical restoration. Initial results have indicated a reduction of static and fatigue resistance with respect to substrate. But more recent works (yet to be published) have revealed improved fatigue strength as measured in comparison to the substrate structural properties.

The research is based on an acceptable materials processing technique.

This paper aims to investigate the changes in tensile properties of novel functionally graded materials (FGMs) and wafer structures created by direct metal deposition (DMD) additive manufacturing (AM) technology.

Laser-assisted DMD was used to create two innovative sets of metallic structures – the functionally graded and wafer-layered structures – using pairs of six different engineering alloys in different combinations. These alloys were selected due to their high popularity within a diverse range of industries and engineering applications. The laser-assisted DMD was selected as a suitable technique to create these complex structures because of its capability to deposit more than one alloy powder at a time. After creation of these structures, their tensile strength was tested in a series of tensile tests and the results were compared with those of single alloy samples.

It was observed that the mechanical properties of FGMs and wafer structure samples were clearly different from those of the single alloy samples, a fact which creates a whole pool of opportunities for development of new materials or structures with desired mechanical properties that cannot be achieved in single alloy parts.

The study demonstrates the application of the DMD process to produce unique structures and materials, which would be high in demand in engineering applications, where metallic parts are exposed to high loads and where excessive tensile stresses may adversely affect the performance of such parts.

The purpose of this paper is to assess the evolution of labour‐market performance in the Organization for Economic Co‐operation and Development (OECD) over the last decade, considering the robustness of the claims made in an important OECD follow‐up study.

The paper sets up an empirical framework calibrated on an important OECD follow‐up study, and suggests some ways in which the impact of unobserved heterogeneity and outliers on policy estimates can be treated in a cross‐section framework. The framework applies to the data for 30 OECD countries.

The paper finds that changes in labour‐market performance are inversely linked to lagged unemployment. Changes in the share of construction workers are also significant even in the presence of various kinds of policy change indicators. As far as the latter are concerned, the results highlight the role of unemployment benefits and, especially, active labour‐market policies.

The kind of policy change indicators used do not allow the adoption of panel data techniques.

An important policy role seems to emerge for unemployment benefit reforms and, even more so, active labour‐market policies. The evidence also supports the contention that the construction sector is important for labour‐market performance.

The paper brings to the fore novel evidence about cross‐country labour‐market performance at a time when this issue is of high interest for citizens and policy‐makers.