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Additive manufacturing technologies have been increasingly applied to the development of radio frequency components in the past few years. Indeed, the free-form capability of these processes allows for the design of novel components, whose actual implementation through conventional machining is rather complex or even not possible. This paper describes a monolithic WR51 component integrating three radio frequency functionalities, namely, bending, twisting, and filtering. Three aluminum prototypes with different bending/twisting radii have been manufactured through the selective laser melting process. They exhibit a measured rejection higher than 60 dB in 17.5 and 21.2 GHz, and a measured return loss better than 20 dB in 12.5 and 15 GHz. Significant mass and envelope reductions (higher than 60% depending on the bending/twisting radius) with respect to the reference subsystem with distinct waveguide components are achieved. These results assess the effectiveness of 3-D metal printing in the miniaturization and integration of waveguide systems. [ABSTRACT FROM PUBLISHER]

In the present work, the fabrication and characterization of non-curling, free-standing TiO2 nanotube mem- branes and their integration in front-side illuminated dye-sensitized solar cells are reported. Vertically oriented TiO2 nanotube arrays were fabricated by anodic oxidation of a titanium foil. Nanotube membranes were detached from the metallic foil, transferred and bonded on transparent fluorine-doped tin oxide/glass substrates employing a TiO2 sol as a binder. Crystalline phase and morphology of the film were investigated, evidencing the formation of a highly ordered 1D nanotubes carpet, with a pure anatase crystalline structure. TiO2 nanotube-based DSCs were fabricated using reversible microfluidic architecture. The cell performances were studied by I-V electrical characterization, incident-photon-to-electron conversion effciency, electrochemical impedance spectroscopy and open circuit voltage decay measurements, showing an increase in electron lifetime compared to nanoparticle-based dye- -sensitized solar cells. [ABSTRACT FROM AUTHOR]

The L-PBF process belongs to the most modern methods of manufacturing complex-shaped parts. It is used especially in the automotive, aviation industries, and in the consumer products industry as well. Numerical simulation in the powder sintering process is a means of optimizing time efficiency, accuracy and predicting future errors. It is one of the means to optimize the L-PBF process, which makes it possible to investigate the influence of individual parameters on additive manufacturing. This research makes it possible to predict the correct orientation of a part based on selected criteria, which are assigned a weighting factor in the form of parameters with which the simulation software Simufact Additive can work. Based on these, three possible orientations of the part were analysed with respect to the area of the supporting material, the volume of the supporting material, the number of voxels, and the building risk. Finally, the results of a simulation and the results of the tensile test were compared. From the results of the static tensile test, as well as from the results of the numerical simulation, it was found that better characteristics were achieved for the orientation of part no. 1 compared to orientation of part No. 3.

Additive manufacturing, including laser powder bed fusion, offers possibilities for the production of materials with properties comparable to conventional technologies. The main aim of this paper is to describe the specific microstructure of 316L stainless steel prepared using additive manufacturing. The as-built state and the material after heat treatment (solution annealing at 1050 °C and 60 min soaking time, followed by artificial aging at 700 °C and 3000 min soaking time) were analyzed. A static tensile test at ambient temperature, 77 K, and 8 K was performed to evaluate the mechanical properties. The characteristics of the specific microstructure were examined using optical microscopy, scanning electron microscopy, and transmission electron microscopy. The stainless steel 316L prepared using laser powder bed fusion consisted of a hierarchical austenitic microstructure, with a grain size of 25 µm as-built up to 35 µm after heat treatment. The grains predominantly contained fine 300-700 nm subgrains with a cellular structure. It was concluded that after the selected heat treatment there was a significant reduction in dislocations. An increase in precipitates was observed after heat treatment, from the original amount of approximately 20 nm to 150 nm., Competing Interests: The authors declare there are no conflict of interest.

Laser powder bed fusion (LPBF) is an additive manufacturing technology that implies using metal powder as a raw material. The powders suitable for this kind of technology must respect some specific characteristics. Controlled gas atomization and post-processing operations can strongly affect the final properties of the powders, and, as a consequence, the characteristics of the bulk components. In fact, a complete characterization of the powders is mandatory to fully determine their properties. Beyond the most used tests, such as the volume particle size distribution (PSD) and flowability, the PSD number, the Hausner ratio and the oxidation level can give additional information otherwise not detectable. The present work concerns the complete characterization of two AlSi10Mg powders: a commercial-grade gas atomized powder and a laboratory-scale gas atomized counterpart. The laboratory-scale gas atomization allows to better manage the amount of the fine particles and the oxidation level. As a consequence, a higher particle packing can be reached with an increase in the final density and tensile strength of the LPBF bulk samples.

Tin-bronze alloys with a tin content of at least 10 wt% have excellent mechanical properties, wear resistance, and corrosion resistance. Among these alloys, Cu-10Sn was investigated in this study for production with the laser powder bed fusion process with a 500W Yb:YAG laser. In particular, a design of experiment (DoE) was developed in order to identify the optimal process parameters to obtain full density, low surface roughness, and high dimensional accuracy. Samples were characterized with Archimedes' method and optical microscopy to determine their final density. It was shown that the first method is fast but not as reliable as the second one. A first mechanical characterization was performed through microhardness tests. Finally, a set of process parameters was identified to produce fully dense samples with low surface roughness and high accuracy. The results showed that the volumetric energy density could represent an approach that is too simplified, therefore limiting the direct correlation with the physical aspects of the process.

Among recently developed high-strength and lightweight alloys, the high-performance Scalmalloy ® certainly stands out for laser powder bed fusion (LPBF) production. The primary goal of this study was to optimize the Scalmalloy ® LPBF process parameters by setting power values suitable for the use of lab-scale machines. Despite that these LPBF machines are commonly characterized by considerably lower maximum power values (around 100 W) compared to industrial-scale machines (up to 480 W), they are widely used when quick setup and short processing time are needed and a limited amount of powder is available. In order to obtain the optimal process parameters, the influence of volumetric energy density (VED) on the sample porosity, microstructure and mechanical properties was accurately studied. The obtained results reveal the stability of the microstructural and mechanical behaviour of the alloy for VEDs higher than 175 Jmm -3 . In this way, an energy-and-time-saving choice at low VEDs can be taken for the LPBF production of Scalmalloy ® . After identifying the low-power optimized process parameters, the effects of the heat treatment on the microstructural and mechanical properties were investigated. The results prove that low-VED heat-treated samples produced with an LPBF lab-scale machine can achieve outstanding mechanical performance compared with the results of energy-intensive industrial production.

Metal-metal composites are a class of composite materials studied for their high ductility and strength, but their potential applications are currently limited by the complex manufacturing processes involved. Electro-sinter-forging (ESF) is a single-pulse electro discharge sintering technique that proved its effectiveness in the rapid sintering of several metals, alloys, and composites. Previous studies proved the processability of Ti and AlSi10Mg by ESF to produce metal-metal composites and defined a correlation between microstructure and processing parameters. This paper presents the wear and corrosion characterizations of two metal-metal composites obtained via ESF with the following compositions: 20% Ti/80% AlSi10Mg and 20% AlSi10Mg/80% Ti. The two materials showed complementary resistance to wear and corrosion. A higher fraction of AlSi10Mg is responsible for forming a protective tribolayer in dry-sliding conditions, while a higher fraction of Titanium confers improved corrosion resistance due to its higher corrosion potential.

Conventionally processed precipitation hardening aluminum alloys are generally treated with T6 heat treatments which are time-consuming and generally optimized for conventionally processed microstructures. Alternatively, parts produced by laser powder bed fusion (L-PBF) are characterized by unique microstructures made of very fine and metastable phases. These peculiar features require specifically optimized heat treatments. This work evaluates the effects of a short T6 heat treatment on L-PBF AlSi7Mg samples. The samples underwent a solution step of 15 min at 540 °C followed by water quenching and subsequently by an artificial aging at 170 °C for 2-8 h. The heat treated samples were characterized from a microstructural and mechanical point of view and compared with both as-built and direct aging (DA) treated samples. The results show that a 15 min solution treatment at 540 °C allows the dissolution of the very fine phases obtained during the L-PBF process; the subsequent heat treatment at 170 °C for 6 h makes it possible to obtain slightly lower tensile properties compared to those of the standard T6. With respect to the DA samples, higher elongation was achieved. These results show that this heat treatment can be of great benefit for the industry.

Laser bed powder fusion (LPBF) is an additive manufacturing technology for the fabrication of semi-finished components directly from computer-aided design modelling, through melting and consolidation, layer upon layer, of a metallic powder, with a laser source. This manufacturing technique is particularly indicated for poor machinable alloys, such as Alloy 625. However, the unique microstructure generated could modify the resistance of the alloy to environment assisted cracking. The aim of this work was to analyze the stress corrosion cracking (SCC) and hydrogen embrittlement resistance behavior of Alloy 625 obtained by LPBF, both in as-built condition and after a standard heat treatment (grade 1). U-bend testing performed in boiling magnesium chloride at 155 and 170 °C confirmed the immunity of the alloy to SCC. However, slow strain rate tests in simulated ocean water on cathodically polarized specimens highlighted the possibility of the occurrence of hydrogen embrittlement in a specific range of strain rate and cathodic polarization. The very fine grain size and dislocation density of the thermally untreated specimens appeared to increase the hydrogen diffusion and embrittlement effect on pre-charged specimens that were deformed at the high strain rate. Conversely, heat treatment appeared to mitigate hydrogen embrittlement at high strain rates, however at the slow strain rate all the specimens showed a similar behavior.