Most material removal in modern manufacturing is currently performed using tools with indexable inserts. Additive manufacturing allows for the creation of new, experimental insert shapes and, more importantly, internal structures, such as channels for coolant. This study deals with developing a process for efficiently manufacturing WC-Co specimens with internal coolant channels with a focus on obtaining a suitable microstructure and surface finish, especially inside the channels. The first part of this study covers the development of process parameters to achieve a microstructure without cracks and with minimal porosity. The next stage focuses solely on improving the surface quality of the parts. Special attention is given to the internal channels, where true surface area and surface quality are evaluated, as these characteristics greatly influence coolant flow. To conclude, WC-Co specimens were successfully manufactured and a microstructure with low porosity and no cracks was achieved and an effective parameter set was found. We have developed a process that produces parts with a surface roughness comparable to those of standard SLS manufacturing of steel parts, while still providing a high-quality internal microstructure. The most suitable parameter set resulted in a profile surface roughness of Ra 4 μm and Rz 31 μm and areal surface roughness of Sa 7 µm and Sz 125 µm.

• Klíčová slova
• 3D printing, additive manufacturing, efficient cooling, indexable insert, preheating, tungsten carbide,
• Publikační typ
• časopisecké články MeSH

Lattice structures, characterized by their repetitive, interlocking patterns, provide an efficient balance of strength, flexibility, and reduced weight, making them essential in fields such as aerospace and automotive engineering. These structures use minimal material while effectively distributing stress, providing high resilience, energy absorption, and impact resistance. Composed of unit cells, lattice structures are highly customizable, from simple 2D honeycomb designs to complex 3D TPMS forms, and they adapt well to additive manufacturing, which minimizes material waste and production costs. In compression tests, lattice structures maintain stiffness even when filled with powder, suggesting minimal effect from the filler material. This paper shows the principles of creating finite element simulations with 3D-printed specimens and with usage of the lattice structure. The comparing of simulation and real testing is also shown in this research. The efficiency in material and energy use underscores the ecological and economic benefits of lattice-based designs, positioning them as a sustainable choice across multiple industries. This research analyzes three selected structures-solid material, pure latices structure, and boxed lattice structure with internal powder. The experimental findings reveal that the simulation error is less than 8% compared to the real measurement. This error is caused by the simplified material model, which is considering the isotropic behavior of the used material PA12GB (not the anisotropic model). The used and analyzed production method was multi jet fusion.

• Klíčová slova
• MJF, additive manufacturing, compression, lattice structures,
• Publikační typ
• časopisecké články MeSH

This article aims to review a redesign approach of a student racing car's clutch lever component, which was topologically optimized and manufactured by Additive Manufacturing (AM). Finite Element Method (FEM) analysis was conducted before and after a Topology Optimization (TO) process in order to achieve equivalent stiffness and the desired safety factor for the optimized part. The redesigned clutch lever was manufactured by using AM-Selective Laser Melting (SLM) and printed from powdered aluminum alloy AlSi10Mg. The final evaluation of the study deals with the experimental test and comparison of the redesigned clutch lever with the existing part which was used in the previous racing car. Using TO as a main redesign tool and AM brought significant changes to the optimized part, especially the following: reduced mass of the component (10%), increased stiffness, kept safety factor above the 3.0 value and ensured the more aesthetic design and a good surface quality. Moreover, using TO and AM gave the opportunity to consolidate multi-part assembly into a single component manufactured by one manufacturing process that reduced the production time. The experimental results justified the simulation results and proved that even though the applied load was almost 1.5× higher than the assumed one, the maximum von Mises stress on the component was still below the yield limit of 220 MPa.

• Klíčová slova
• 3D printing, AlSi10Mg, FEM, SLM, additive manufacturing, finite element method, selective laser melting, topology optimization,
• Publikační typ
• časopisecké články MeSH

One of the concepts behind Generation IV reactors is a molten salt coolant system, where the materials for the reactor itself and for the primary and secondary circuit components are subjected to extreme chemical and thermal stresses. Due to the unavailability of these materials, a nickel-molybdenum alloy known as MoNiCr has been developed in the Czech Republic. This paper discusses the manufacturing process for the MoNiCr alloy, covering conventional casting technology, forming, powder atomization, additive manufacturing (AM) using the directed energy deposition (DED-LB) process, and final heat treatment. Special attention was given to the quality of the input powders for additive manufacturing, particularly regarding the optimization of the chemical composition, which significantly influenced the quality of the additively manufactured components. AM enables the realization of complex structural designs that are critical for energy applications, despite the high susceptibility of the MoNiCr alloy to solidification cracking. Through AM, a test body was successfully produced with a maximum defect rate of 0.03% and the following mechanical properties: a yield strength (YS) of 279 MPa, an ultimate tensile strength (UTS) of 602 MPa, and an elongation (El) of 51%.

• Klíčová slova
• additive manufacturing (AM), directed energy deposition (DED-LB), miniature tensile test specimens (MTTs), molten salt reactor (MSR), nickel alloy MoNiCr, solidification cracking,
• Publikační typ
• časopisecké články MeSH

The NiTi alloy, known as Nitinol, represents one of the most investigated smart alloys, exhibiting a shape memory effect and superelasticity. These, among many other remarkable attributes, enable its utilization in various applications, encompassing the automotive industry, aviation, space exploration, and, notably, medicine. Conventionally, Nitinol is predominantly produced in the form of wire or thin sheets that allow producing many required components. However, the manufacturing of complex shapes poses challenges due to the tenacity of the NiTi alloy, and different processing routes at elevated temperatures have to be applied. Overcoming this obstacle may be facilitated by additive manufacturing methods. This article provides an overview of the employment of additive manufacturing methods, allowing the preparation of the required shapes of Nitinol products while retaining their exceptional properties and potential applications.

• Klíčová slova
• NiTi alloy, additive manufacturing, shape memory alloy,
• Publikační typ
• časopisecké články MeSH
• přehledy MeSH

There is a large number of materials that can be used for FDM additive manufacturing technology. These materials have different strength properties, they are designed for different purposes. They can be highly strong or flexible, abrasion-resistant, or designed for example for environments with higher thermal loads. However recently new innovative and progressive materials have come to the practice, which include nano-composite particles, bringing new added value. One such material is the Conductive PLA material, which is capable of conducting electric current. The aim of this article is to present the material properties of this material. The article describes the design of the experiment, the process of measuring the resistance of samples printed by FDM device, measuring the maximum tensile strength of samples. The article includes a statistical evaluation of the measured data, with the determination of the significance of individual factors of the experiment as well as the evaluation of the overall result of the experiments.

• Klíčová slova
• FDM, additive manufacturing, conductive, electro conductive, fused deposition modeling, resistance, strength,
• Publikační typ
• časopisecké články MeSH

The paper presents the original results of cyclic testing of materials that are identical in chemical composition but produced by two different technologies: conventional metallurgy and additive manufacturing. For the aluminium alloy AlSi10Mg and the austenitic steel 316L, tensile curves, tension-compression and torsion alternating fatigue curves are experimentally obtained and presented. The experimental results are compared for two fabrication technologies-conventional metallurgy and additive DLMS technology. The results indicate a significant effect of anisotropy on the fatigue performance of the AM materials and a different slope of the fatigue life curves in the cyclic torsion versus cyclic tension-compression. The static and, in particular, the fatigue properties of both materials are discussed in relation to the microstructure of the materials after conventional production and after additive manufacturing. This comparison allowed us to explain both the causes of the anisotropy of the AM materials and the different slope of the curves for normal and shear stresses under cyclic loading. Using the example of the strength assessment of bicycle frames, the possibility of progressively wider use of additive manufacturing for load-bearing structures is presented.

• Klíčová slova
• 316L, additive manufacturing, aluminium alloy, fatigue properties, tension and torsion cyclic tests,
• Publikační typ
• časopisecké články MeSH

The paper is focused on the examination of the internal quality of joints created in a multi-material additive manufacturing process. The main part of the work focuses on experimental production and non-destructive testing of restrained joints of modified PLA (polylactic acid) and ABS (Acrylonitrile butadiene styrene) three-dimensional (3D)-printed on RepRap 3D device that works on the "open source" principle. The article presents the outcomes of a non-destructive materials test in the form of the data from the Laser Amplified Ultrasonography, microscopic observations of the joints area and tensile tests of the specially designed samples. The samples with designed joints were additively manufactured of two materials: Specially blended PLA (Market name-PLA Tough) and conventionally made ABS. The tests are mainly focused on the determination of the quality of material connection in the joints area. Based on the results obtained, the samples made of two materials were compared in the end to establish which produced material joint is stronger and have a lower amount of defects.

• Klíčová slova
• Additive manufacturing, FFF technology, laser amplified ultrasonography, tensile testing,
• Publikační typ
• časopisecké články MeSH

The properties of each lattice structure are a function of four basic lattice factors, namely the morphology of the unit cell, its tessellation, relative density, and the material properties. The recent advancements in additive manufacturing (AM) have facilitated the easy manipulation of these factors to obtain desired functionalities. This review attempts to expound on several such strategies to manipulate these lattice factors. Several design-based grading strategies, such as functional grading, with respect to size and density manipulation, multi-morphology, and spatial arrangement strategies, have been discussed and their link to the natural occurrences are highlighted. Furthermore, special emphasis is given to the recently designed tessellation strategies to deliver multi-functional lattice responses. Each tessellation on its own acts as a novel material, thereby tuning the required properties. The subsequent section explores various material processing techniques with respect to multi-material AM to achieve multi-functional properties. The sequential combination of multiple materials generates novel properties that a single material cannot achieve. The last section explores the scope for combining the design and process strategies to obtain unique lattice structures capable of catering to advanced requirements. In addition, the future role of artificial intelligence and machine learning in developing function-specific lattice properties is highlighted.

• Klíčová slova
• additive manufacturing, design strategies, lattice factors, lattice structures, multi-functional properties, process strategies,
• Publikační typ
• časopisecké články MeSH
• přehledy MeSH

The rapid growth of Additive Manufacturing (AM) in the past decade has demonstrated a significant potential in cost-effective production with a superior quality product. A numerical simulation is a steep way to learn and improve the product quality, life cycle, and production cost. To cope with the growing AM field, researchers are exploring different techniques, methods, models to simulate the AM process efficiently. The goal is to develop a thermo-mechanical weld model for the Directed Energy Deposition (DED) process for 316L stainless steel at an efficient computational cost targeting to model large AM parts in residual stress calculation. To adapt the weld model to the DED simulation, single and multi-track thermal simulations were carried out. Numerical results were validated by the DED experiment. A good agreement was found between predicted temperature trends for numerical simulation and experimental results. A large number of weld tracks in the 3D solid AM parts make the finite element process simulation challenging in terms of computational time and large amounts of data management. The method of activating elements layer by layer and introducing heat in a cyclic manner called a thermal cycle heat input was applied. Thermal cycle heat input reduces the computational time considerably. The numerical results were compared to the experimental data for thermal and residual stress analyses. A lumping of layers strategy was implemented to reduce further computational time. The different number of lumping layers was analyzed to define the limit of lumping to retain accuracy in the residual stress calculation. The lumped layers residual stress calculation was validated by the contour cut method in the deposited sample. Thermal behavior and residual stress prediction for the different numbers of a lumped layer were examined and reported computational time reduction.

• Klíčová slova
• 316L steel, additive manufacturing, directed energy deposition, finite element method, residual stress,
• Publikační typ
• časopisecké články MeSH