Welcome to the Amira-Avizo Software Use Case Gallery

Metallic powders are commonly used in additive manufacturing processes. While their post-process consolidated properties are widely studied, there is little research on the properties of the powders prior to consolidation. Understanding the powder characteristics before use in additive manufacturing processes could lead to fine-tuning properties of additively manufactured materials. The three-dimensional grain structure of metals can be useful in predicting their properties and ... Read more

Continuous carbon fibre-reinforced polymer (CCFRP) composites have been increasingly used in airframes and other high-end industrial products due to their superior mechanical properties such as high strength-weight and stiffness-weight ratios […] Additive manufacturing (also known as 3D printing) has shown potential to fabricate continuous fibre-reinforced composites with highly complex shapes in both 2D and 3D. Among them, Fused Filament Fabrication (FFF) 3D printing melts and deposits... Read more

Wire arc additive manufacturing (WAAM) technology has attracted considerable interest in large-scale metallic components, but porosity and low deposition rate are the two dominating technical challenges in WAAM of aluminum alloy. In order to effectively solve these problems, a novel method of hot-wire arc additive manufacturing is used to fabricate aluminum alloy. Systematic studies are carried out to investigate the formation mechanism of the pores, the macro/microstructures, as well as the ... Read more

Material synthesis techniques have been historically used to engineer the mechanical and biological properties of biomaterials. Despite the overall success of this approach in different fronts […] there are still major unaddressed challenges due to the limited range of material properties that can be obtained through such synthesis techniques […]. Recent advances in additive manufacturing (AM) have initiated a new paradigm, which could facilitate better control of mechanical and b... Read more

Accurate detection, characterization, and prediction of defects has great potential for immediate impact in the production of fully-dense and defect free metal additive manufacturing (AM) builds. Accordingly, this paper presents Defect Structure Process Maps (DSPMs) as a means of quantifying the role of porosity as an exemplary defect structure in powder bed printed materials. Synchrotron-based micro-computed tomography (μSXCT) was used to demonstrate that metal AM defects follow predictable... Read more

Drop-on-demand jetting of metals offers a fully digital manufacturing approach to surpass the limitations of the current generation powder-based additive manufacturing technologies. However, research on this topic has been restricted mainly to near-net shaping of relatively low melting temperature metals. Here it is proposed a novel approach to jet molten metals at high-temperatures (>1000 °C) to enable the direct digital additive fabrication of micro- to macro-scale objects. […] ... Read more

Additive manufacturing (AM) of aluminum alloy components has drawn broad attention from industrial customers in recent years. With the advantages of low cost and high deposition rate, wire + arc additive manufacturing (WAAM) has been recognized as a promising AM technology in producing large-scale aluminum alloy structural parts. However, the adverse effect of internal defects on mechanical properties has limited the application of WAAM aluminum alloys. Micropores, as one of the most harmfu... Read more

The electrode microstructural properties significantly influence the efficiency and durability of many electrochemical devices including solid oxide fuel cells. Despite the possibility of simulating the electrochemical phenomena within real three-dimensional microstructures, the potential of such 3D microstructural information has not yet been fully exploited. We introduce here a completely new methodology for the advanced characterization of inhomogeneous current distribution base... Read more

Electron Beam Melting (EBM) is an Additive Manufacturing (AM) process which can be used to fabricate complex 3D metal components. Ti-6Al-4V is one of the high value aerospace materials that has been widely used in the EBM process. However, defects such as gas pores and lack of fusion are often found in the as-built components, which can make a significant difference to the fatigue resistance of the parts. The Manufacturing Technology Centre (MTC) uses X-ray Computed Tomography (XCT) and 3D im... Read more

Open-cell foams as structured catalyst supports are promising candidates for the design of high throughput catalytic processes. In this contribution, we employ a coupled numerical and experimental approach to assess the pressure losses in foams. (…) we explore virtually-generated foam models and their 3D printed replicas for a combined CFD and experimental study of fluid dynamics in foams. In particular, we focus our analysis on the low Reynolds number regime, where deviations between t... Read more

This paper reports our simulations of the metal powder fusion additive manufacturing process based on a two-fluid model. In simulations of metal behavior in which heat is applied by high-density energy sources (e.g., laser or electron beam), the aspects that need to be correctly modeled include boiling and evaporation, as well as melting and solidification. The potential of the two-fluid model to clarify numerous physical phenomena—deep penetration, plume generation, spatter generation due ... Read more

Laser-matter interactions in laser additive manufacturing (LAM) occur on short time scales (10^-6 – 10^-3 s) and have traditionally proven difficult to characterise. We investigate these interactions during LAM of stainless steel (SS316 L) and 13-93 bioactive glass powders using a custom built LAM process replicator (LAMPR) with in situ and operando synchrotron X-ray radiography. This reveals a range of melt track solidification phenomena as... Read more

Metal additive manufacturing techniques such as the powder-bed systems are developing as a novel method for producing complex components.

This study uses synchrotron-based X-ray microtomography to investigate porosity in electron beam melted Ti-6Al-4V in the as-built and post-processed state for two different powders. The presence of gas porosity in the starting powder was shown to correlate to porosity in the as-built components. This porosity was observed to shrink after a hot isosta... Read more