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In this study, a combined simulation and experimental approach is utilized to investigate the influence of hatch spacing on the microstructure and as-built quality of 316L stainless steel (SS) samples fabricated by selective laser melting (SLM). A three-dimensional finite element model (FEM) is employed to investigate heat transfer and melt pool during the SLM of 316L SS. The phase transformation and variation of the thermo-physical properties of the materials are considered in this model. The effects of hatch spacing (H) on the temperature field, microstructure and melt pool size, overlap rate, surface quality, and relative density during the SLM of 316L SS are investigated. The simulated results indicate that, as the hatch spacing increases, the depth increases and the width of the melt pool decreases. Meanwhile, with the increase of hatch spacing, the simulated temperature of the subsequent tracks falls below the melting temperature of the first track. Moreover, the microstructures were found to coarsen with the increasing hatch spacing due to the reduced cooling rate. The optimized hatch spacing and overlap rate between adjacent tracks were obtained from numerical simulations. Simulation results illustrate that, when the optimized hatch spacing of 100 μm is adopted, fully dense parts with a smooth surface can be fabricated by SLM, thus experimentally validating the simulation results.

The macroscopic mechanical performance of additive manufactured structures is essential for the design and application of multiscale microlattice structure. Performance is affected by microstructure and geometrical imperfection, which are strongly influenced by the size of the struts in selective laser melting (SLM) lattice structures. In this paper, the effect of size on microstructure, geometrical imperfection, and mechanical properties was systemically studied by conducting experimental tests. A series of AlSi10Mg rod-shaped samples with various diameters were fabricated using SLM. The uniaxial tensile test results show that with the decrease in build diameter, strength and Young’s modulus of strut decreased by 30% more than the stable state. The main reasons for this degradation were investigated through microscopic observation and micro X-ray computed tomography (μ-CT). In contrast with large-sized strut, the inherent porosity (1.87%) and section geometrical deviation (3%) of ponysize strut is greater because of the effect of thermal transform and hydrogen evolution, and the grain size is 0.5 μm. The discrepancy in microstructure, geometrical imperfection, and mechanical properties induced by size effect should be considered for the design and evaluation of SLM-fabricated complex structures.

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Polishing can be more uniform if the polishing path provides uniform coverage of the surface. It is known that Peano paths can provide uniform coverage of planar surfaces. Peano paths also contain short path segments and turns: (1) all path segments have the same length, (2) path segments are mutually orthogonal at the turns, and (3) path segments and turns are uniformity distributed over the domain surface. These make Peano paths an attractive candidate among polishing tool paths because they enhance multidirectional approaches of the tool to each surface location. A method for constructing Peano paths for uniform coverage of aspherical surfaces is proposed in this paper. When mapped to the aspherical surface, the path also contains short path segments and turns, and the above attributes are approximately preserved. Attention is paid so that the path segments are still well distributed near the vertex of the surface. The proposed tool path was used in the polishing of a number of parabolic BK7 specimens using magnetorheological finishing (MRF) and pitch with cerium oxide. The results were rather good for optical lenses and confirm that a Peano-like path was useful for polishing, for MRF, and for pitch polishing. In the latter case, the surface roughness achieved was 0.91 nm according to WYKO measurement.

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In order to meet the requirement of the more extreme and severe aerothermodynamic environment faced by the future spacecrafts for high-speed Earth return missions, novel ablation resistant/heat insulation/lightweight integrated resin matrix composites are designed for the heatshields for these vehicles. Proposing the concept of security zone and heat insulation zone into the novel designs, not only the ablation resistant and heat insulation abilities can be improved, but also the weight of the entire material can be effectively reduced.Simultaneously, a computer modeling is established to evaluate the comprehensive performance of integrated high temperature materials. A variety of material process design parameters is introduced into the model while taking the respective properties of fiber weave and matrix into consideration. Computer codes are written for solving the model based on the numerical method for solving nonlinear equations. Under two typical extreme aerothermodynamic environments faced by future aircrafts, the effects of material process design parameters on the comprehensive performance are analyzed, which includes ablation resistant ability, heat insulation capacity, and lightweight level. Finally, the optimal design scheme of the new integrated resin matrix composite under the specific environment is determined. This work helps to the on-demand design of new thermal protection materials for extreme entry or reentry environments.

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