Research Outcome

List of articles submitted to or published in refereed journals:

Theme 1: Material Development
  1. A. Das, J. Muniz-Lerma, E. Espiritu, A. Nommeots-Nomm, K. Waters, M. Brochu, Contribution of Cellulosic Fibre Filter on Atmosphere Moisture Content in Laser Powder Bed Fusion (LPBF) Additive Manufacturing, Scientific Reports, 2019
  2. X. Shen, H. Naguib, A Robust Ink Deposition System for Binder Jetting and Material Jetting, Additive Manufacturing, 2019
  3. A. Bogno, W. Hearn, J. E. Spinelli, J. Valloton, H. Henein, Quantification of Microstructure to Reveal the Solidification Path of an Alloy, ICASP5-CSSCR5, IOP Conf. Series: Materials Science and Engineering, 2019
  4. A. Bogno, J. Valloton, D. .Jimenez, M. Rappaz, H. Henein, Rapid Solidification of Al-Cu Droplets of Near Eutectic Composition, ICASP5-CSSCR5, IOP Conf. Series: Materials Science and Engineering, 2019
  5. S. Atabay, O. Sanchez-Mata, J. Muniz-Lerma, M. Brochu, Microstructure and Mechanical Properties of Rene 41 Alloy Manufactured by Laser Powder Bed Fusion, Materials Science and Engineering: A, 2020
  6. J. Valloton, A. Bogno, H. Henein, D. Herlach, D. Sediako, Scandium Effect on Undercooling and Dendrite Morphology of Al-4.5wt% Cu Droplets , Metallurgical and Materials Transactions A, 2019
  7. A. Wickeler, H. Naguib, Novel Origami-inspired Metamaterials: Design, Mechanical Testing and Finite Element Modelling, Materials & Design, 2019
  8. F. Ahmed, U. Ali, E. Marzbanrad, K. Choi, Y. Mahmoodkhani, E. Toyserkani, Study of Powder Recycling and Its Effect on Printed Parts During Laser Powder-Bed Fusion of 17-4 PH Stainless Steel, Materials Processing and Technology, 2019
  9. X. Shen, M. Chu, F. Hariri, G. Vedula, H. Naguib, Binder Jetting Fabrication of Highly Flexible and Electrically Conductive Graphene/PVOH Composites, Additive Manufacturing, 2020
  10. H. Henein, A. Bogno, W. Hearn, J. Valloton, Metastable dendrite morphologies in Aluminum alloys, Journal of Phase Equilibria and Diffusion , 2020
  11. A. Wickeler, H. Naguib, 3D printed geometrically tessellated sheets with origami-inspired patterns, Journal of Cellular Plastics, 2021
  12. S. Atabay, O Sanchez-Mata, J. Muñiz-Lerma , M. Brochu, Effect of Heat Treatment on the Microstructure and Elevated Temperature Tensile Properties of Rene 41 Alloy Produced by LPBF, Journal of Alloys and Compounds, 2021
  13. O. Craig, A. Bois-Brochu, K. Plucknett, Geometry and Surface Characteristics of H13 Hot-Work Tool Steel Manufactured Using Laser Directed Energy Deposition, International Journal of Advanced Manufacturing Technology, 2021
  14. A. Bogno, M. Tamboli, A. Sabouraud, A. Qureshi, H. Henein, Manufacturing of 3D Lattice Structures by Hybrid Investment Casting, , Under Review
  15. G. Sweet, I. Donaldson, C. Schade, P. Bishop, Laser free-form fabrication of dual phase DP600 steel using water atomized feedstock powder, Additive Manufacturing, 2021
  16. G. Sweet, M. Amegadzie, I. Donaldson, C. Schade, P. Bishop, Laser-Based Directed Energy Deposition (L-DED) Processing of Water Atomized 42CrMo4 Powder, Lasers in Manufacturing and Materials Processing, 2022
  17. T. Li, T. Chen, X. Shen, H. Shi, E. Jabari, H. Naguib, A Binder Jet 3D Printed MXene Composite for Strain Sensing and Energy Storage Application, Nanoscale, 2022
  18. T. Lehmann, D. Rose, E. Ranjbar, M. Ghasri-Khouzani, M. Tavakoli, H. Henein, T. Wolfe, A. Qureshi, Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges, International Materials Reviews, 2021
  19. H. Sun, Z. Liu, G. Azimi, Y. Zou, Selective laser melting of maraging steels using recycled powders: a comprehensive microstructural and mechanical investigation, Metallurgical and Materials Transactions A, 2021
  20. S. Atabay, O. Sanchez-Mata, J. Muniz-Lerma, M. Brochu, Microstructure and Mechanical Properties of Difficult to Weld Rene 77 Superalloy produced by Laser Powder Bed Fusion, Materials Science and Engineering: A, 2021
  21. O. Craig, A. Bois-Brochu, K. Plucknett, Microstructure Development in H13 Hot-Work Tool Steel Fabricated Using Laser Directed Energy Deposition, , Under Review
  22. A. Rayner, R. Cooke, I. Donaldson, P. Bishop, Binder Jet Printing AISI 5120 Chromium Steel Powder, Metallurgical and Materials Transactions A, 2023
  23. D. Mutel, S. Gelinas, C. Blais, Production of tool steel powders by water atomization for additive manufacturing by powder bed fusion and directed energy deposition, , Under Review
  24. D. Rose, J. Forth, H. Henein, T. Wolfe, A. Qureshi, Automated semantic segmentation of NiCrBSi-WC optical microscopy images using convolutional neural networks, Computational Materials Science, 2022
  25. K. McLellan, Y.C. Sun, H. Naguib, A Review of 4D Printing: Materials, Structures, and Designs Towards the Printing of Biomedical Wearable Devices, Bioprinting, 2022
  26. K. McLellan, T. Li, Y. Sun, M. Jakubinek, H. Naguib, 4D Printing of MXene Composites for Deployable Actuating Structures, ACS Applied Polymer Materials, 2022
  27. T. Li, E. Jabari, K. McLellan, H. Naguib, Review of Additive Manufacturing with 2D MXene: Techniques, Applications, and Future Perspectives, Progress in Additive Manufacturing, 2023
  28. K. McLellan, Y. Sun, T. Li, T. Chen, H. Naguib, 4D precipitation printing technologies toward sensing devices using microporous structures, Progress in Additive Manufacturing, 2022
  29. J. Valloton, SG. Vogel, H. Henein, Microstructural study of containerless solidification of Al-5wt%Ce alloy, IOP Conf. Series: Materials Science and Engineering, 2023
  30. J. Valloton, N. Mahdi, L. Rabago, J. Chung, H. Henein, In situ solidification of eutectic Al-33wt%Cu droplets, IOP Conf. Series: Materials Science and Engineering, 2023
  31. D. Mutel, S. Gelinas, C. Blais, Rheological characterization of water atomized tool steel powders developed for laser powder bed fusion by supervised and unsupervised machine learning, Powder Metallurgy, 2023
  32. D. Diaz, A. Bogno, M. Dias, J. Valloton, D. Ivey, H. Henein, Effect of Ce Addition in Hypereutectic Al-Si Alloys During Rapid Solidification, Proceedings of the 62nd Conference of Metallurgists, COM 2023, Toronto, ON, Canada, 2023
  33. T. Ramakrishnan, A. Kumar, P. Hudon, M. Brochu, Laser powder bed fusion additive manufacturing of Mo and TZM exoskeleton with Cu infiltration for new heat sinks configuration, Advanced Engineering Materials, 2023
  34. A. Rayner, G. Sweet, O. Craig, M. Habibnejad, P. Bishop, A Parametric Study on the Freeform Fabrication of Near-beta Alloy Ti-55511 Printed by Laser Directed Energy Deposition (L-DED) using a Statistical Design of Experiments (DOE) Approach, , Under Review
  35. O. Craig, E. Moreau, J. Toddy, N. Murphy, S. Halliday, S. Corbin, K. Plucknett, Functionally Gradient H13 Tool Steel/OFHC Cu Composites Manufactured by Laser Directed Energy Deposition , Journal of Alloys and Compounds, Under Review
Theme 2: Advanced Process Modeling
  1. L. Lui, P. Kamm, F. Garcia-Moreno, J. Banhart, D. Pasini, Elastic and Failure Response of Imperfect Three-Dimensional Lattices: The Role of Geometric Defects Induced By Selective Laser Melting, Journal of Mechanics and Physics of Solids, 2017
  2. A. Bogno, W. Hearn, J. E. Spinelli, J. Valloton, H. Henein, Quantification of Microstructure to Reveal the Solidification Path of an Alloy, ICASP5-CSSCR5, IOP Conf. Series: Materials Science and Engineering, 2019
  3. A. Bogno, J. Valloton, D. .Jimenez, M. Rappaz, H. Henein, Rapid Solidification of Al-Cu Droplets of Near Eutectic Composition, ICASP5-CSSCR5, IOP Conf. Series: Materials Science and Engineering, 2019
  4. Z. Luo, F. Zhao, Efficient Thermal Finite Element Modeling of Selective Laser Melting of Inconel 718, Computational Mechanics, 2019
  5. A. Moussa, D. Melancon, A. El Elmi, D. Pasini, Topology Optimization of Imperfect Lattice Materials Built with Process-induced Defects via Powder Bed Fusion, Additive Manufacturing, 2020
  6. A. Moussa, S. Rahman, M. Xu, M. Tanzer, D. Pasini, Topology Optimization of 3D-printed Structurally Porous Cage for Acetabular Reinforcement Intotal Hip Arthroplasty, Mechanical Behavior of Biomedical Materials, 2020
  7. Z. Luo, F. Zhao, Numerical Simulation of Part-level Temperature Fields During Selective Laser Melting of Stainless Steel 316L, International Journal of Advanced Manufacturing Technologies, 2019
  8. Z. Luo, F. Zhao, A Survey of Finite Element Analysis of Temperature and Thermal Stress Fields in Powder Bed Fusion Additive Manufacturing, Additive Manufacturing, 2018
  9. B. Rupal, N. Anwer, M. Secanell, A. Qureshi, Geometric Tolerance and Manufacturing Assemblability Estimation of Metal Additive Manufacturing (AM) Processes, Materials & Design, 2020
  10. Y. Zhang, S. Yang, G. Dong, F. Zhao, Predictive Manufacturability Assessment System for Laser Powder Bed Fusion Processes through a Hybrid Machine Learning Model, Additive Manufacturing, 2021
  11. A. El Elmi, D. Melancon, M. Asgari, L. Liu, D. Pasini, Experimental and numerical investigation of selective laser melting–induced defects in Ti–6Al–4V octet truss lattice material: the role of material microstructure and morphological variations, Journal of Materials Research, 2020
  12. Y. Zhang, S. Yang, F. Zhao, Manufacturability Analysis of Metal Laser-based Powder Bed Fusion Additive Manufacturing -A Survey, The International Journal of Advanced Manufacturing Technology, 2020
  13. Y. Zhang, F. Zhao, Hybrid Sparse Convolutional Neural Networks for Predicting Manufacturability of Laser Powder Bed Fusion Processes, Journal of Manufacturing Systems, 2021
  14. A. Ghosh, S. Biswas, T. Turner, A Kietzig, M. Brochu, Surface, microstructure, and tensile deformation characterization of LPBF SS316L microstruts micromachined with femtosecond laser, Materials & Design, 2021
  15. A. Ghosh, A. Kumar, N. Joy, A. Kietzig, M. Brochu, Characterization of femtosecond laser micromachined specimens extracted from PBF-LB/M microstruts: Analyzing surfaces fabricated via internally linked machined kerfs, Materialia, 2021
  16. A. Ghosh, A. Kumar, A. Harris, A. Kietzig, M. Brochu, Fatigue behavior of stainless steel 316L microstruts fabricated by laser powder bed fusion, Materialia, 2022
  17. A. Ghosh, A. Kumar, A. Kietzig, M. Brochu, Analysis of the effect of surface morphology on tensile behavior of LPBF SS316L microstruts, Materials Science and Engineering: A, 2021
  18. J. Valloton, A. Bogno, M. Rappaz, H. Henein, , Numerical model of rapidly solidified Al-33wt%Cu eutectic growth during Impulse Atomization, Metallurgical and Materials Transactions A, 2021
  19. A. Khobzi, F. Farhang Merh, S. Cockcroft, D. Maijer, The role of block-type support structure design on the thermal field and deformation in components fabricated by Laser Powder Bed Fusion, Journal of Additive Manufacturing, 2022
  20. P. Pourabdollah, F. Farhang Mehr, D. Maijer, S. Cockcroft, , A novel approach for the numerical analysis of in situ distortion on a component made by the direct energy deposition additive manufacturing process, The International Journal of Advanced Manufacturing Technology, 2022
  21. B. Rupal, T. Singh, T. Wolfe, M. Secanell, A. Qureshi, Tri-Planar Geometric Dimensioning and Tolerancing Characteristics of SS 316L Laser Powder Bed Fusion Process Test Artifacts and Effect of Base Plate Removal, Materials MDPI, 2021
  22. Y. Zhang, Y. Zhao, A Web-based Automated Manufacturability Analyzer and Recommender for Additive Manufacturing (MAR-AM) via a Hybrid Machine Learning Model, Expert Systems with Applications, 2022
  23. A. Ghosh, P. Behera, A. Kietzig, M. Brochu, In-situ characterization of tensile deformation in 250 mm SS316L microstruts fabricated by laser powder bed fusion, , Under Review
  24. P. Pourabdollah, F. Farhangmehr, S. Cockcroft, D. Maijer, A. Chakraborty, A Mechanistically Consistent Thermomechanical Model for the Prediction of Stress and Strain Evolution in Proximity to the Melt Pool in Powder Bed Fusion Additive Manufacturing, Additive Manufacturing, Under Review
  25. A. Mulhi, S. Dehgahi, P. Waghmare, A. Qureshi, Process Parameter Optimization of 2507 Super Duplex Stainless Steel Additively Manufactured by Laser Powder Bed Fusion Technique, Metals, 2023
  26. F. Rahimi, P. Pourabdollah, F. Farhang Mehr, S. Cockcroft, D. Maijer, A Macroscale Heat Transfer Analysis of the Build Chamber in a Commercial Electron Beam Powder Bed Fusion (EB-PBF) Additive Manufacturing System During Component Fabrication, Additive Manufacturing, 2023
  27. P. Pourabdollah, F. Farhang Mehr, S. Cockcroft, D. Maijer, A New Variant of the Inherent Strain Method for the Prediction of Distortion in Powder Bed Fusion Additive Manufacturing Processes, The International Journal of Advanced Manufacturing Technology, Under Review
  28. M. Hassanabadi, S. Imani Shahabad, A. Keshavarzkermani, R. Eybel, A. Gerlich, E. Toyserkani, A Numerical Modelling for Laser Powder-bed Fusion of Ti-alloy with a Hybrid Heat Source: An Investigation on Solidification and Microstructure Formation, Optics & Laser Technology, 2022
  29. S. Imani Shahabad, G. Karimi, E. Toyserkani, An Extended Rosenthal’s Model for Laser Powder-Bed Fusion Additive Manufacturing: Energy Auditing of Thermal Boundary Conditions, Lasers in Manufacturing and Materials Processing, 2021
  30. A. El Elmi, D. Pasini, Soft metamaterials with programmable functionalities through soft inclusions, Soft Matter, Under Review
Theme 3: Process Monitoring and Control
  1. G. Shanbhag, M. Vlasea, The effect of Reuse Cycles on Ti-6Al-4V Powder Properties Processed by Electron Beam Melting, Journal of Manufacturing Letters, 2020
  2. K. Taherkhani, E. Sheydaeian, C. Eischer, M. Otto, E. Toyserkani, Development of a defect-detection platform using photodiodes signals collected from the melt pool of laser powder-bed fusion, Additive Manufacturing, 2021
  3. G. Shanbhag, E. Wheat, S. Moylan, M. Vlasea, Effect of sample geometry and orientation on tensile properties of Ti-6Al-4V manufactured by electron beam powder bed fusion, Additive Manufacturing, 2021
  4. T. Lehmann, D. Rose, E. Ranjbar, M. Ghasri-Khouzani, M. Tavakoli, H. Henein, T. Wolfe, A. Qureshi, Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges, International Materials Reviews, 2020
  5. G. van Houtum, M. Vlasea, Active learning via adaptive weighted uncertainty sampling applied to additive manufacturing, Additive Manufacturing, 2021
  6. K. Taherkhani, C. Eischer, E. Toyserkani, An unsupervised machine learning algorithm for in-situ defect-detection in laser powder-bed fusion, Journal of Manufacturing Processes, 2022
  7. G. Shanbhag, M. Vlasea, Effect of varying preheating temperatures in electron beam powder bed fusion: Part I Assessment of the effective powder cake thermal conductivity, Journal of Manufacturing Science and Engineering, 2021
  8. A. Martinez, M. Ansari, M. Wang, A. Marzo, E. Toyserkani, On the application of sound radiation force for focusing of powder stream in directed energy deposition, Ultrasonics, 2022
  9. G. Shanbhag, M. Vlasea, Powder Reuse Cycles in Electron Beam Powder Bed Fusion - Variation of Powder Characteristics, Journal of Materials, 2021
  10. G. Shanbhag, M. Vlasea, Effect of varying preheating temperatures in electron beam powder bed fusion: Part II Assessment of the surface topography and geometric fidelity, Journal of Manufacturing Science and Engineering, Under Review
  11. S. Teng, S. Dehgahi, H. Henein, T. Wolfe, A. Qureshi, Effect of surface texture, viewing angle, and surface condition on the emissivity of wire arc directed energy deposition manufactured 7075 nano treated aluminum alloy, The International Journal of Advanced Manufacturing Technology, 2022
  12. H. Farag, E. Toyserkani, B. Khamesee, Non-Destructive Testing Using Eddy Current Sensors for Defect Detection in Additively Manufactured Titanium and Stainless-Steel Parts, Sensors, 2022
  13. M. Ansari, A. Martinez, M. Khamooshi, A. Keshavarzkermani, R. Esmaeilizadeh, E. Toyserkani, Analytical modeling of multi-track powder-fed laser directed energy deposition: On the relationships among process, deposition dimensions, and solidification microstructure in additively manufactured near-beta titanium alloy, Journal of Materials Processing Technology, 2022
  14. K. Taherkhani, O. Ero, F. Liravi, S. Toorandaz, E. Toyserkani, On the application of in-situ monitoring systems and machine learning algorithms for developing quality assurance platforms in laser powder bed fusion: A review, Manufacturing Processes, 2023
  15. A. Martinez, M. Klumpp, E. Toyserkani, Directed energy deposition powder stream modeling using a Gaussian beam ray representation, Powder Technology, 2022
  16. K. Taherkhani, G. Cantzler, C. Eischer, E. Toyserknai, Development of control systems for laser powder bed fusion, The International Journal of Advanced Manufacturing Technology ,
  17. R. van Blitterswijk, L. Botelho, M. Farshidianfar, P. Etman, A. Khajepour, Adaptive thermal model for real-time peak temperature and cooling rate prediction in laser material processing, Journal of Manufacturing Processes, 2023
  18. A. Martinez, M. Worner, E. Toyserkani, Directed energy deposition powder stream modeling using a Gaussian beam ray representation, Journal of Physics D: Applied Physics, 2022
  19. A. Martinez, M. Ansari, A. Marzo, M. Wang, S. Soo, E. Toyserkani, Ultrasound particle lensing: powder stream control in directed energy deposition using acoustic radiation force fields, Additive Manufacturing, 2023
Theme 4: Novel AM Processes and Products
  1. Y. Huang, B. Khamesee, E. Toyserkani, Electrodynamic concentration of non-ferrous metallic particles in the moving gas-powder stream: Mathematical modeling and analysis, International Journal of Magnetics and Electromagnetics, 2019
  2. Y. Huang, M. Ansari, H. Asgari, M. Farshidianfar, D. Sarkar, B. Khamesee, E. Toyserkani, Rapid Prediction of Real-time Thermal Characteristics, Solidification Parameters and Microstructure in Laser Directed Energy Deposition, Journal of Materials Processing Technology, 2019
  3. Y. Tang, F. Zhao, Z. Gao, Design of Conformal Porous Structures for the Cooling Systems of an Injection Mold, ASME, Journal of Mechanical Design, 2019
  4. A. Moussa, D. Melancon, A. El Elmi, D. Pasini, Topology Optimization of Imperfect Lattice Materials Built with Process-induced Defects via Powder Bed Fusion, Additive Manufacturing, 2020
  5. A. Moussa, S. Rahman, M. Xu, M. Tanzer, D. Pasini, Topology Optimization of 3D-printed Structurally Porous Cage for Acetabular Reinforcement Intotal Hip Arthroplasty, Mechanical Behavior of Biomedical Materials, 2020
  6. P. Kumar, Y. Huang, E. Toyserkani, B. Khamesee, , Development of a Magnetic Levitation System for Additive Manufacturing: Simulation Analyses, IEEE Transactions on Magnetics, 2020
  7. F. Sikan, P. Wanjara, J. Gholipour, A. Kumar, M. Brochu, Thermo-mechanical modelling of wire-fed electron beam additive manufacturing , Materials, 2021
  8. S. Omar, K. Plucknett, The Influence of DED Process Parameters and Heat-Treatment Cycle on the Microstructure and Hardness of AISI D2 Tool Steel, Journal of Manufacturing Processes, 2022
  9. F. Sikan, P. Wanjara, J. Gholipour, S. Atabay, M. Brochu, Effect of substrate condition on wire fed electron beam additive deposition, Materials Science and Engineering: A, 2022
  10. F. Sikan, P. Wanjara, J. Gholipour, M. Brochu, Use of Miniature Tensile Specimens for Measuring Mechanical Properties in the Steady State and Transient Zones of Ti-6Al-4V Wire-Fed Electron Beam Deposits, Materials Science and Engineering: A, 2022
  11. F. Sikan, P. Wanjara, S. Atabay, J. Gholipour, M. Brochu, Evaluation of Electron Beam Wire-fed Deposition Technology for Titanium Compressor Blade Repair, Materials Today Communications, 2022
  12. S. Omar, K. Plucknett, The Effects of Deposited Layer Thickness on the Material and Geometrical Properties of Laser DED Processed AISI D2 Tool Steel, Steel Research International, Under Review
  13. P. Kumar, B. Khamesee, , Development and Analysis of a Novel Magnetic Levitation System with a Feedback Controller for Additive Manufacturing Applications, Actuators, 2022
  14. P. Kumar, S. Malik, E. Toyserkani, B. Khamesee, Development of an Electromagnetic Micromanipulator Levitation System for Metal Additive Manufacturing Applications, Micromachines, 2022
  15. Z. Gao, G. Dong, T. Tang, Y. Zhao, , Machine learning aided design of conformal cooling channels for injection molding, Journal of Intelligent Manufacturing, 2021
  16. Z. Russell, M. Amegadzie, A. David, K. Plucknett, , Scratch resistance and damage mechanisms arising in TiC-Ni3Al based laser DED clads on D2 tool steel, Surface & Coatings Technology, Under Review
  17. Z. Russell, K. Plucknett, , Evaluation of TiC-Ni3Al Laser Clad onto Tool Steel Using a Suspension-based Powder Preplacement Approach, , Under Review
  18. Z. Russell, K. Plucknett, , Aqueous Corrosion Performance of Gel based TiC-based Laser DED Clads on D2 Tool Steel Substrates, Corrosion Science, Under Review