Simone Venettacci | Università degli studi Niccolò Cusano, telematica Roma (original) (raw)

Papers by Simone Venettacci

Progress in Additive Manufacturing, 2024

The purpose of this study is to characterize the mechanical properties of laser-sintered polyamid... more The purpose of this study is to characterize the mechanical properties of laser-sintered polyamide specimens subjected to water immersion for up to 28 days to facilitate the implementation and diffusion of this technology and material in components that are exposed to high-humidity or liquid-filled environments, as for biomedical, naval, and maritime sectors. In addition to conventional tensile tests, flat-top cylinder indentation tests were carried out to define a local dependence of the properties along the building direction. Water absorption reaches saturation after 2 days of immersion with a weight variation of around 10.49% and a resulting diffusion coefficient one order of magnitude greater than the value of the base material, due to the porosity of the samples. Mechanical properties deteriorate due to the reduction in crystallinity and degradation of molecular chains. After just 2 h of immersion, the elastic modulus decreases from ~ 1 to ~ 0.8 GPa, the yield stress experiences a drop from ~ 20 MPa down to ~ 14 MPa and the ultimate tensile strength undergoes a decrease of 5 MPa from ~ 30 MPa as built. While no significant variations were observed for the elongation at the break due to the concurrent effect of plasticization and molecular degradation. Finally, the indentation tests highlight a local dependence of the properties along the building direction in favour of the central part of the samples, as it exposes a smaller surface to the surrounding environment during immersion.

The International Journal of Advanced Manufacturing Technology, 2024

The laser-based thermomechanical joining process was adopted to produce hybrid components made of... more The laser-based thermomechanical joining process was adopted to produce hybrid components made of AISI 304 stainless steel and semi-transparent thermoplastic materials, i.e. polypropylene and polyamide. The process parameters, i.e. laser power, laser-polymer interaction time, and metal surface texture, were optimized using the full factorial experimental approach, and the joints’ quality and performance were examined to determine the best operational parameters’ combination. Shear tests were carried out to evaluate the resistance of the joints, while morphological and fracture surface analyses were performed to have a better understanding of the phenomena that emerged during the joining process. The findings demonstrated that the shear force and the joint area were significantly influenced primarily by the texture, followed by the laser power, and finally the interaction time. The optimal combination allowed the realization of joints whose maximum shear force reached around 750 N for polypropylene and around 2200 N for polyamide, achieving respectively 60% and 53% of the tensile force of the polymer base materials.

Lasers in Manufacturing and Materials Processing, 2024

The study of energy fractions plays a fundamental role in laser joining operations: from their kn... more The study of energy fractions plays a fundamental role in laser joining operations: from their knowledge, it is possible to calculate the amount of laser beam energy that is effectively available during the formation of chemical and physical bonds, and how much energy is dissipated. This study examines semi-crystalline polymers of polyamide 6.6 (PA), polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE), and polypropylene (PP), semitransparent to light radiation, with the aim of studying the influence of surface roughness on the distribution of energy fractions, and in particular on the reflection portion. For this purpose, polymeric samples with different surface finishing were prepared and characterized by profilometric analysis. Subsequently, an experimental setup was implemented to directly measure the transmitted ratio, obtaining the reflected energy fraction from the Beer-Lambert law, and the absorbed ratio by energy balance. The results showed a decrease in the power transmitted by polymers subjected to surface treatment, due to an increase in the reflection fraction, a phenomenon particularly evident for PET, for which the reflection share increased from ~ 0.5% to ~ 15.3%, following P240 treatment. A lower influence was verified for PA and especially PTFE, due to a lower influence of the treatment on surface morphology. On the basis of the experimental results, it is hypothesised that roughening the lower section of the irradiated polymer could allow an increase in the total internal reflection fraction, favouring the joint at the interface point.

International Journal of Advanced Manufacturing Technology, 2023

This work proposes the assessment of the economic and environmental impacts for the replacement o... more This work proposes the assessment of the economic and environmental impacts for the replacement of conventional aluminium-made brackets for overhead locker within commercial aircrafts. To this end, a 3D printed support made of carbon reinforced polyether ether ketone (PEEK) was fabricated through the fused deposition modelling (FDM) technique by using the Roboze ARGO 35010 3D printer. After verifying the mechanical performance in terms of quasi-static and fatigue life response through a finite element analysis and the technological feasibility in reproducing such a geometry, the economic assessment highlighted the benefits of using FDM. This can be directly related to the reduction of the annual fuel consumption, which per single aircraft on the Italian route Rome-Milan is estimated at approximately 1740 ton/year, leading to a saving of approximately 320,000 €/year, thanks to the reduction of the brackets’ weight of around 50%. The environmental analysis has shown that the proposed solution is highly eco-sustainable, allowing the reduction of around 550 ton/year of CO2 per aircraft, thanks to a lower consumption of jet fuel during flight, as well as of the overall environmental impact associated with air transport, for each damage class. These results showed how the innovative strategy described offers a concrete possibility to reduce the costs and environmental impacts associated with aviation in order to promote greater sustainability of the entire sector.

Journal of Manufacturing Processes, 2023

The subject of the present paper deals with the description of an innovative coating process, bas... more The subject of the present paper deals with the description of an innovative coating process, based on polymer powder fluidized bed technology, applied in combination with an adhesive silicone primer. This study aims to overcome the problems of traditional coating systems for mechanical complex-geometry components, for applications where high precision in thin film deposition and high coating uniformity, at a micrometer level, are required. In this context, the case study of wire die spring coating is here proposed, carrying out a validation of the proposed technical solution, compared to the traditional process based on electrostatic coating, through an aesthetic, morphological and mechanical experimental characterization. The results showed that the innovative deposition system ensures excellent aesthetic performance, depositing a homogeneous coating, with a constant thickness of ~15–20 μm, on the surface of the complex geometry component analyzed, as opposed to ~25–90 μm for the traditional process. The proposed technique also ensures an excellent coating uniformity both inside the coils and on the external surfaces, as well as a complete protective coverage of the springs and their uniform coloring, with significantly lower consumption of coating powder, thus verifying the full technological feasibility of the fluidized bed deposition process, which is applicable also on non-conductive surfaces. Finally, the surface morphology of the specimens coated with the advanced system showed a memory effect of the substrate, while the analysis of the mechanical behavior remarked a higher fragility in terms of scratch test resistance, typical of thin films, compared to the reference.

Polymer Testing, 2023

This study deals with the experimental analysis of the effects of laser radiation on semi-crystal... more This study deals with the experimental analysis of the effects of laser radiation on semi-crystalline polyethylenebased polymers. This paper has been developed as basis for future development of an innovative joining system, based on laser technology, to produce hybrid structures consisting of metal and polymer parts. Several process monitoring techniques, such as mechanical tensile test, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), flat-top cylinder indentation test (FIMEC) and infrared analysis (FTIR) have been used to evaluate the thermo-mechanical properties of the tested materials, with the aim to identify the technological process window for the joining process. The investigation, focused on two thermoplastic samples in high density polyethylene (HDPE) and polyethylene terephthalate (PET), aimed to investigate any structural changes caused by the laser irradiation of the polymer materials. Results showed no degradation for PET material and only a minor oxidation effect for black high-density polyethylene (HDPE) sample. The achievements of this study are of crucial importance for the identification and setting of the optimal irradiation parameters during laser joining operations, thus avoiding ineffective heating or excessive degradation of the material.

Materials, 2023

The work provides an economic sustainability and environmental impact analysis for the validation... more The work provides an economic sustainability and environmental impact analysis for the validation of a biocide-free antifouling coating for marine applications able to reduce fuel consumption during navigation, CO2 emissions, and the overall environmental impacts associated with shipping, thanks to the reduction of incrustation and the avoidance of biocides release into the water. The results, related to the life cycle of the coating of a motor yacht, with an average sailing life of 25 years, show around 8.8% reduction in overall costs compared to a conventional paint, thanks to a more efficient antifouling action, which reduces the annual fuel consumption by ~13,700 kg/y, or ~9.6%. This leads to a reduction in CO2 emissions, associated with fuel consumption, of ~43.3 ton/y, as well as a lowering of the overall environmental impacts associated with the life cycle of the paint, by almost 10% for the most impactful damage classes, ensuring a greater environmental sustainability of the innovative coating, for the overall service life of the yacht on which it is applied.

Journal of Manufacturing Processes, 2022

This study deals with the experimental analysis of the tribological properties of AlSi10Mg alloy ... more This study deals with the experimental analysis of the tribological properties of AlSi10Mg alloy components manufactured by Laser Powder Bed Fusion (LPBF). The influence of the LPBF parameters and building orientation was investigated for density, roughness, hardness, and wearing properties, as weight loss, wear volume, and friction coefficient. The tribological characterization was carried out by means of Ball on Plate Tests, using both 100Cr6 steel and alumina balls as counterpart. Then, the Analysis of Variance (ANOVA) allowed to verify the significance of process parameters, counterpart material and test area. The experimental results highlight the anisotropic effect of the process parameters on the performance of the manufactured samples for all the response variables. Tribological tests performed with steel ball showed an adhesive wear phenomenon, while the alumina ball an adhesive one. No remarkable differences were detected for varying the test area along the building direction. Finally, the analysis of the wear tests at increasing distance showed a progressive increase in the friction coefficient and a corresponding reduction in the wear rate for both counterpart materials.

CIRP Journal of Manufacturing Science and Technology, 2022

Additive manufacturing of metal powder materials through Laser Powder Bed Fusion (LPBF) allows fo... more Additive manufacturing of metal powder materials through Laser Powder Bed Fusion (LPBF) allows for a single-step fabrication process of complex geometries. However, the introduction of such an innovative technology opens new questions about the fatigue life of functional components especially intended for applications where the products are subjected to severe time-varying loading conditions. In this context, the present work aims at evaluating the fatigue strength of 316L stainless steel samples fabricated through laser powder bed fusion by controlling the building orientation and the volumetric energy density. The work at first presents the response of the LPBF fabricated samples to a monotonic tensile load for varying building orientations. It follows the presentation of their fatigue response to a reverse bending loading condition. Quasi-static tensile tests show that LPBF specimens have lower elastic modulus but higher ultimate and yield strength than the original bulk material, whereby the results evidence a strong anisotropy related to the building orientation. Porosity and building orientation are found to strongly affect the fatigue behavior, with the fatigue limit which lowers from 50% of the ultimate strength of the bulk material down to 20% for the LPBF-ed specimens. Finally, the observation of the failure surfaces suggests that the early fracture of the samples is due to the concomitant initiations of cracks at different sites that eventually coalesce and promote the failure.

Progress in Additive Manufacturing, 2023

Fabrication of dental restorations made of zirconia-based biomaterials with enhanced mechanical a... more Fabrication of dental restorations made of zirconia-based biomaterials with enhanced mechanical and tribological properties together with customized surface topography and microstructure for promoting enamel adhesion and cell proliferation while hindering bacterial spreading is a very challenging task to accomplish through conventional machining operations. In fact, traditional milling processes of sintered ceramics are typically labor-intensive, therefore expensive and time-consuming, and these aspects can be further exasperated when microsized features are required. On the other hand, unconventional techniques such as laser milling can represent a suitable solution to produce miniaturized individualized structures on advanced ceramics since it is a non-contact thermal process that ensures the elimination of cutting forces and allows hard and brittle materials to be machined without the need for special equipment which requires high investments and long processing times. In this context, this study aims to investigate the capability of a nanosecond pulsed fiber laser to machine samples made of yttria-stabilized zirconia through a systematic experimental approach in order to identify the most suitable process operational parameters combinations that ensure the obtainment of specific surface topographies while minimizing the machining time. The milling process is carried out by using a 30 W Q-switched Yb:YAG fiber laser by controlling laser beam scan speed, scan strategy and hatch distance and following a multi-level factorial design-based experimentation. The adoption of the laser technology to machine yttria-stabilized zirconia results in a high-repeatable, accurate and time-saving process allowing easy control of the process outcomes.

Sustainable Production and Consumption, 2022

This study deals with an economic and environmental Life Cycle Assessment of an innovative therma... more This study deals with an economic and environmental Life Cycle Assessment of an innovative thermal energy storage - based on phase change materials embedded in open-cell copper foams - coupled with a solar heating and cooling residential system located in Italy. The results are compared with a traditional water-based storage with the same energy storing capacity. For both systems, an auxiliary gas-fired boiler is considered to integrate the renewable energy, in order to satisfy the building heating and cooling needs. Compared to the traditional system, the innovative storage guaranteed a lower natural gas consumption, 428 m3/y respect to 525 m3/y, due to better energy utilization obtained with a constant heat release/accumulation temperature during the solidification/melting phase of the paraffin. This reduction compensates the greater impact due to the consumption of raw materials and energy during the assembly phase of the innovative storage, and determine an abatement of the environmental impact over the 20 years of operation of about 14.6%, i.e. 1517 pt against 1777 pt in terms of global impact indicator. On the other hand, the innovative system proposed appears to be still expensive if compared to the conventional water-based storage, with an estimated annual cost of € 1,240 against € 696.

Optics and Lasers in Engineering, 2017

Abstract External force laser-assisted bending of Titanium Grade-2 flat sheets to achieve sharp b... more Abstract External force laser-assisted bending of Titanium Grade-2 flat sheets to achieve sharp bending angles (>140°) with small fillet radii is herein investigated. In particular, the influence of the operational parameters, laser power, scan speed, number of passes, on bending angles and fillet radii of the metal substrates is analysed. The experimental results show that shaping of the substrates can be performed with great reliability, being springback largely minimised in broad operational ranges. Exploratory Data Analysis (EDA) allows the design of first approximation technological models and, in turn, the development of 3d processing maps. Based on the experimental findings, numerical modelling of the bending process by the Finite Element Method (FEM) through ABAQUS/Explicit software is also developed. The numerical model is found to match with great accuracy the experimental results, being it also extremely flexible and responsive to the change of the operational parameters.

Journal of Coatings Technology and Research, 2014

In the present investigation, scratch resistance, chemical inertness, and corrosion resistance of... more In the present investigation, scratch resistance, chemical inertness, and corrosion resistance of methyl phenyl polysiloxane coatings on Fe 430 B structural steel with or without an organo-silane intermediate layer were analyzed. The role of Al-Mg pigments dispersed in the resin was studied, too. The high molecular weight of the polysiloxane resin ensures good adhesion to the substrate, low porosity, and high mechanical stability. The good ductility and low steric hindrance of the methyl groups coupled with the chemical inertness of the phenyl groups yields coatings with utmost endurance to aggressive chemicals and, above all, that are suitable as corrosion retardants on sensitive steel substrates. Last, the dispersion in the resin of particles, which act as a corrosion inhibitor, as well as the interposition of organo-silane layers between substrate and polysiloxane resin, can improve further the potential of the designed barrier coatings.

Surface and Coatings Technology, 2013

The manufacturing of pigmented multi-layer protective coatings is the matter of the present inves... more The manufacturing of pigmented multi-layer protective coatings is the matter of the present investigation. Finely sieved Al-Mg (4.5 wt.%) powders were used in combination with a phenyl-methyl silicone resin to form single or multi-layered coatings with good erosion-corrosion properties. The coatings were formed on low carbon steel by alternating a layer of resin deposited by dipping or spraying to a layer of dry metallic powders deposited by fluidized bed. Baking in convection oven at 250. °C for 45. min allowed the full consolidation of the composite coatings. The visual appearance of the coatings and the uniformity in them of the powder distribution were assessed by scanning electron microscopy. The favorable erosion-corrosion endurance of the developed coating systems were investigated by progressive load scratch tests, dry sliding linear reciprocating tribological tests and dipping in acid and salty solutions. In conclusion, the good protection grade the coatings are able to provide together with the viability of the manufacturing process ensure a high potential of the proposed technology in several industrial domains.

Journal of Applied Polymer Science, 2014

Hybrid organic-inorganic coatings can be extremely beneficial to improve the performance of steel... more Hybrid organic-inorganic coatings can be extremely beneficial to improve the performance of steel substrates as their outstanding adhesion strength, scratch resistance, and chemical endurance. However, the design and manufacture of the appropriate coating systems on the different metal alloys can be troublesome. Defective coatings can cause the deterioration of their performance, especially the resistance to aggressive chemicals. In this work, the deposition of functionalized methyl phenyl polysiloxane resins on hot rolled and high strength Fe 430 B steel substrates with and without an intermediate layer of a hybrid organic-inorganic grafting polymer (vinyltriethoxysilane) is comparatively evaluated. Visual appearance, scratch and wear resistance of the coatings as well as their attitude to act as chemical proof barriers are investigated. Proper functionalization of methyl phenyl polysiloxane resins with hydroxyl and alkoxy groups can lead to coatings that are well adhered to the underlying substrates, thus exploiting all the performance they were designed for. In this case, the use of an organo-silane interlayer can further increment the final properties of the overall coating systems.

Applicazioni Laser, 2014

Viene sperimentato l’impiego di un laser a diodi per realizzare forme complesse seguendo la tecni... more Viene sperimentato l’impiego di un laser a diodi per realizzare forme complesse seguendo la tecnica Origami. In particolare, l’attenzione è stata posta su di un oggetto geometrico detto “origami spoon” e si è tentata la realizzazione di una parte di esso
usando la omonima tecnica laser. L’approccio sperimentale ha permesso di identificare una finestra tecnologica tale da favorire elevati angoli di piega ma non il danneggiamento superficiale, di individuare i percorsi necessari e di selezionare la sequenza operativa più appropriata di tali percorsi al fine di ottenere una forma che fosse il più possibile aderente al modello prestabilito.

International Journal of Refractory Metals and Hard Materials, 2015

The present work deals with the post-treatment of thermally-sprayed WC–Co/NiCr coatings deposited... more The present work deals with the post-treatment of thermally-sprayed WC–Co/NiCr coatings deposited by (High Velocity Oxygen Fuel) HVOF on a cylindrical substrate in AA 6082 T6 aluminium alloy with a High Power Diode Laser (HPDL). Laser operational parameters, especially laser power and scan rate, were investigated to find the best settings to improve the mechanical response of the WC–Co/NiCr coatings, preventing the onset of surface damage. Visual appearance and morphology of the coatings were investigated by contact gauge profilometry and scanning electron microscopy. The material microstructure was studied by combined scanning electron microscopy and energy dispersive X-ray spectroscopy. Hardness and wear resistance were analysed by instrumented indentation tests. Appropriate combinations of laser parameters were found to enhance significantly the mechanical performance of the WC–Co/NiCr coatings, whose structure was dense, compact and uniform, with hardness and wear endurance highly improved. In contrast, extreme irradiation densities of the laser beam should be carefully avoided to reduce the onset of defectiveness as wide fractures and/or additional porosities inside the thermally sprayed material.

CIRP Journal of Manufacturing Science and Technology, 2020

In industrial practise, decision makers should know performance characteristics, cost- and energy... more In industrial practise, decision makers should know performance characteristics, cost- and energy-related impacts for choosing the most suitable manufacturing technology for a specific product. In this context, the present work focuses on a technical, economic and environmental evaluation of the Selective Laser Melting processing of 316L stainless steel flat washers compared with the industrial CO2 Laser Cutting. The SLM process allows obtaining components with improved mechanical performance, with an increase of 15% and 48% in tensile strength and hardness, respectively. While surface roughness is more than 11 times worse than the hot rolled samples. The economic analysis showed the greater cost-effectiveness of the LC technology, ensuring the production of a single component at the price of 0.63 €, against 45.13 € necessary for the SLM, which is mainly due to the high consumption of the assistant gas (i.e. Argon). The health and environmental impacts evaluation showed that the LC is around 2.5 times more eco- and human-friendly if compared with the SLM process. In particular, the most relevant damage effect is given by the depletion of the fossil fuels due to a high electricity consumption. However, the observed trend between the two technologies appears to be very similar, thus revealing the possibility of reducing the impact potentials associated to the SLM process with its continuous technological advancements, by making the process itself able to move from small to medium or high volume production rates.

Procedia CIRP, 2020

This study deals with the proposal of a combined fuzzy-genetic algorithm model able to describe t... more This study deals with the proposal of a combined fuzzy-genetic algorithm model able to describe the inherent uncertainties related to the manufacture of aluminium foams by using the dissolution and sintering process. The combined method allows taking into account both the uncertainty related to the model and the statistical process variability, with the aim of controlling the capability of this material at absorbing compression energy, for different set of process parameters. The use of genetic algorithms allows the optimization of the fuzzy supports in order to take into account most of the experimental data in combination with the smallest uncertainty.

Procedia CIRP, 2020

This study wants to propose a fuzzy model able to describe the inherent uncertainties related to ... more This study wants to propose a fuzzy model able to describe the inherent uncertainties related to a laser-assisted bending process and it is aimed at controlling of the springback phenomena, for a different set of laser process parameters. The process maps obtained are used to select the operational parameters in order to obtain the desired process output, providing as additional information how much the uncertainty of the model and the process varies by changing those operational parameters. The fuzzy model has also been used to assess the optimal parameters in order to satisfy the requirement of the least-cost.

Progress in Additive Manufacturing, 2024

The International Journal of Advanced Manufacturing Technology, 2024

Lasers in Manufacturing and Materials Processing, 2024

International Journal of Advanced Manufacturing Technology, 2023

Journal of Manufacturing Processes, 2023

Polymer Testing, 2023

Materials, 2023

Journal of Manufacturing Processes, 2022

CIRP Journal of Manufacturing Science and Technology, 2022

Progress in Additive Manufacturing, 2023

Sustainable Production and Consumption, 2022

Optics and Lasers in Engineering, 2017

Journal of Coatings Technology and Research, 2014

Surface and Coatings Technology, 2013

Journal of Applied Polymer Science, 2014

Applicazioni Laser, 2014

International Journal of Refractory Metals and Hard Materials, 2015

CIRP Journal of Manufacturing Science and Technology, 2020

Procedia CIRP, 2020

Acta Polytechnica CTU Proceedings, 2024

Mechanical systems, regardless of their complexity, very often require that different parts must ... more Mechanical systems, regardless of their complexity, very often require that different parts must move relative to each other by sliding their surfaces, therefore appropriate tribological properties are needed. This request appears particularly evident for components fabricated through Metal Additive Manufacturing processes, due to their typical high surface roughness. In the current study, the Laser Powder Bed Fusion technique with optimized parameters is used to produce samples made of AlSi10Mg alloy. Their tribo-technological properties are investigated through progressive load scratch and dry ball-on-plate wear tests. Along with a global characterization, a local analysis has been performed to identify any variations induced by the building direction. The friction coefficient and the wear rate are generally higher than as-cast specimens. Finally, local trends suggest that the central parts of the samples average offer higher resistance to wear and scratch than the outer areas.

Acta Polytechnica CTU Proceedings, 2024

Laser powder bed fusion process is a versatile metal additive manufacturing process. Although sig... more Laser powder bed fusion process is a versatile metal additive manufacturing process. Although significant progress has been made so far, there is still limited large-scale adoption of this technique by the industry. The main problems are repeatability and lack of proper knowledge. In this work, an innovative and non-destructive testing methodology, based on flat-top cylinder indentation, was used to define the mechanical properties of laser powder bed fused aluminium alloy to highlight any variations induced by the combination of process parameters, for global characterization, and by the building direction, for local characterization. Results show similar or improved global mechanical properties of the laser powder bed fused specimens when compared to traditional die-casted ones. Indentation tests highlight a local dependence of properties along the building direction in favor of the upper part of the samples.

Materials Research Proceedings, 2023

The freedom to manufacture metal components with very complex geometries using additive manufactu... more The freedom to manufacture metal components with very complex geometries using additive manufacturing techniques, such as laser powder bed fusion (LPBF), has opened new possibilities to produce innovative solutions with a high technological impact. It is therefore pivotal to have a detailed knowledge of the performance characteristics, both in the short and in the long term. Within this framework, this study firstly highlights the monotonic tensile properties of the LPBF samples by changing the laser scanning speed, the layer thickness, and the building orientation. Then, within the same process conditions, the fatigue life is investigated through reverse bending loading tests. The results verify an improved resistance, a reduced rigidity, and a strong anisotropy for the LPBF specimens if compared to the bulk material. The dependence on the orientation, together with the porosity of the LPBF samples, are the primarily responsible for the reduction of the fatigue limit.

Procedia CIRP, 2023

Metal additive manufacturing processes are generally governed by a complex interaction of many pr... more Metal additive manufacturing processes are generally governed by a complex interaction of many process parameters, from those connected with the energy source, to those concerning the processed material. Therefore, making decisions and deducing control actions require considering different sources of uncertainty, both aleatoric, e.g. due to the process variability, and epistemic, e.g. due to the inability to describe accurately the physics of the process. The proposed fuzzy-based decision-making approach overcomes this difficulty as it incorporates imperfect information into a decision model for metal additive manufacturing optimization by taking into account both the random and the systematic errors.

Procedia CIRP, 2022

Procedia CIRP, 2020

2021 IEEE International Workshop on Metrology for Industry 4.0 and IoT, MetroInd 4.0 and IoT 2021, 2021

Making decisions and inferring control actions in manufacturing environments requires considering... more Making decisions and inferring control actions in manufacturing environments requires considering many sources of uncertainty. The inherent ability of fuzzy logic to incorporate imperfect information into a decision model has made it suitable for production optimization by combining both productivity and final quality requirements. Indeed, in selective laser melting processes, these aspects must take into account the complex interaction of many process parameters. The proposed fuzzy-based decision-making approach overcomes this difficulty by taking into account heterogeneous error sources associated with both process variability and modelling assumptions, in general unable to accurately describe the process physics. The experimental part of the work concerned the creation of the starting data set on which develop the fuzzy model by evaluating the ultimate tensile strength of the AISi10Mg printed samples by varying the building orientation and the volumetric energy density. Then, the fuzzy process map allowed to define the optimal process parameters' combination able to minimize the uncertainty due to the process variability and the simplification introduced in the model, together with the requested performing properties. It suggests that for orientations lower than 40° and energy lower than 73 J/mm3 it is possible to guarantee a tensile strength within the range 300-366 MPa.