Caratterizzazione microstrutturale e frattografica di componenti in acciaio 316L prodotti tramite Selective Laser Melting

Il Selective Laser Melting è un processo di additive manufacturing che consiste nella realizzazione di componenti metallici tridimensionali, sovrapponendo strati di polvere, che viene via via fusa mediante una sorgente controllata di energia (laser). È una tecnica produttiva che viene utilizzata da più di 20 anni ma solo ora sta assumendo un ruolo rilevante nell’industria. È un processo versatile ma complesso che ad oggi permette di processare solo un numero limitato di leghe. Il presente lavoro di tesi riguarda in particolare lo studio, dal punto di vista microstrutturale, di componenti in acciaio inossidabile austenitico AISI-316L processato mediante Selective Laser Melting, attività svolta in collaborazione con il Gruppo di Tecnologia – Laser del Dipartimento di Ingegneria Industriale. Alla base dell’attività sperimentale è stata svolta anche un’ampia ricerca bibliografica per chiarire lo stato dell’arte sul processo e sulla lega in questione, la microstruttura, i difetti, le proprietà meccaniche e l’effetto dei parametri di processo sul componente finito. Le attività sperimentali hanno previsto una prima fase di caratterizzazione delle polveri di 316L, successivamente la caratterizzazione dei campioni prodotti tramite selective laser melting, in termini di microstruttura e difetti correlati al processo. Le analisi hanno rivelato la presenza di una microstruttura “gerarchica” costituita da melt pool, grani e celle submicrometriche. I difetti rinvenuti sono pori, delaminazione degli strati, particelle di polvere non fuse. Infine è stata eseguita la caratterizzazione frattografica dei campioni sottoposti a prove di trazione e di fatica a flessione rotante (attività condotte dal gruppo Laser) per identificare la morfologia di frattura e i siti di innesco della cricca di fatica.

A review of rapid prototyping techniques for tissue engineering purposes

Rapid prototyping (RP) is a common name for several techniques, which read in data from computer-aided design (CAD) drawings and manufacture automatically threedimensional objects layer-by-layer according to the virtual design. The utilization of RP in tissue engineering enables the production of three-dimensional scaffolds with complex geometries and very fine structures. Adding micro- and nanometer details into the scaffolds improves the mechanical properties of the scaffold and ensures better cell adhesion to the scaffold surface. Thus, tissue engineering constructs can be customized according to the data acquired from the medical scans to match the each patient’s individual needs. In addition RP enables the control of the scaffold porosity making it possible to fabricate applications with desired structural integrity. Unfortunately, every RP process has its own unique disadvantages in building tissue engineering scaffolds. Hence, the future research should be focused into the development of RP machines designed specifically for fabrication of tissue engineering scaffolds, although RP methods already can serve as a link between tissue and engineering.

Scaffolds de polihidroxibutirato construídos por prototipagem rápida funcionalizados com hidroxiapatita e peptídeo osteogênico

Com a evolução da engenharia tecidual novos materiais estão sendo estudados visando o tratamento de defeitos ósseos. O objetivo deste projeto foi preparar e caracterizar scaffolds a base de polihidroxibutirato (PHB), apatita e peptídeo osteogênico, osteogenic growth peptide (OGP), para aplicação em reparação óssea. Além disso, avaliar a liberação prolongada do peptídeo incorporado aos scaffolds na forma livre ou incorporado a lipossomas. Os scaffolds de PHB foram confeccionados por prototipagem rápida (PR) empregando a tecnologia Selective Laser Sintering (SLS). Posteriormente, a apatita foi incorporada in situ por meio de ciclos alternados de imersão em soluções de CaCl2 e Na2HPO4, respectivamente. Neste estudo foram selecionadas 2 marcações para o OGP, uma com 5,6-carboxifluoresceína (CF) e outra com triptofano (W), para análise de liberação prolongada. Os peptídeos foram incorporados ao sistema de liberação no momento de seu preparo. A caracterização por espalhamento de luz dos sistemas de liberação desenvolvidos mostrou que os peptídeos marcados com CF foram os melhores desenvolvidos. Portanto estes peptídeos foram adsorvidos nos scaffolds de PHB-CaP. Estudos in vitro foram realizados para avaliar o perfil de liberação do peptídeo OGP-CF do sistema de liberação controlada. A incorporação da apatita às matrizes de PHB foi confirmada por análises de microscopia eletrônica de varredura/ espectroscopia de energia dispersiva (MEV/EDS), espectroscopia na região do infravermelho (FTIR), absorção atômica, a difratometria de raios-X (DRX). Estas análises sugeriram que a principal fase precipitada foi -TCP. O sistema de liberação lipossoma/OGP-CF foi caracterizado pelas análises de dicroísmo circular e espalhamento de luz, que confirmaram a presença do peptídeo nas amostras. Após a análise da liberação, observou-se que o sistema PHB-CaP/OGP-CF obteve ...

Process for reinforcing SLS parts by epoxy resin

[ES]The purpose of this paper is to report on the use of a combination of selective laser sintering (SLS) and vacuum casting to create plastic composites made by additive manufacturing.

Rapid Manufacturing - auch mit SLM

Rapid Manufacturing (RM) wurde als Schlagwort in der letzten Zeit insbesondere aus dem Bereich des Selective Laser Sintering (SLS) bekannt. In dieser inzwischen über 15-jährigen Technologieentwicklung wurden in den vergangenen Jahren bedeutende Fortschritte erzielt, die die Bauteileigenschaften nahe an die Anforderungen für End-Teile heran brachten. So ist das RM denn auch weniger aus der Sicht grösserer Losgrösse zu verstehen. Viel mehr bedeutet Rapid Manufacturing, dass die Bauteile nach einer generativen Fertigung direkt im Endprodukt resp. der Endanwendung zum Einsatz kommt. Das Selective Laser Melting, mit welchem aus metallischen Pulvermaterialien direkt Metallteile in Standardmaterialien hergestellt werden können, ist aufgrund der guten Materialeigenschaften für RM prädestiniert. In den ersten Anwendungsfeldern des SLM–Verfahrens standen die Herstellung von Werkzeugeinsätzen mit konturnaher Kühlung (Conformal Cooling) im Vordergrund, wobei diese Werkzeuge unter dem Begriff RM verstanden werden müssen, da die Werkzeuge direkt für die Endanwendung - den Spritzgussprozess - verwendet werden. Aktuelle Trends gehen jedoch in Richtung der Fertigung von Funktionsteilen z.B. für den Maschinenbau. Obwohl sich in der Fertigung komplexer Funktionsteile noch Probleme, z.B. mit in Bezug auf die generative Baurichtung überhängender Bauteilstrukturen ergeben, zeigen sich trotzdem erhebliche Vorteile eines RM mittels SLM. Neben klaren Vorteilen durch das mögliche Customizing von Bauteilen können bei kleineren Bauteilgrössen auch erhebliche Kostenvorteile erzielt werden. Allerdings zeigen die Grenzen der aktuellen Möglichkeiten, in welchen Bereichen das SLM-Verfahren weiterer Entwicklung bedarf. Themen wie Produktivität, die Problematik der nach wie vor notwendigen Supportstrukturen wie auch Qualitätssicherung müssen in den nächsten Jahren angegangen werden, wenn dieses Verfahren den Schritt hin zu einem etablierten Produktionsverfahren und damit zu breiterer Akzeptanz und Anwendung finden soll

Selektives Lasersintern von teilkristallinen Thermoplasten

Da eine flexible Fertigung im Bereich von Losgrößen zwischen 1-1000 Stück in vielen Wirtschaftszweigen vermehrt an Bedeutung gewinnt, steigt das Interesse an Verfahren wie dem Selektiven Lasersintern. Dennoch sollen die Eigenschaften von in Serie eingesetzten Werkstoffen erreicht werden. Aufgrund der bestehenden werkstofflichen Restriktionen auf Polyamid 12 wird aktuell an der Verarbeitung anderer teilkristalliner Thermoplaste geforscht. In diesem Beitrag werden die sich in der Markteinführung befindlichen Werkstoffe vorgestellt und basierend auf der Verarbeitung weiterer Thermoplaste die bestehende Modellvorstellung zum Lasersintern erweitert.

Trends and Expertise Exchange within Rapid Manufacturing in Europe

Rapid Manufacturing (RM) umfasst den Begriff der direkten und wirtschaftlichen Bauteilherstellung des Serienprodukts aus 3D-Daten. Die Hauptvorteile sind u.a. das Wegfallen von Werkzeugen und eine Designfreiheit in der Produktentwicklung, die noch vor wenigen Jahren undenkbar war. Wenngleich heute eine Vielzahl von Werkstoffen im Kunststoff- und Metallbereich einsetzbar sind, konzentriert sich die Verbreitung des RM allerdings auf besondere Technologie- und Wirtschaftszweige, aufgrund mangelnder Erfahrungswerte, teilweise abweichender Werkstoffeigenschaften, fehlender Standards und ungeeigneter Testmethoden. In der Praxis sind Ingenieure und Techniker stark darauf bedacht, auf etablierte Abläufe und Standards zurückzugreifen. Es ist daher schwer einen geeigneten RM-Prozess aufzubauen, wo wichtige Eingangsgrößen meist unbekannt sind. In diesem Bericht wird beschrieben, welche Informationskanäle es innerhalb Europas zum Thema RM gibt und welche Hochschulen und Forschungszentren Aktivitäten aufweisen. Darüber hinaus werden Anwendungsfelder des RM aufgeführt, die über die bekannten Anwendungsfelder hinaus gehen. Dazu gehören Anwendungen im Bereich der Elektrotechnik, Raumfahrtinstrumentation und der Mode. Obwohl nicht alle Anwendungen des RM in diesem Bericht aufgeführt werden, sind einige Schlüsselinformationen im Bereich innovativer Anwendungen von RM enthalten.

Properties comparison of Injected and SLS material

Most of the plastic injection companies are focused in the production of some products with a high exigency standard levels. That is why, to compete and gain some market share in front of the concurrency of companies from other countries, they need to be able to introduce new rapid prototyping techniques and product development.

Selektives Lasersintern von teilkristallinen Thermoplasten

Da eine flexible Fertigung im Bereich von Losgrößen zwischen 1-1000 Stück in vielen Wirtschaftszweigen vermehrt an Bedeutung gewinnt, steigt das Interesse an Verfahren wie dem Selektiven Lasersintern. Dennoch sollen die Eigenschaften von in Serie eingesetzten Werkstoffen erreicht werden. Aufgrund der bestehenden werkstofflichen Restriktionen auf Polyamid 12 wird aktuell an der Verarbeitung anderer teilkristalliner Thermoplaste geforscht. In diesem Beitrag werden die sich in der Markteinführung befindlichen Werkstoffe vorgestellt und basierend auf der Verarbeitung weiterer Thermoplaste die bestehende Modellvorstellung zum Lasersintern erweitert.

On the role of magnesium and nitrogen in the infiltration of aluminium by aluminium for rapid prototyping applications

Selective laser sintering has been used to fabricate an aluminium alloy powder preform which is subsequently debound and infiltrated with a second aluminium alloy. This represents a new rapid manufacturing system for aluminium that can be used to fabricate large, intricate parts. The base powder is an alloy such as AA6061. The infiltrant is a binary or higher-order eutectic based on either Al-Cu or At-Si. To ensure that infiltration occurs without loss of dimensional precision, it is important that a rigid skeleton forms prior to infiltration. This can be achieved by the partial transformation of the aluminium to aluminium nitride. In order for this to occur throughout the component, magnesium powder must be added to the alumina support powder which surrounds the part in the furnace. The magnesium scavenges the oxygen and thereby creates a microclimate in which aluminium nitride can form. The replacement of the ionocovalent Al2O3 with the covalent AlN on the surface of the aluminium powders also facilitates wetting and thus spontaneous and complete infiltration. (C) 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Expanding the Design Space: Forging the Transition from 3D Printing to Additive Manufacturing

Thesis (Master's)--University of Washington, 2016-08

Laser-fused refractory oxides for optical coatings

Laser sintering was carried out using a high power continuous-wave CO2 laser to prepare pellets of zirconia (ZrO2), hafnia (HfO2) and yttria (Y2O3) mixed oxides as starting materials in the deposition of optical coatings. Hardened recrystallized pellets appeared to have been formed during laser treatment. X-ray diffraction analysis revealed a monoclinic-to-tetragonal phase transformation in the binary system while the ternary system was found to have a mixture of two crystalline phases. Cross-sectional scanning electron microscopy showed two isothermal crystalline regions in the ternary system. The optical inhomogeneity was low in the films deposited from the laser-fused pellets, but the absorption at a wavelength of 351 nm increased with increasing HfO2 content. The films deposited from laser-fused pellets were analysed by electron spectroscopy for chemical analysis and found to be stoichiometric and homogeneous.

Pan-retinal photocoagulation and other forms of laser treatment and drug therapies for non-proliferative diabetic retinopathy: systematic review and economic evaluation

BACKGROUND: Diabetic retinopathy is an important cause of visual loss. Laser photocoagulation preserves vision in diabetic retinopathy but is currently used at the stage of proliferative diabetic retinopathy (PDR).

OBJECTIVES: The primary aim was to assess the clinical effectiveness and cost-effectiveness of pan-retinal photocoagulation (PRP) given at the non-proliferative stage of diabetic retinopathy (NPDR) compared with waiting until the high-risk PDR (HR-PDR) stage was reached. There have been recent advances in laser photocoagulation techniques, and in the use of laser treatments combined with anti-vascular endothelial growth factor (VEGF) drugs or injected steroids. Our secondary questions were: (1) If PRP were to be used in NPDR, which form of laser treatment should be used? and (2) Is adjuvant therapy with intravitreal drugs clinically effective and cost-effective in PRP?

ELIGIBILITY CRITERIA: Randomised controlled trials (RCTs) for efficacy but other designs also used.

REVIEW METHODS: Systematic review and economic modelling.

RESULTS: The Early Treatment Diabetic Retinopathy Study (ETDRS), published in 1991, was the only trial designed to determine the best time to initiate PRP. It randomised one eye of 3711 patients with mild-to-severe NPDR or early PDR to early photocoagulation, and the other to deferral of PRP until HR-PDR developed. The risk of severe visual loss after 5 years for eyes assigned to PRP for NPDR or early PDR compared with deferral of PRP was reduced by 23% (relative risk 0.77, 99% confidence interval 0.56 to 1.06). However, the ETDRS did not provide results separately for NPDR and early PDR. In economic modelling, the base case found that early PRP could be more effective and less costly than deferred PRP. Sensitivity analyses gave similar results, with early PRP continuing to dominate or having low incremental cost-effectiveness ratio. However, there are substantial uncertainties. For our secondary aims we found 12 trials of lasers in DR, with 982 patients in total, ranging from 40 to 150. Most were in PDR but five included some patients with severe NPDR. Three compared multi-spot pattern lasers against argon laser. RCTs comparing laser applied in a lighter manner (less-intensive burns) with conventional methods (more intense burns) reported little difference in efficacy but fewer adverse effects. One RCT suggested that selective laser treatment targeting only ischaemic areas was effective. Observational studies showed that the most important adverse effect of PRP was macular oedema (MO), which can cause visual impairment, usually temporary. Ten trials of laser and anti-VEGF or steroid drug combinations were consistent in reporting a reduction in risk of PRP-induced MO.

LIMITATION: The current evidence is insufficient to recommend PRP for severe NPDR.

CONCLUSIONS: There is, as yet, no convincing evidence that modern laser systems are more effective than the argon laser used in ETDRS, but they appear to have fewer adverse effects. We recommend a trial of PRP for severe NPDR and early PDR compared with deferring PRP till the HR-PDR stage. The trial would use modern laser technologies, and investigate the value adjuvant prophylactic anti-VEGF or steroid drugs.

STUDY REGISTRATION: This study is registered as PROSPERO CRD42013005408.

FUNDING: The National Institute for Health Research Health Technology Assessment programme.

Desenvolvimento, comportamento mecânico e microestrutural de uma prótese mandibular em liga de titânio produzida por sinterização direta a laser de metal (DMLS)

Pós-graduação em Engenharia Mecânica - FEIS