The development of a scanning strategy for the manufacture of porous biomaterials by selective laser melting.

Porous structures are used in orthopaedics to promote biological fixation between metal implant and host bone. In order to achieve rapid and high volumes of bone ingrowth the structures must be manufactured from a biocompatible material and possess high interconnected porosities, pore sizes between 100 and 700 microm and mechanical strengths that withstand the anticipated biomechanical loads. The challenge is to develop a manufacturing process that can cost effectively produce structures that meet these requirements. The research presented in this paper describes the development of a 'beam overlap' technique for manufacturing porous structures in commercially pure titanium using the Selective Laser Melting (SLM) rapid manufacturing technique. A candidate bone ingrowth structure (71% porosity, 440 microm mean pore diameter and 70 MPa compression strength) was produced and used to manufacture a final shape orthopaedic component. These results suggest that SLM beam overlap is a promising technique for manufacturing final shape functional bone ingrowth materials.

Surface quality of profile extrusion dies manufactured by Selective Laser Melting

The design of plastics profile extrusion dies becomes increasingly more complex so that conventional manufacture processes reach their limit in the die manufacture. A feasible manufacture of arbitrarily designed dies is only possible by additive manufacturing. An especially promising process is hereby the Selective Laser Melting with which metal parts with series identical mechanical properties can be produced without the need for part specific tooling or downstream sintering processes. Disadvantegeous is, however, the relatively rough surface of additively manufactured parts. Against this background, the manufacturing of an profile extrusion die by Selective Laser Melting and the plastics profile surface quality, that can be achieved with such dies, is investigated. For this purpose, profiles are extruded both with an additively manufactured die and a conventionally milled sample of the same die geometry. In case of the additively manufactured die a concept for the surface finishing of the flow channel is required, which can be applied to arbitrarily shaped geometries. Therefore, two different reworking processes are applied only to the die land of the flow channel. The comparison of the surface roughnesses shows that the additively manufactured die with a polished die land delivers the same surface quality as the conventional die.

Selective Laser Melting of the Eutectic Silver-Copper Alloy Ag 28 wt % Cu

The aim of this work was to perform a detailed investigation of the use of Selective Laser Melting (SLM) technology to process eutectic silver-copper alloy Ag 28 wt. % Cu (also called AgCu28). The processing occurred with a Realizer SLM 50 desktop machine. The powder analysis (SEM-topography, EDX, particle distribution) was reported as well as the absorption rates for the near-infrared (NIR) spectrum. Microscope imaging showed the surface topography of the manufactured parts. Furthermore, microsections were conducted for the analysis of porosity. The Design of Experiments approach used the response surface method in order to model the statistical relationship between laser power, spot distance and pulse time.

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 survey on mechanisms and critical parameters on solidification of selective laser melting during fabrication of Ti-6Al-4V prosthetic acetabular cup

Additive Manufacturing (AM) includes a range of approaches that correlate with computer aided design (CAD) and manufacturing by fabrication via precise layers and is a promising method for the production of medical tools. In this study, different aspects and mechanisms of solidification for curved surfaces based on equilibrium at curved interfaces, Monge patch, interfacial and Gibbs energy will be discussed. Also, the effect of capillarity, geometry, substrate temperature, cooling rate and scanning parameters in the solidification of a prosthetic acetabular cup (PAC) using selective laser melting (SLM) is analysed. The contributions of this work are analysing solidification and effective factors in this process to produce parts with a higher quality and mechanical properties such as strength, strain, porosity, relative density and hardness. Results indicate that due to the surface to volume (S/V) ratio, and the increasing effect of the radius on Monge patch, thermal stresses and surface forces are more prevalent on outer surfaces. Moreover, solidification and mechanical properties are related to capillarity, geometry, substrate temperature, cooling rate, scanning power and speed. The results also indicate the interaction of solute diffusion and heat transfer with interatomic forces in large S/V ratio and at small scales tend to improve solidification.

An improved static model for tool deflection in machining of Ti–6Al–4V acetabular shell produced by selective laser melting

Tool deflection during milling operation leads to dimensional error, decreasing surface quality and increasing rejection rate. In this study, tool deflection during the milling of the inner surfaces of Ti–6Al–4V prosthetic acetabular shell produced by selective laser melting (SLM) was modelled. The first purpose of this research is to provide a general static cutting tool deflection model for ball nose cutters where deviation of machine components and tool holder are so small as to be considered negligible. This is because the values of machine component and tool holder deflection were lower than standard tolerances (10 μm) and found to be lower than 1/15 of tool deflection. The second and third objectives of this work involve calculating contact surfaces by determining workpiece and tool geometry and choosing second moment of inertia using a novel cross section method (CSM). Static models for three quasi-analytical methods (QAM) that are simple cantilever beam model (SCBM), two-section model (TWSM) and our three section model (THSM) are presented. THSM showed high accuracy which was validated by 3D finite element method (FEM3D) and experimental measurements. The accuracy of tool deflection calculation using THSM by computing, shank, flute and ball head deflection and also utilizing CSM to determine second moment of inertia showed notable improvements.

Tool wear and surface integrity analysis of machined heat treated selective laser melted Ti-6Al-4V

In this study, the tool wear and surface integrity during machining of wrought and Selective LaserMelted (SLM) titanium alloy (after heat treatment) are studied. Face turning trails were carried out onboth the materials at different cutting speeds of 60,120 and 180 m/min. Cutting tools and machinedspecimens collected are characterized using scanning electron microscope, surface profiler and opticalmicroscope to study the tool wear, machined surface quality and machining induced microstructuralalterations. It was found that high cutting speeds lead to rapid tool wear during machining of SLMTi-6Al-4V materials. Rapid tool wear observed at high cutting speeds in machining SLM Ti-6Al-4Vresulted in damaging the surface integrity by 1) Deposition of chip/work material on the machinedsurface giving rise to higher surface roughness and 2) Increasing the depth of plastic deformationon the machined sub surface.

A numerical study of thermocapillary flow in a rectangular cavity during laser melting

The surface tension gradient driven flow that occurs during laser melting has been studied. The vorticity-streamfunction form of the Navier-Stokes equations and the energy equation has been solved by the ‘Alternative Direction Implicit’ method. It has been shown that the inertia forces in the melt strongly influence the flow pattern in the melt. The convection in the melt modifies the isotherms in the melt at high surface tension Reynolds number and high Prandtl number. The buoyancy driven flow has been shown to be negligible compared to the surface tension gradient driven flow in laser melting.

Role of surface tension driven convection in pulsed - laser melting and solidification

Surface melting by a stationary, pulsed laser has been modelled by the finite element method. The role of the surface tension driven convection is investigated in detail. Numerical results are presented for a triangular laser pulse of durations 10, 50 and 200 ms. Though the magnitude of the velocity is high due to the surface tension forces, the present results indicate that a finite time is required for convection to affect the temperature distribution within the melt pool. The effect of convection is very significant for pulse durations longer than 10 ms.

Numerical Simulation of Transient Thermal Field and Residual Stress in Laser Melting Process

以激光熔凝表面强韧化处理为背景,应用空间弹塑性有限单元和高精度数值算法同时考虑材料组织性能的变化模拟工件的温度场及残余应力,研究激光熔凝加工中瞬时温度场及残余应力数值模拟,同时考虑相变潜热及相变塑性的影响,用算例验证了模型的正确性,给出了不同时刻温度场分布及残余应力分布。

Numerical Simulation of Transient Thermal Field in Laser Melting Process

Numerical simulation of thermal field was studied in laser processing. The 3-D finite element model of transient thermal calculation is given by thermal conductive equation. The effects of phase transformation latent are considered. Numerical example is given to verify the model. Finally the real example of transient thermal field is given.