Numerical research of influence of laser radiation parameters on the formation of intermetallic phases from metal powders in selective laser melting technology

Science.gov (United States)

Agapovichev, A. V.; Knyazeva, A. G.; Smelov, V. G.

2017-10-01

A large number of factors influence the quality of the material obtained with selective laser melting. Through correct understanding and managing these factors, it is possible to achieve the necessary quality of the materials, which is highly competitive to the traditional production methods. The technique of selective laser melting is a complex process in which a large number of parameters affect the quality of the final product. The complexity of the process of selective laser melting consists of many thermal, physical and chemical interactions, which are influenced by a large number of parameters. The main parameters of SLM are scanning rate, laser radiation power and layer thickness. In the framework of this paper, there was made an attempt to take into account real physical and chemical processes taking place during the selective laser melting of an Ni-Al alloy.

Heat transfer model and finite element formulation for simulation of selective laser melting

Science.gov (United States)

Roy, Souvik; Juha, Mario; Shephard, Mark S.; Maniatty, Antoinette M.

2017-10-01

A novel approach and finite element formulation for modeling the melting, consolidation, and re-solidification process that occurs in selective laser melting additive manufacturing is presented. Two state variables are introduced to track the phase (melt/solid) and the degree of consolidation (powder/fully dense). The effect of the consolidation on the absorption of the laser energy into the material as it transforms from a porous powder to a dense melt is considered. A Lagrangian finite element formulation, which solves the governing equations on the unconsolidated reference configuration is derived, which naturally considers the effect of the changing geometry as the powder melts without needing to update the simulation domain. The finite element model is implemented into a general-purpose parallel finite element solver. Results are presented comparing to experimental results in the literature for a single laser track with good agreement. Predictions for a spiral laser pattern are also shown.

Selective laser melting of Al-12Si

OpenAIRE

Prashanth, Konda Gokuldoss

2014-01-01

Selective laser melting (SLM) is a powder-based additive manufacturing technique consisting of the exact reproduction of a three dimensional computer model (generally a computer-aided design CAD file or a computer tomography CT scan) through an additive layer-by-layer strategy. Because of the high degree of freedom offered by the additive manufacturing, parts having almost any possible geometry can be produced by SLM. More specifically, with this process it is possible to build parts with ext...

Prediction and Control of Selective Laser Melting Product Microstructure, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Despite the rapid commercialization of additive manufacturing technology such as selective laser melting, SLM, there are gaps in models for material microstructure...

Parameters in selective laser melting for processing metallic powders

Science.gov (United States)

Kurzynowski, Tomasz; Chlebus, Edward; Kuźnicka, Bogumiła; Reiner, Jacek

2012-03-01

The paper presents results of studies on Selective Laser Melting. SLM is an additive manufacturing technology which may be used to process almost all metallic materials in the form of powder. Types of energy emission sources, mainly fiber lasers and/or Nd:YAG laser with similar characteristics and the wavelength of 1,06 - 1,08 microns, are provided primarily for processing metallic powder materials with high absorption of laser radiation. The paper presents results of selected variable parameters (laser power, scanning time, scanning strategy) and fixed parameters such as the protective atmosphere (argon, nitrogen, helium), temperature, type and shape of the powder material. The thematic scope is very broad, so the work was focused on optimizing the process of selective laser micrometallurgy for producing fully dense parts. The density is closely linked with other two conditions: discontinuity of the microstructure (microcracks) and stability (repeatability) of the process. Materials used for the research were stainless steel 316L (AISI), tool steel H13 (AISI), and titanium alloy Ti6Al7Nb (ISO 5832-11). Studies were performed with a scanning electron microscope, a light microscopes, a confocal microscope and a μCT scanner.

Multi-objective optimization of cellular scanning strategy in selective laser melting

DEFF Research Database (Denmark)

Ahrari, Ali; Deb, Kalyanmoy; Mohanty, Sankhya

2017-01-01

The scanning strategy for selective laser melting - an additive manufacturing process - determines the temperature fields during the manufacturing process, which in turn affects residual stresses and distortions, two of the main sources of process-induced defects. The goal of this study is to dev......The scanning strategy for selective laser melting - an additive manufacturing process - determines the temperature fields during the manufacturing process, which in turn affects residual stresses and distortions, two of the main sources of process-induced defects. The goal of this study......, the problem is a combination of combinatorial and choice optimization, which makes the problem difficult to solve. On a process simulation domain consisting of 32 cells, our multi-objective evolutionary method is able to find a set of trade-off solutions for the defined conflicting objectives, which cannot...

Heat transfer modelling and stability analysis of selective laser melting

International Nuclear Information System (INIS)

Gusarov, A.V.; Yadroitsev, I.; Bertrand, Ph.; Smurov, I.

2007-01-01

The process of direct manufacturing by selective laser melting basically consists of laser beam scanning over a thin powder layer deposited on a dense substrate. Complete remelting of the powder in the scanned zone and its good adhesion to the substrate ensure obtaining functional parts with improved mechanical properties. Experiments with single-line scanning indicate, that an interval of scanning velocities exists where the remelted tracks are uniform. The tracks become broken if the scanning velocity is outside this interval. This is extremely undesirable and referred to as the 'balling' effect. A numerical model of coupled radiation and heat transfer is proposed to analyse the observed instability. The 'balling' effect at high scanning velocities (above ∼20 cm/s for the present conditions) can be explained by the Plateau-Rayleigh capillary instability of the melt pool. Two factors stabilize the process with decreasing the scanning velocity: reducing the length-to-width ratio of the melt pool and increasing the width of its contact with the substrate

Peculiarities of single track formation from TI6AL4V alloy at different laser power densities by selective laser melting

Directory of Open Access Journals (Sweden)

Yadroitsava, I.

2015-11-01

Full Text Available This paper describes the geometrical characteristics of single tracks manufactured by selective laser melting (SLM at different laser powers (20-170 W and scanning speeds (0.1-2.0 m/s. Simulation of temperature distribution during processing is carried out. A conclusion about the optimal process parameters and peculiarities of selective laser melting of Ti6Al4V alloy at low and high laser powers and scanning speeds is reached. The analysis of temperature fields creates opportunities to build parts with the desired properties by using SLM.

A semi-analytical thermal modelling approach for selective laser melting

NARCIS (Netherlands)

Yang, Y.; van Keulen, A.; Ayas, C.

2018-01-01

Selective laser melting (SLM) wherein a metal part is built in a layer-by-layer manner in a powder bed is a promising and versatile way for manufacturing components with complex geometry. However, components built by SLM suffer from substantial deformation of the part and residual stresses.

Fatigue behavior of porous biomaterials manufactured using selective laser melting.

Science.gov (United States)

Yavari, S Amin; Wauthle, R; van der Stok, J; Riemslag, A C; Janssen, M; Mulier, M; Kruth, J P; Schrooten, J; Weinans, H; Zadpoor, A A

2013-12-01

Porous titanium alloys are considered promising bone-mimicking biomaterials. Additive manufacturing techniques such as selective laser melting allow for manufacturing of porous titanium structures with a precise design of micro-architecture. The mechanical properties of selective laser melted porous titanium alloys with different designs of micro-architecture have been already studied and are shown to be in the range of mechanical properties of bone. However, the fatigue behavior of this biomaterial is not yet well understood. We studied the fatigue behavior of porous structures made of Ti6Al4V ELI powder using selective laser melting. Four different porous structures were manufactured with porosities between 68 and 84% and the fatigue S-N curves of these four porous structures were determined. The three-stage mechanism of fatigue failure of these porous structures is described and studied in detail. It was found that the absolute S-N curves of these four porous structures are very different. In general, given the same absolute stress level, the fatigue life is much shorter for more porous structures. However, the normalized fatigue S-N curves of these four structures were found to be very similar. A power law was fitted to all data points of the normalized S-N curves. It is shown that the measured data points conform to the fitted power law very well, R(2)=0.94. This power law may therefore help in estimating the fatigue life of porous structures for which no fatigue test data is available. It is also observed that the normalized endurance limit of all tested porous structures (<0.2) is lower than that of corresponding solid material (c.a. 0.4). © 2013.

Single track and single layer formation in selective laser melting of niobium solid solution alloy

Directory of Open Access Journals (Sweden)

Yueling GUO

2018-04-01

Full Text Available Selective laser melting (SLM was employed to fabricate Nb-37Ti-13Cr-2Al-1Si (at% alloy, using pre-alloyed powders prepared by plasma rotating electrode processing (PREP. A series of single tracks and single layers under different processing parameters was manufactured to evaluate the processing feasibility by SLM, including laser power, scanning speed, and hatch distance. Results showed that continuous single tracks could be fabricated using proper laser powers and scanning velocities. Both the width of a single track and its penetration depth into a substrate increased with an increase of the linear laser beam energy density (LED, i.e., an increase of the laser power and a decrease of the scanning speed. Nb, Ti, Si, Cr, and Al elements distributed heterogeneously over the melt pool in the form of swirl-like patterns. An excess of the hatch distance was not able to interconnect neighboring tracks. Under improper processing parameters, a balling phenomenon occurred, but could be eliminated with an increased LED. This work testified the SLM-processing feasibility of Nb-based alloy and promoted the application of SLM to the manufacture of niobium-based alloys. Keywords: Additive manufacturing, Melt pool, Niobium alloy, Powder metallurgy, Selective laser melting

On the role of melt flow into the surface structure and porosity development during selective laser melting

International Nuclear Information System (INIS)

Qiu, Chunlei; Panwisawas, Chinnapat; Ward, Mark; Basoalto, Hector C.; Brooks, Jeffery W.; Attallah, Moataz M.

2015-01-01

In this study, the development of surface structure and porosity of Ti–6Al–4V samples fabricated by selective laser melting under different laser scanning speeds and powder layer thicknesses has been studied and correlated with the melt flow behaviour through both experimental and modelling approaches. The as-fabricated samples were investigated using optical microscopy (OM) and scanning electron microscopy (SEM). The interaction between laser beam and powder particles was studied by both high speed imaging observation and computational fluid dynamics (CFD) calculation. It was found that at a high laser power and a fixed powder layer thickness (20 μm), the samples contain particularly low porosity when the laser scanning speeds are below 2700 mm/s. Further increase of scanning speed led to increase of porosity but not significantly. The porosity is even more sensitive to powder layer thickness with the use of thick powder layers (above 40 μm) leading to significant porosity. The increase of porosity with laser scanning speed and powder layer thickness is not inconsistent with the observed increase in surface roughness complicated by increasingly irregular-shaped laser scanned tracks and an increased number of discontinuity and cave-like pores on the top surfaces. The formation of pores and development of rough surfaces were found by both high speed imaging and modelling, to be strongly associated with unstable melt flow and splashing of molten material

Selective Laser Melting Produced Ti-6Al-4V: Post-Process Heat Treatments to Achieve Superior Tensile Properties.

Science.gov (United States)

Ter Haar, Gerrit M; Becker, Thorsten H

2018-01-17

Current post-process heat treatments applied to selective laser melting produced Ti-6Al-4V do not achieve the same microstructure and therefore superior tensile behaviour of thermomechanical processed wrought Ti-6Al-4V. Due to the growing demand for selective laser melting produced parts in industry, research and development towards improved mechanical properties is ongoing. This study is aimed at developing post-process annealing strategies to improve tensile behaviour of selective laser melting produced Ti-6Al-4V parts. Optical and electron microscopy was used to study α grain morphology as a function of annealing temperature, hold time and cooling rate. Quasi-static uniaxial tensile tests were used to measure tensile behaviour of different annealed parts. It was found that elongated α'/α grains can be fragmented into equiaxial grains through applying a high temperature annealing strategy. It is shown that bi-modal microstructures achieve a superior tensile ductility to current heat treated selective laser melting produced Ti-6Al-4V samples.

Improving accuracy of overhanging structures for selective laser melting through reliability characterization of single track formation on thick powder beds

DEFF Research Database (Denmark)

Mohanty, Sankhya; Hattel, Jesper Henri

2016-01-01

Repeatability and reproducibility of parts produced by selective laser melting is a standing issue, and coupled with a lack of standardized quality control presents a major hindrance towards maturing of selective laser melting as an industrial scale process. Consequently, numerical process...... modelling has been adopted towards improving the predictability of the outputs from the selective laser melting process. Establishing the reliability of the process, however, is still a challenge, especially in components having overhanging structures.In this paper, a systematic approach towards...... establishing reliability of overhanging structure production by selective laser melting has been adopted. A calibrated, fast, multiscale thermal model is used to simulate the single track formation on a thick powder bed. Single tracks are manufactured on a thick powder bed using same processing parameters...

A comparison of corrosion resistance of cobalt-chromium-molybdenum metal ceramic alloy fabricated with selective laser melting and traditional processing.

Science.gov (United States)

Zeng, Li; Xiang, Nan; Wei, Bin

2014-11-01

A cobalt-chromium-molybdenum alloy fabricated by selective laser melting is a promising material; however, there are concerns about the change in its corrosion behavior. The purpose of this study was to evaluate the changes in corrosion behavior of a cobalt-chromium-molybdenum alloy fabricated by the selective laser melting technique before and after ceramic firing, with traditional processing of cobalt-chromium-molybdenum alloy serving as a control. Two groups of specimens were designated as group selective laser melting and group traditional. For each group, 20 specimens with a cylindrical shape were prepared and divided into 4 cells: selective laser melting as-cast, selective laser melting fired in pH 5.0 and 2.5, traditional as-cast, and traditional fired in pH 5.0 and 2.5. Specimens were prepared with a selective laser melting system for a selective laser melting alloy and the conventional lost wax technique for traditional cast alloy. After all specimen surfaces had been wet ground with silicon carbide paper (1200 grit), each group of 10 specimens was put through a series of ceramic firing cycles. Microstructure, Vickers microhardness, surface composition, oxide film thickness, and corrosion behavior were examined for specimens before and after ceramic firing. Three-way ANOVA was used to evaluate the effect of porcelain firing and pH values on the corrosion behavior of the 2 alloys (α=.05). Student t tests were used to compare the Vickers hardness. Although porcelain firing changed the microstructure, microhardness, and x-ray photoelectron spectroscopy results, it showed no significant influence on the corrosion behavior of the selective laser melting alloy and traditional cast alloy (P>.05). No statistically significant influence was found on the corrosion behavior of the 2 alloys in different pH value solutions (P>.05). The porcelain firing process had no significant influence on the corrosion resistance results of the 2 alloys. Compared with traditional

Fatigue crack growth behavior of Inconel 718 produced by selective laser melting

Czech Academy of Sciences Publication Activity Database

Konečná, R.; Kunz, Ludvík; Nicoletto, G.; Bača, A.

2016-01-01

Roč. 35, č. 10 (2016), s. 31-40 ISSN 1971-8993 Institutional support: RVO:68081723 Keywords : Inconel 718 * Selective laser melting * Microstructure * Fatigue crack growth * Fractography Subject RIV: JL - Materials Fatigue, Friction Mechanics

Coaxial monitoring of temperature field in selective pulsed laser melting

Science.gov (United States)

Liu, Che; Chen, Zhongyun; Cao, Hongzhong; Zhou, Jianhong

2017-10-01

Selective Laser Melting is a rapid manufacturing technology which produces complex parts layer by layer. The presence of thermal stress and thermal strain in the forming process often leads to defects in the formed parts. In order to detect fabricate errors and avoid failure which caused by thermal gradient in time. An infrared thermal imager and a high speed CCD camera were applied to build a coaxial optical system for real-time monitoring the temperature distribution and changing trend of laser affected zone in SLM forming process. Molten tracks were fabricated by SLM under different laser parameters such as frequency, pulse width. And the relationship between the laser parameters and the temperature distribution were all obtained and analyzed.

Multiphysics modeling of selective laser sintering/melting

Science.gov (United States)

Ganeriwala, Rishi Kumar

A significant percentage of total global employment is due to the manufacturing industry. However, manufacturing also accounts for nearly 20% of total energy usage in the United States according to the EIA. In fact, manufacturing accounted for 90% of industrial energy consumption and 84% of industry carbon dioxide emissions in 2002. Clearly, advances in manufacturing technology and efficiency are necessary to curb emissions and help society as a whole. Additive manufacturing (AM) refers to a relatively recent group of manufacturing technologies whereby one can 3D print parts, which has the potential to significantly reduce waste, reconfigure the supply chain, and generally disrupt the whole manufacturing industry. Selective laser sintering/melting (SLS/SLM) is one type of AM technology with the distinct advantage of being able to 3D print metals and rapidly produce net shape parts with complicated geometries. In SLS/SLM parts are built up layer-by-layer out of powder particles, which are selectively sintered/melted via a laser. However, in order to produce defect-free parts of sufficient strength, the process parameters (laser power, scan speed, layer thickness, powder size, etc.) must be carefully optimized. Obviously, these process parameters will vary depending on material, part geometry, and desired final part characteristics. Running experiments to optimize these parameters is costly, energy intensive, and extremely material specific. Thus a computational model of this process would be highly valuable. In this work a three dimensional, reduced order, coupled discrete element - finite difference model is presented for simulating the deposition and subsequent laser heating of a layer of powder particles sitting on top of a substrate. Validation is provided and parameter studies are conducted showing the ability of this model to help determine appropriate process parameters and an optimal powder size distribution for a given material. Next, thermal stresses upon

Alumina-zirconium ceramics synthesis by selective laser sintering/melting

International Nuclear Information System (INIS)

Shishkovsky, I.; Yadroitsev, I.; Bertrand, Ph.; Smurov, I.

2007-01-01

In the present paper, porous refractory ceramics synthesized by selective laser sintering/melting from a mixture of zirconium dioxide, aluminum and/or alumina powders are subjected to optical metallography and X-ray analysis to study their microstructure and phase composition depending on the laser processing parameters. It is shown that high-speed laser sintering in air yields ceramics with dense structure and a uniform distribution of the stabilizing phases. The obtained ceramic-matrix composites may be used as thermal and electrical insulators and wear resistant coating in solid oxide fuel cells, crucibles, heating elements, medical tools. The possibility to reinforce refractory ceramics by laser synthesis is shown on the example of tetragonal dioxide of zirconium with hardened micro-inclusion of Al 2 O 3 . By applying finely dispersed Y 2 O 3 powder inclusions, the type of the ceramic structure is significantly changed

Selective Laser Melting Produced Ti-6Al-4V: Post-Process Heat Treatments to Achieve Superior Tensile Properties

Directory of Open Access Journals (Sweden)

Gerrit M. Ter Haar

2018-01-01

Full Text Available Current post-process heat treatments applied to selective laser melting produced Ti-6Al-4V do not achieve the same microstructure and therefore superior tensile behaviour of thermomechanical processed wrought Ti-6Al-4V. Due to the growing demand for selective laser melting produced parts in industry, research and development towards improved mechanical properties is ongoing. This study is aimed at developing post-process annealing strategies to improve tensile behaviour of selective laser melting produced Ti-6Al-4V parts. Optical and electron microscopy was used to study α grain morphology as a function of annealing temperature, hold time and cooling rate. Quasi-static uniaxial tensile tests were used to measure tensile behaviour of different annealed parts. It was found that elongated α’/α grains can be fragmented into equiaxial grains through applying a high temperature annealing strategy. It is shown that bi-modal microstructures achieve a superior tensile ductility to current heat treated selective laser melting produced Ti-6Al-4V samples.

A finite volume alternate direction implicit approach to modeling selective laser melting

DEFF Research Database (Denmark)

Hattel, Jesper Henri; Mohanty, Sankhya

2013-01-01

Over the last decade, several studies have attempted to develop thermal models for analyzing the selective laser melting process with a vision to predict thermal stresses, microstructures and resulting mechanical properties of manufactured products. While a holistic model addressing all involved...... to accurately simulate the process, are constrained by either the size or scale of the model domain. A second challenging aspect involves the inclusion of non-linear material behavior into the 3D implicit FE models. An alternating direction implicit (ADI) method based on a finite volume (FV) formulation...... is proposed for modeling single-layer and few-layers selective laser melting processes. The ADI technique is implemented and applied for two cases involving constant material properties and non-linear material behavior. The ADI FV method consume less time while having comparable accuracy with respect to 3D...

Point, surface and volumetric heat sources in the thermal modelling of selective laser melting

NARCIS (Netherlands)

Yang, Y.; Ayas, C.; Brabazon, Dermot; Naher, Sumsun; Ul Ahad, Inam

2017-01-01

Selective laser melting (SLM) is a powder based additive manufacturing technique suitable for producing high precision metal parts. However, distortions and residual stresses within products arise during SLM because of the high temperature gradients created by the laser heating. Residual stresses

Analysis and optimisation of vertical surface roughness in micro selective laser melting

International Nuclear Information System (INIS)

Abele, Eberhard; Kniepkamp, Michael

2015-01-01

Surface roughness is a major disadvantage of many additive manufacturing technologies like selective laser melting (SLM) compared to established processes like milling or drilling. With recent advancements the resolution of the SLM process could be increased to layer heights of less than 10 μm leading to a new process called micro selective laser melting (μSLM). The purpose of this paper is to analyze the influence of the μSLM process parameters and exposure strategies on the morphology of vertical surfaces. Contour scanning using varying process parameters was used to increase the surface quality. It is shown that it is possible to achieve average surface roughness of less than 1.7 μm using low scan speeds compared to 8–10 μm without contour scanning. Furthermore it is shown that a contour exposure prior to the core exposure leads to surface defects and thus increased roughness. (paper)

Predictive modeling, simulation, and optimization of laser processing techniques: UV nanosecond-pulsed laser micromachining of polymers and selective laser melting of powder metals

Science.gov (United States)

Criales Escobar, Luis Ernesto

One of the most frequently evolving areas of research is the utilization of lasers for micro-manufacturing and additive manufacturing purposes. The use of laser beam as a tool for manufacturing arises from the need for flexible and rapid manufacturing at a low-to-mid cost. Laser micro-machining provides an advantage over mechanical micro-machining due to the faster production times of large batch sizes and the high costs associated with specific tools. Laser based additive manufacturing enables processing of powder metals for direct and rapid fabrication of products. Therefore, laser processing can be viewed as a fast, flexible, and cost-effective approach compared to traditional manufacturing processes. Two types of laser processing techniques are studied: laser ablation of polymers for micro-channel fabrication and selective laser melting of metal powders. Initially, a feasibility study for laser-based micro-channel fabrication of poly(dimethylsiloxane) (PDMS) via experimentation is presented. In particular, the effectiveness of utilizing a nanosecond-pulsed laser as the energy source for laser ablation is studied. The results are analyzed statistically and a relationship between process parameters and micro-channel dimensions is established. Additionally, a process model is introduced for predicting channel depth. Model outputs are compared and analyzed to experimental results. The second part of this research focuses on a physics-based FEM approach for predicting the temperature profile and melt pool geometry in selective laser melting (SLM) of metal powders. Temperature profiles are calculated for a moving laser heat source to understand the temperature rise due to heating during SLM. Based on the predicted temperature distributions, melt pool geometry, i.e. the locations at which melting of the powder material occurs, is determined. Simulation results are compared against data obtained from experimental Inconel 625 test coupons fabricated at the National

Aging Behaviour and Mechanical Performance of 18-Ni 300 Steel Processed by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Riccardo Casati

2016-09-01

Full Text Available An 18-Ni 300 grade maraging steel was processed by selective laser melting and an investigation was carried out on microstructural and mechanical behaviour as a function of aging condition. Owing to the rapid cooling rate, the as-built alloy featured a full potential for precipitate strengthening, without the need of a solution treatment prior to aging. The amount of reversed austenite found in the microstructure increased after aging and revealed to depend on aging temperature and time. Similarly to the corresponding wrought counterpart, also in the selective laser-melted 18-Ni 300 alloy, aging promoted a dramatic increase in strength with respect to the as-built condition and a drop in tensile ductility. No systematic changes were found in tensile properties as a function of measured amount of austenite. It is proposed that the submicrometric structure and the phase distribution inherited by the rapid solidification condition brought by selective laser melting are such that changes in tensile strength and ductility are mainly governed by the effects brought by the strengthening precipitates, whereas the concurrent reversion of the γ-Fe phase in different amounts seems to play a minor role.

Microstructure of Ti-6Al-4V produced by selective laser melting

International Nuclear Information System (INIS)

Simonelli, M; Tse, Y Y; Tuck, C

2012-01-01

Ti-6Al-4V is the most widely used titanium alloy. Manufacturing of Ti-6Al-4V components using novel additive processing techniques such as selective laser melting is of great interest. This study focuses on the microstructure characterisation of Ti-6Al-4V components produced by selective laser melting (SLM) with full (Ti-6Al-4V base plate) and partial (Ti-6Al-4V needle-shaped bed) support. The starting material, a plasma atomised powder, and the component products are studied using various microscopy techniques including optical, scanning electron and transmission electron microscopy and electron backscattered diffraction (EBSD). Powder particles are fully dense, possess a spherical shape and are composed of acicular α phase. The as-built material shows oriented acicular martensitic phase with well defined columnar grains. The morphology of martensitic phase and microstructural evolution will be discussed in relation to the SLM processing parameters employed and the different cooling rates experienced by the components.

Development of Physics-Based Numerical Models for Uncertainty Quantification of Selective Laser Melting Processes

Data.gov (United States)

National Aeronautics and Space Administration — The goal of the proposed research is to characterize the influence of process parameter variability inherent to Selective Laser Melting (SLM) and performance effect...

Preheat effect on titanium plate fabricated by sputter-free selective laser melting in vacuum

Science.gov (United States)

Sato, Yuji; Tsukamoto, Masahiro; Shobu, Takahisa; Yamashita, Yorihiro; Yamagata, Shuto; Nishi, Takaya; Higashino, Ritsuko; Ohkubo, Tomomasa; Nakano, Hitoshi; Abe, Nobuyuki

2018-04-01

The dynamics of titanium (Ti) melted by laser irradiation was investigated in a synchrotron radiation experiment. As an indicator of wettability, the contact angle between a selective laser melting (SLM) baseplate and the molten Ti was measured by synchrotron X-rays at 30 keV during laser irradiation. As the baseplate temperature increased, the contact angle decreased, down to 28° at a baseplate temperature of 500 °C. Based on this result, the influence of wettability of a Ti plate fabricated by SLM in a vacuum was investigated. It was revealed that the improvement of wettability by preheating suppressed sputtering generation, and a surface having a small surface roughness was fabricated by SLM in a vacuum.

Observation of melting conditions in selective laser melting of metals (SLM)

Science.gov (United States)

Thombansen, U.; Abels, Peter

2016-03-01

Process observation in 3D printing of metals currently is one of the central challenges. Many companies strive to employ this additive manufacturing process in their production chains in order to gain competitive advantages through added flexibility in product design and embedded features. The new degrees of freedom are accompanied with the challenge to manufacture every detail of the product to the predefined specifications. Products with filigree internal structures for example require a perfect build to deliver the performance that was designed into these structures. Melting conditions determine properties such as grain structure and density of the finished part before it is sent to post processing steps. Monitoring of such melting conditions is still a challenge where the use of photodiodes, pyrometry and camera systems contribute to an overall picture that might identify errors or deviations during the build process. Additional considerations must be made to decide if these sensors are applied coaxially or from a lateral perspective. Furthermore, setting parameters of focal plane array (FPA) sensors are discussed and events that are seen in the machine vision image are compared against the pyrometry data. The resume of the experiments suggests the application of multiple sensors to the selective laser melting process (SLM) as they jointly contribute to an identification of events. These events need to be understood in order to establish cause effect relationships in the future.

Study on the Selective Laser Melting of CuSn10 Powder.

Science.gov (United States)

Deng, Chengyang; Kang, Jinwu; Feng, Tao; Feng, Yunlong; Wang, Xiang; Wu, Pengyue

2018-04-17

The selective laser melting of tin bronze (CuSn 10 ) powder was performed with a laser energy density intensity level at 210, 220, and 230 J/mm². The composition was homogeneous with almost all tin dissolved into the matrix. The grain size of the obtained alpha copper phase was around 5 μm. The best properties were achieved at 220 J/mm² laser energy density with a density of 8.82 g/cm³, hardness of 78.2 HRB (Rockwell Hardness measured on the B scale), yield strength of 399 MPa, tensile strength of 490 MPa, and an elongation that reached 19%. “Balling effect” appeared and resulted into a decrease of properties when the laser energy density increased to 230 J/mm².

Thermal behavior and densification mechanism during selective laser melting of copper matrix composites: Simulation and experiments

International Nuclear Information System (INIS)

Dai, Donghua; Gu, Dongdong

2014-01-01

Highlights: • Thermal behavior and densification activity during SLM of composites are simulated. • Temperature distributions and melt pool dimensions during SLM are disclosed. • Motion behaviors of gaseous bubbles in laser induced melt pool are elucidated. • Simulation results show good agreement with the obtained experimental results. - Abstract: Simulation of temperature distribution and densification process of selective laser melting (SLM) WC/Cu composite powder system has been performed, using a finite volume method (FVM). The transition from powder to solid, the surface tension induced by temperature gradient, and the movement of laser beam power with a Gaussian energy distribution are taken into account in the physical model. The effect of the applied linear energy density (LED) on the temperature distribution, melt pool dimensions, behaviors of gaseous bubbles and resultant densification activity has been investigated. It shows that the temperature distribution is asymmetric with respect to the laser beam scanning area. The center of the melt pool does not locate at the center of the laser beam but slightly shifts towards the side of the decreasing X-axis. The dimensions of the melt pool are in sizes of hundreds of micrometers and increase with the applied LED. For an optimized LED of 17.5 kJ/m, an enhanced efficiency of gas removal from the melt pool is realized, and the maximum relative density of laser processed powder reaches 96%. As the applied LED surpasses 20 kJ/m, Marangoni flow tends to retain the entrapped gas bubbles. The flow pattern has a tendency to deposit the gas bubbles at the melt pool bottom or to agglomerate gas bubbles by the rotating flow in the melt pool, resulting in a higher porosity in laser processed powder. The relative density and corresponding pore size and morphology are experimentally acquired, which are in a good agreement with the results predicted by simulation

Testing of Selective Laser Melting Turbomachinery Applicable to Exploration Upper Stage

Science.gov (United States)

Calvert, Marty; Turpin, Jason; Nettles, Mindy

2015-01-01

This task is to design, fabricate, and spin test to failure a Ti6-4 hydrogen turbopump impeller that was built using the selective laser melting (SLM) fabrication process (fig. 1). The impeller is sized around upper stage engine requirements. In addition to the spin burst test, material testing will be performed on coupons that are built with the impeller.

Selective Laser Melting of Ti-45Nb Alloy

Directory of Open Access Journals (Sweden)

Holger Schwab

2015-04-01

Full Text Available Ti-45Nb is one of the potential alloys that can be applied for biomedical applications as implants due to its low Young’s modulus. Ti-45Nb (wt.% gas atomized powders were used to produce bulk samples by selective laser melting with three different parameter sets (energy inputs. A β-phase microstructure consisting of elliptical grains with an enriched edge of titanium was observed by scanning electron microscopy and X-ray diffraction studies. The mechanical properties of these samples were evaluated using hardness and compression tests, which suggested that the strength of the samples increases with increasing energy input within the range considered.

Influence of Support Configurations on the Characteristics of Selective Laser-Melted Inconel 718

Science.gov (United States)

Nadammal, Naresh; Kromm, Arne; Saliwan-Neumann, Romeo; Farahbod, Lena; Haberland, Christoph; Portella, Pedro Dolabella

2018-03-01

Samples fabricated using two different support configurations by following identical scan strategies during selective laser melting of superalloy Inconel 718 were characterized in this study. Characterization methods included optical microscopy, electron back-scattered diffraction and x-ray diffraction residual stress measurement. For the scan strategy considered, microstructure and residual stress development in the samples were influenced by the support structures. However, crystallographic texture intensity and the texture components formed within the core part of the samples were almost independent of the support. The formation of finer grains closer to the support as well as within the columnar grain boundaries resulted in randomization and texture intensity reduction by nearly half for the sample built on a lattice support. Heat transfer rates dictated by the support configurations in addition to the scan strategy influenced the microstructure and residual stress development in selective laser-melted Inconel 718 samples.

Selective laser melting of Invar 36: Microstructure and properties

International Nuclear Information System (INIS)

Qiu, Chunlei; Adkins, Nicholas J.E.; Attallah, Moataz M.

2016-01-01

Invar 36 samples have been fabricated by selective laser melting at a constant laser power but with varied laser scanning speeds. Some samples were further heat treated or hot isostatically pressed (HIPed). The obtained microstructures were studied using optical and electron microscopes, X-ray diffraction and electron backscatter diffraction techniques and the properties evaluated through both tensile testing and thermal expansion measurement. It was found that the as-fabricated samples show very low porosity (<0.5%) when the laser scanning speeds are below 3200 mm/s but show remarkably increased porosity above 3200 mm/s (at 400 W). Increased scanning speed also led to increasingly irregular-shaped laser scanned tracks together with an increased number of pores on sample surfaces and keyhole features within the samples, all indicative of increasingly unstable melt flow behaviour. The as-fabricated microstructure was dominated by columnar γ grains decorated by nanosized α precipitates, resulting in development of texture. Heat treatment did not change microstructure significantly while HIPing closed the majority of pores but also caused pronounced coarsening of α precipitates especially those located at grain boundaries during subsequent slow cooling. With the presence of elongated pores, the vertically built samples were found to show much lower elongation than horizontally built samples while in the absence of pores their ductility has been significantly improved but their tensile strengths are still lower than the latter. The vertically built samples generally failed in a transgranular mode while the horizontally built samples failed in an intergranular mode. HIPing greatly degraded tensile properties due to the presence of coarse grain boundary α precipitates weakening the bonding between grains. Irrespective of building orientations, the as-fabricated samples show low coefficients of thermal expansion below 300 °C comparable to conventionally

Study on the Selective Laser Melting of CuSn10 Powder

Directory of Open Access Journals (Sweden)

Chengyang Deng

2018-04-01

Full Text Available The selective laser melting of tin bronze (CuSn10 powder was performed with a laser energy density intensity level at 210, 220, and 230 J/mm2. The composition was homogeneous with almost all tin dissolved into the matrix. The grain size of the obtained alpha copper phase was around 5 μm. The best properties were achieved at 220 J/mm2 laser energy density with a density of 8.82 g/cm3, hardness of 78.2 HRB (Rockwell Hardness measured on the B scale, yield strength of 399 MPa, tensile strength of 490 MPa, and an elongation that reached 19%. “Balling effect” appeared and resulted into a decrease of properties when the laser energy density increased to 230 J/mm2.

Long fatigue crack growth in Inconel 718 produced by selective laser melting

Czech Academy of Sciences Publication Activity Database

Konečná, R.; Kunz, Ludvík; Nicoletto, G.; Bača, A.

2016-01-01

Roč. 92, NOV (2016), s. 499-506 ISSN 0142-1123. [CP 2015 - International Conference on Crack Paths /5./. Ferrara, 16.09.2015-18.09.2015] Institutional support: RVO:68081723 Keywords : Inconel 718 * Selective laser melting * Microstructure * Fatigue crack growth * Fractography Subject RIV: JL - Materials Fatigue, Friction Mechanics Impact factor: 2.899, year: 2016

Microstructural and mechanical approaches of the selective laser melting process applied to a nickel-base superalloy

International Nuclear Information System (INIS)

Vilaro, T.; Colin, C.; Bartout, J.D.; Nazé, L.; Sennour, M.

2012-01-01

Highlights: ► We examine the as-fabricated microstructure of the Nimonic 263 processed by selective laser melting. ► We optimized heat treatments to modify the microstructure and improve the mechanical properties. ► We tested through tensile tests the various microstructures in order to compare the effects of the heat treatments. - Abstract: This article aims at presenting the Nimonic 263 as-processed microstructure of the selective laser melting which is an innovative process. Because the melting pool is small and the scanning speed of the laser beam is relatively high, the as-processed microstructure is out-of-equilibrium and very typical to additive manufacturing processes. To match the industrial requirement, the microstructures are modified through heat treatments in order to either produce precipitation hardening or relieve the thermal stresses. Tensile tests at room temperature give rise to high mechanical properties close or above those presented by Wang et al. . However, it is noted a strong anisotropy as a function of the building direction of the samples because of the columnar grain growth.

Process observation in fiber laser-based selective laser melting

Science.gov (United States)

Thombansen, Ulrich; Gatej, Alexander; Pereira, Milton

2015-01-01

The process observation in selective laser melting (SLM) focuses on observing the interaction point where the powder is processed. To provide process relevant information, signals have to be acquired that are resolved in both time and space. Especially in high-power SLM, where more than 1 kW of laser power is used, processing speeds of several meters per second are required for a high-quality processing results. Therefore, an implementation of a suitable process observation system has to acquire a large amount of spatially resolved data at low sampling speeds or it has to restrict the acquisition to a predefined area at a high sampling speed. In any case, it is vitally important to synchronously record the laser beam position and the acquired signal. This is a prerequisite that allows the recorded data become information. Today, most SLM systems employ f-theta lenses to focus the processing laser beam onto the powder bed. This report describes the drawbacks that result for process observation and suggests a variable retro-focus system which solves these issues. The beam quality of fiber lasers delivers the processing laser beam to the powder bed at relevant focus diameters, which is a key prerequisite for this solution to be viable. The optical train we present here couples the processing laser beam and the process observation coaxially, ensuring consistent alignment of interaction zone and observed area. With respect to signal processing, we have developed a solution that synchronously acquires signals from a pyrometer and the position of the laser beam by sampling the data with a field programmable gate array. The relevance of the acquired signals has been validated by the scanning of a sample filament. Experiments with grooved samples show a correlation between different powder thicknesses and the acquired signals at relevant processing parameters. This basic work takes a first step toward self-optimization of the manufacturing process in SLM. It enables the

Parameter optimization for selective laser melting of TiAl6V4 alloy by CO2 laser

Science.gov (United States)

Baitimerov, R. M.; Lykov, P. A.; Radionova, L. V.; Safonov, E. V.

2017-10-01

TiAl6V4 alloy is one of the widely used materials in powder bed fusion additive manufacturing technologies. In recent years selective laser melting (SLM) of TiAl6V4 alloy by fiber laser has been well studied, but SLM by CO2-lasers has not. SLM of TiAl6V4 powder by CO2-laser was studied in this paper. Nine 10×10×10 mm cubic specimens were fabricated using different SLM process parameters. All of the fabricated specimens have a good dense structure and a good surface finish quality without dimensional distortion. The lowest porosity that was achieved was about 0.5%.

Antibacterial Titanium Produced Using Selective Laser Melting

Science.gov (United States)

Macpherson, Andrew; Li, Xiaopeng; McCormick, Paul; Ren, Ling; Yang, Ke; Sercombe, Timothy B.

2017-12-01

Titanium and titanium alloys used in current medical and dental applications do not possess antibacterial properties, and therefore, postoperative infection remains a significant risk. Recently, the addition of silver and copper to conventional biomaterials has been shown to produce a material with good antibacterial properties. In this article, we investigate selective laser melting as a method of producing antibacterial Ti-6Al-4V containing elemental additions of Cu or Ag. The addition of Ag had no effect on the microstructure or strength, but it did result in a 300% increase in the ductility of the alloy. In contrast, the addition of Cu resulted in an increase in strength but in a decrease in ductility, along with a change in the structure of the material. The Cu-containing alloy also showed moderate antibacterial properties and was superior to the Ag-containing alloy.

On the role of thermal fluid dynamics into the evolution of porosity during selective laser melting

International Nuclear Information System (INIS)

Panwisawas, C.; Qiu, C.L.; Sovani, Y.; Brooks, J.W.; Attallah, M.M.; Basoalto, H.C.

2015-01-01

Thermal fluid dynamics and experiments have been used to study the evolution of pores during selective laser melting of Ti-6Al-4V. Scanning electron micrographs show that the morphology of pores changed from near-spherical to elongated shape as the laser scan speed increased. Computational fluid dynamics suggests that this is caused by the change of flow pattern in the melt pool which is dictated by forces such as vapour pressure, gravitational force, capillary and thermal capillary forces exerted on the metallic/gaseous interface

Performance of High Layer Thickness in Selective Laser Melting of Ti6Al4V

Directory of Open Access Journals (Sweden)

Xuezhi Shi

2016-12-01

Full Text Available To increase building rate and save cost, the selective laser melting (SLM of Ti6Al4V with a high layer thickness (200 μm and low cost coarse powders (53 μm–106 μm at a laser power of 400 W is investigated in this preliminary study. A relatively large laser beam with a diameter of 200 μm is utilized to produce a stable melt pool at high layer thickness, and the appropriate scanning track, which has a smooth surface with a shallow contact angle, can be obtained at the scanning speeds from 40 mm/s to 80 mm/s. By adjusting the hatch spacings, the density of multi-layer samples can be up to 99.99%, which is much higher than that achieved in previous studies about high layer thickness selective laser melting. Meanwhile, the building rate can be up to 7.2 mm3/s, which is about 2 times–9 times that of the commercial equipment. Besides, two kinds of defects are observed: the large un-melted defects and the small spherical micropores. The formation of the un-melted defects is mainly attributed to the inappropriate overlap rates and the unstable scanning tracks, which can be eliminated by adjusting the processing parameters. Nevertheless, the micropores cannot be completely eliminated. It is worth noting that the high layer thickness plays a key role on surface roughness rather than tensile properties during the SLM process. Although a sample with a relatively coarse surface is generated, the average values of yield strength, ultimate tensile strength, and elongation are 1050 MPa, 1140 MPa, and 7.03%, respectively, which are not obviously different than those with the thin layer thickness used in previous research; this is due to the similar metallurgical bonding and microstructure.

Performance of High Layer Thickness in Selective Laser Melting of Ti6Al4V.

Science.gov (United States)

Shi, Xuezhi; Ma, Shuyuan; Liu, Changmeng; Chen, Cheng; Wu, Qianru; Chen, Xianping; Lu, Jiping

2016-12-01

To increase building rate and save cost, the selective laser melting (SLM) of Ti6Al4V with a high layer thickness (200 μm) and low cost coarse powders (53 μm-106 μm) at a laser power of 400 W is investigated in this preliminary study. A relatively large laser beam with a diameter of 200 μm is utilized to produce a stable melt pool at high layer thickness, and the appropriate scanning track, which has a smooth surface with a shallow contact angle, can be obtained at the scanning speeds from 40 mm/s to 80 mm/s. By adjusting the hatch spacings, the density of multi-layer samples can be up to 99.99%, which is much higher than that achieved in previous studies about high layer thickness selective laser melting. Meanwhile, the building rate can be up to 7.2 mm³/s, which is about 2 times-9 times that of the commercial equipment. Besides, two kinds of defects are observed: the large un-melted defects and the small spherical micropores. The formation of the un-melted defects is mainly attributed to the inappropriate overlap rates and the unstable scanning tracks, which can be eliminated by adjusting the processing parameters. Nevertheless, the micropores cannot be completely eliminated. It is worth noting that the high layer thickness plays a key role on surface roughness rather than tensile properties during the SLM process. Although a sample with a relatively coarse surface is generated, the average values of yield strength, ultimate tensile strength, and elongation are 1050 MPa, 1140 MPa, and 7.03%, respectively, which are not obviously different than those with the thin layer thickness used in previous research; this is due to the similar metallurgical bonding and microstructure.

Microstructure and tensile properties of selectively laser-melted and of HIPed laser-melted Ti–6Al–4V

International Nuclear Information System (INIS)

Qiu, Chunlei; Adkins, Nicholas J.E.; Attallah, Moataz M.

2013-01-01

Ti–6Al–4V samples have been prepared by selective laser melting (SLM) with varied processing conditions. Some of the samples were stress-relieved or hot isostatically pressed (HIPed). The microstructures of all samples were characterised using optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD) and the tensile properties measured before and after HIPing. It was found that the porosity level generally decreased with increase of laser power and laser scanning speed. Horizontally built samples were found to have a higher level of porosity than vertically built samples. The as-fabricated microstructure was dominated by columnar grains and martensites. HIPing closed the majority of the pores and also fully transformed the martensite into α and β phases. The as-fabricated microstructure exhibits very high tensile strengths but poor ductility with elongation generally smaller than 10%. The horizontally built samples show even lower elongation than vertically built samples. HIPing considerably improved ductility but led to a reduction in strength. With HIPing, the SLMed samples were found to show tensile properties comparable with those thermomechanically processed and annealed samples

Reducing residual stresses and deformations in selective laser melting through multi-level multi-scale optimization of cellular scanning strategy

DEFF Research Database (Denmark)

Mohanty, Sankhya; Hattel, Jesper Henri

2016-01-01

. A multilevel optimization strategy is adopted using a customized genetic algorithm developed for optimizing cellular scanning strategy for selective laser melting, with an objective of reducing residual stresses and deformations. The resulting thermo-mechanically optimized cellular scanning strategies......, a calibrated, fast, multiscale thermal model coupled with a 3D finite element mechanical model is used to simulate residual stress formation and deformations during selective laser melting. The resulting reduction in thermal model computation time allows evolutionary algorithm-based optimization of the process...

3D-imaging of selective laser melting defects in a Co–Cr–Mo alloy by synchrotron radiation micro-CT

International Nuclear Information System (INIS)

Zhou, Xin; Wang, Dianzheng; Liu, Xihe; Zhang, DanDan; Qu, Shilian; Ma, Jing; London, Gary; Shen, Zhijian; Liu, Wei

2015-01-01

Microstructure defects set the mechanical property limits for solid Co–Cr–Mo alloy prepared by selective laser melting (SLM). Previous studies were mainly based on 2D SEM images and thus not able to provide information of the 3D morphologies of the complex defects. In this paper, the remaining porosities in Co–Cr–Mo alloy parts prepared by selective laser melting were presented in relation to the laser processing parameters. In order to understand the defect forming mechanism, accurate 3D images of defects inside SLM fabricated Co–Cr–Mo samples were provided by synchrotron radiation micro-CT imaging of 300 μm thick slices cut from a 10 mm cube. With 3D reconstructed images distinctive morphologies of SLM defects spanning across the consolidated powder layers were generated. The faults can be classified as single layer or multi-layers defects. The accidental single layer defects form as gaps between adjacent laser melt tracks or melt track discontinuousness caused by inherent fluid instability under various disturbances. The first formed single layer defect generates often a multi-layer defect spanning for 2–3 subsequent powder layers. By stabilizing the melt pool flow and by reducing the surface roughness through adjusting processing parameters it appears possible to reduce the defect concentrations

[Influence of implants prepared by selective laser melting on early bone healing].

Science.gov (United States)

Liu, J Y; Chen, F; Ge, Y J; Wei, L; Pan, S X; Feng, H L

2018-02-18

To evaluate the influence of the rough surface of dental implants prepared by selective laser melting (SLM) on early bone healing around titanium implants. A total of sixteen titanium implants were involved in our research, of which eight implants were prepared by SLM (TIXOS Cylindrical, Leader-Novaxa, Milan, Italy; 3.3 mm×10 mm, internal hex) and the other eight were sandblasted, large-grit and acid-etched (SLA) implants (IMPLUS Cylindrical, Leader-Novaxa, Milan, Italy; 3.3 mm×10 mm, internal hex). All of the dental implants were inserted into the healed extraction sockets of the mandible of two adult male Beagle dogs. Half of the dental implants were designed to be healed beneath the mucosa and the other half were intended to be healed transgingivally and were immediately loaded by acrylic resin bridge restoration. Three types of tetracycline fluorescent labels, namely calcein blue, alizarin complexone and calcein, were administered into the veins of the Beagle dogs 2, 4, and 8 weeks after implant placement respectively for fluorescent evaluation of newly formed bone peri-implant. Both Beagle dogs were euthanized 12 weeks after implant insertion and the mandible block specimens containing the titanium implants and surrounding bone and soft tissue of each dog were carefully sectioned and dissected. A total of 16 hard tissue slices were obtained and stained with toluidine blue for microscopic examination and histomorphometric measurements. Histological observation was made for each slice under light microscope and laser scanning confocal microscope (LSCM). Comparison on new bone formation around titanium implants of each group was made and mineral apposition rate (MAR) was calculated for each group. Dental implants prepared by selective laser melting had achieved satisfying osseointegration to surrounding bone tissue after the healing period of 12 weeks. Newly formed bone tissue was observed creeping on the highly porous surface of the SLM implant and growing

In vitro biocompatibility of CoCrMo dental alloys fabricated by selective laser melting.

Science.gov (United States)

Hedberg, Yolanda S; Qian, Bin; Shen, Zhijian; Virtanen, Sannakaisa; Wallinder, Inger Odnevall

2014-05-01

Selective laser melting (SLM) is increasingly used for the fabrication of customized dental components made of metal alloys such as CoCrMo. The main aim of the present study is to elucidate the influence of the non-equilibrium microstructure obtained by SLM on corrosion susceptibility and extent of metal release (measure of biocompatibility). A multi-analytical approach has been employed by combining microscopic and bulk compositional tools with electrochemical techniques and chemical analyses of metals in biologically relevant fluids for three differently SLM fabricated CoCrMo alloys and one cast CoCrMo alloy used for comparison. Rapid cooling and strong temperature gradients during laser melting resulted in the formation of a fine cellular structure with cell boundaries enriched in Mo (Co depleted), and suppression of carbide precipitation and formation of a martensitic ɛ (hcp) phase at the surface. These features were shown to decrease the corrosion and metal release susceptibility of the SLM alloys compared with the cast alloy. Unique textures formed in the pattern of the melting pools of the three different laser melted CoCrMo alloys predominantly explain observed small, though significant, differences. The susceptibility for corrosion and metal release increased with an increased number (area) of laser melt pool boundaries. This study shows that integrative and interdisciplinary studies of microstructural characteristics, corrosion, and metal release are essential to assess and consider during the design and fabrication of CoCrMo dental components of optimal biocompatibility. The reason is that the extent of metal release from CoCrMo is dependent on fabrication procedures. Copyright © 2014 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Selective laser melting-produced porous titanium scaffolds regenerate bone in critical size cortical bone defects

NARCIS (Netherlands)

J. van der Stok (Johan); O.P. van der Jagt (Olav); S. Amin Yavari (Saber); M.F.P. de Haas (Mirthe); J.H. Waarsing (Jan); H. Jahr (Holger); E.M.M. van Lieshout (Esther); P. Patka (Peter); J.A.N. Verhaar (Jan); A.A. Zadpoor (Amir Abbas); H.H. Weinans (Harrie)

2013-01-01

textabstractPorous titanium scaffolds have good mechanical properties that make them an interesting bone substitute material for large bone defects. These scaffolds can be produced with selective laser melting, which has the advantage of tailoring the structure's architecture. Reducing the strut

Design and manufacture of customized dental implants by using reverse engineering and selective laser melting technology.

Science.gov (United States)

Chen, Jianyu; Zhang, Zhiguang; Chen, Xianshuai; Zhang, Chunyu; Zhang, Gong; Xu, Zhewu

2014-11-01

Recently a new therapeutic concept of patient-specific implant dentistry has been advanced based on computer-aided design/computer-aided manufacturing technology. However, a comprehensive study of the design and 3-dimensional (3D) printing of the customized implants, their mechanical properties, and their biomechanical behavior is lacking. The purpose of this study was to evaluate the mechanical and biomechanical performance of a novel custom-made dental implant fabricated by the selective laser melting technique with simulation and in vitro experimental studies. Two types of customized implants were designed by using reverse engineering: a root-analog implant and a root-analog threaded implant. The titanium implants were printed layer by layer with the selective laser melting technique. The relative density, surface roughness, tensile properties, bend strength, and dimensional accuracy of the specimens were evaluated. Nonlinear and linear finite element analysis and experimental studies were used to investigate the stress distribution, micromotion, and primary stability of the implants. Selective laser melting 3D printing technology was able to reproduce the customized implant designs and produce high density and strength and adequate dimensional accuracy. Better stress distribution and lower maximum micromotions were observed for the root-analog threaded implant model than for the root-analog implant model. In the experimental tests, the implant stability quotient and pull-out strength of the 2 types of implants indicated that better primary stability can be obtained with a root-analog threaded implant design. Selective laser melting proved to be an efficient means of printing fully dense customized implants with high strength and sufficient dimensional accuracy. Adding the threaded characteristic to the customized root-analog threaded implant design maintained the approximate geometry of the natural root and exhibited better stress distribution and

Highly porous, low elastic modulus 316L stainless steel scaffold prepared by selective laser melting

Czech Academy of Sciences Publication Activity Database

Čapek, Jaroslav; Machová, M.; Fousová, M.; Kubásek, J.; Vojtěch, D.; Fojt, J.; Jablonská, E.; Lipov, J.; Ruml, T.

2016-01-01

Roč. 69, Dec (2016), 631–639 ISSN 0928-4931 R&D Projects: GA ČR GBP108/12/G043 Institutional support: RVO:68378271 Keywords : selective laser melting * 316L stainless steel * porous implants * scaffolds Subject RIV: BM - Solid Matter Physics ; Magnetism

Tracking the course of the manufacturing process in selective laser melting

Science.gov (United States)

Thombansen, U.; Gatej, A.; Pereira, M.

2014-02-01

An innovative optical train for a selective laser melting based manufacturing system (SLM) has been designed under the objective to track the course of the SLM process. In this, the thermal emission from the melt pool and the geometric properties of the interaction zone are addressed by applying a pyrometer and a camera system respectively. The optical system is designed such that all three radiations from processing laser, thermal emission and camera image are coupled coaxially and that they propagate on the same optical axis. As standard f-theta lenses for high power applications inevitably lead to aberrations and divergent optical axes for increasing deflection angles in combination with multiple wavelengths, a pre-focus system is used to implement a focusing unit which shapes the beam prior to passing the scanner. The sensor system records synchronously the current position of the laser beam, the current emission from the melt pool and an image of the interaction zone. Acquired data of the thermal emission is being visualized after processing which allows an instant evaluation of the course of the process at any position of each layer. As such, it provides a fully detailed history of the product This basic work realizes a first step towards self-optimization of the manufacturing process by providing information about quality relevant events during manufacture. The deviation from the planned course of the manufacturing process to the actual course of the manufacturing process can be used to adapt the manufacturing strategy from one layer to the next. In the current state, the system can be used to facilitate the setup of the manufacturing system as it allows identification of false machine settings without having to analyze the work piece.

Investigation on Mechanical Properties’ Anisotropy of Rod Units in Lattice Structures Fabricated by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Jing Chenchen

2017-01-01

Full Text Available Lattice structure with high strength and low mass using selective laser melting (SLM has been a hot topic. However, there are some problems in the fabrication of lattice structure by SLM. Rod unit is the basic component of lattice structure and its performance affects the whole structure. It is necessary to investigate the influence of selective laser melting on rod unit’s mechanical properties. A series of rod units with different inclination angle and diameter were fabricated by SLM in this research. And the mechanical properties of these units were measured by tensile test. The results show that the rod units with different diameters and inclination angles have good mechanical properties and show no difference. It is a good news for lattice structure designing for there is no necessary to consider the mechanical properties’ anisotropy of rod units.

Microstructure and mechanical properties of a novel β titanium metallic composite by selective laser melting

International Nuclear Information System (INIS)

Vrancken, B.; Thijs, L.; Kruth, J.-P.; Van Humbeeck, J.

2014-01-01

Selective laser melting (SLM) is an additive manufacturing process in which functional, complex parts are produced by selectively melting consecutive layers of powder with a laser beam. This flexibility enables the exploration of a wide spectrum of possibilities in creating novel alloys or even metal–metal composites with unique microstructures. In this research, Ti6Al4V-ELI powder was mixed with 10 wt.% Mo powder. In contrast to the fully α′ microstructure of Ti6Al4V after SLM, the novel microstructure consists of a β titanium matrix with randomly dispersed pure Mo particles, as observed by light optical microscopy, scanning electron microscopy and X-ray diffraction. Most importantly, the solidification mechanism changes from planar to cellular mode. Microstructures after heat treatment indicate that the β phase is metastable and locate the β transus at ∼900 °C, and tensile properties are equal to or better than conventional β titanium alloys

Manufacturing of thin-walled parts for machinery by selective laser melting

Directory of Open Access Journals (Sweden)

Bobyr Vitaliy

2017-01-01

Full Text Available The paper describes the technology of selective laser melting, as well as its capabilities in the manufacture of thin-wall honeycomb energy absorber (HEA. The effect of the technological parameters of the building process on the HEA walls’ thickness is studied. Conformity analysis of the mass-dimensional characteristics of the finished composition with the predefined parameters of the 3D-CAD model is carried out. Dependencies of building parameterson the quality of the manufactured HEA are established, general recommendations for the practical use of technology in the creation of HEAare given.

Processing of a metastable titanium alloy (Ti-5553 by selective laser melting

Directory of Open Access Journals (Sweden)

C. Zopp

2017-09-01

Material densities above 99.93% were achieved by optimisation of energy input during selective laser melting process. However, the use of reference fraction (10–63 μm allowed the highest material density. Regarding to surface quality, an impact of coarse grain (53–63 μm was identified and an optimised grain size distribution derived. An optimum averaged surface roughness could be calculated, using a grain size between 25–32 μm.

Selective laser melting of hypereutectic Al-Si40-powder using ultra-short laser pulses

Science.gov (United States)

Ullsperger, T.; Matthäus, G.; Kaden, L.; Engelhardt, H.; Rettenmayr, M.; Risse, S.; Tünnermann, A.; Nolte, S.

2017-12-01

We investigate the use of ultra-short laser pulses for the selective melting of Al-Si40-powder to fabricate complex light-weight structures with wall sizes below 100 μ {m} combined with higher tensile strength and lower thermal expansion coefficient in comparison to standard Al-Si alloys. During the cooling process using conventional techniques, large primary silicon particles are formed which impairs the mechanical and thermal properties. We demonstrate that these limitations can be overcome using ultra-short laser pulses enabling the rapid heating and cooling in a non-thermal equilibrium process. We analyze the morphology characteristics and micro-structures of single tracks and thin-walled structures depending on pulse energy, repetition rate and scanning velocity utilizing pulses with a duration of 500 {fs} at a wavelength of 1030 {nm}. The possibility to specifically change and optimize the microstructure is shown.

Surface Quality Research for Selective Laser Melting of Ti-6Al-4V Alloy

Directory of Open Access Journals (Sweden)

Król M.

2016-09-01

Full Text Available One of the innovative technology of producing the components is Selective Laser Melting (SLM belongs to additive manufacturing techniques. SLM technology has already been successfully applied in the automotive, aerospace and medical industries. Despite progress in material flexibility and mechanical performances, relatively poor surface finish still presents a significant weakness in the SLM process.

Strong morphological and crystallographic texture and resulting yield strength anisotropy in selective laser melted tantalum

International Nuclear Information System (INIS)

Thijs, Lore; Montero Sistiaga, Maria Luz; Wauthle, Ruben; Xie, Qingge; Kruth, Jean-Pierre; Van Humbeeck, Jan

2013-01-01

Selective laser melting (SLM) makes use of a high energy density laser beam to melt successive layers of metallic powders in order to create functional parts. The energy density of the laser is high enough to melt refractory metals like Ta and produce mechanically sound parts. Furthermore, the localized heat input causes a strong directional cooling and solidification. Epitaxial growth due to partial remelting of the previous layer, competitive growth mechanism and a specific global direction of heat flow during SLM of Ta result in the formation of long columnar grains with a 〈1 1 1〉 preferential crystal orientation along the building direction. The microstructure was visualized using both optical and scanning electron microscopy equipped with electron backscattered diffraction and the global crystallographic texture was measured using X-ray diffraction. The thermal profile around the melt pool was modeled using a pragmatic model for SLM. Furthermore, rotation of the scanning direction between different layers was seen to promote the competitive growth. As a result, the texture strength increased to as large as 4.7 for rotating the scanning direction 90° every layer. By comparison of the yield strength measured by compression tests in different orientations and the averaged Taylor factor calculated using the viscoplastic self-consistent model, it was found that both the morphological and crystallographic texture observed in SLM Ta contribute to yield strength anisotropy

RESIDUAL STRESS MEASUREMENTS AND STRUCTURAL INTEGRITY IMPLICATIONS FOR SELECTIVE LASER MELTED TI-6AL-4V

Directory of Open Access Journals (Sweden)

Knowles, C. R.

2012-11-01

Full Text Available Selective laser melting (SLM of Ti-6Al-4V has significant potential in the aerospace and biotechnology industries. SLM employs a focused laser beam to melt successive layers of metallic powder into complex components. This process can result in the generation of high thermally-induced residual stresses. These residual stresses, together with micro-flaws/ pores from the inherent fabrication process, may lead to premature fatigue crack initiation and propagation at relatively low cyclic stresses. The hole-drilling strain gauge method was used to evaluate residual stresses within SLM Ti-6Al-4V specimens, with the intention of understanding the associated mechanisms for the successful application of SLM Ti-6Al-4V in industry.

Metallurgy of high-silicon steel parts produced using Selective Laser Melting

International Nuclear Information System (INIS)

Garibaldi, Michele; Ashcroft, Ian; Simonelli, Marco; Hague, Richard

2016-01-01

The metallurgy of high-silicon steel (6.9%wt.Si) processed using Selective Laser Melting (SLM) is presented for the first time in this study. High-silicon steel has great potential as a soft magnetic alloy, but its employment has been limited due to its poor workability. The effect of SLM-processing on the metallurgy of the alloy is investigated in this work using microscopy, X-Ray Diffraction (XRD) and Electron Backscatter Diffraction (EBSD). XRD analysis suggests that the SLM high-silicon steel is a single ferritic phase (solid solution), with no sign of phase ordering. This is expected to have beneficial effects on the material properties, since ordering has been shown to make silicon steels more brittle and electrically conductive. For near-fully dense samples, columnar grains with a high aspect ratio and oriented along the build direction are found. Most importantly, a <001> fibre-texture along the build direction can be changed into a cube-texture when the qualitative shape of the melt-pool is altered (from shallow to deep) by increasing the energy input of the scanning laser. This feature could potentially open the path to the manufacture of three-dimensional grain-oriented high-silicon steels for electromechanical applications.

Modeling of the thermal physical process and study on the reliability of linear energy density for selective laser melting

Directory of Open Access Journals (Sweden)

Zhaowei Xiang

2018-06-01

Full Text Available A finite element model considering volume shrinkage with powder-to-dense process of powder layer in selective laser melting (SLM is established. Comparison between models that consider and do not consider volume shrinkage or powder-to-dense process is carried out. Further, parametric analysis of laser power and scan speed is conducted and the reliability of linear energy density as a design parameter is investigated. The results show that the established model is an effective method and has better accuracy allowing for the temperature distribution, and the length and depth of molten pool. The maximum temperature is more sensitive to laser power than scan speed. The maximum heating rate and cooling rate increase with increasing scan speed at constant laser power and increase with increasing laser power at constant scan speed as well. The simulation results and experimental result reveal that linear energy density is not always reliable using as a design parameter in the SLM. Keywords: Selective laser melting, Volume shrinkage, Powder-to-dense process, Numerical modeling, Thermal analysis, Linear energy density

Numerical analysis of the effects of non-conventional laser beam geometries during laser melting of metallic materials

International Nuclear Information System (INIS)

Safdar, Shakeel; Li, Lin; Sheikh, M A

2007-01-01

Laser melting is an important industrial activity encountered in a variety of laser manufacturing processes, e.g. selective laser melting, welding, brazing, soldering, glazing, surface alloying, cladding etc. The majority of these processes are carried out by using either circular or rectangular beams. At present, the melt pool characteristics such as melt pool geometry, thermal gradients and cooling rate are controlled by the variation of laser power, spot size or scanning speed. However, the variations in these parameters are often limited by other processing conditions. Although different laser beam modes and intensity distributions have been studied to improve the process, no other laser beam geometries have been investigated. The effect of laser beam geometry on the laser melting process has received very little attention. This paper presents an investigation of the effects of different beam geometries including circular, rectangular and diamond shapes on laser melting of metallic materials. The finite volume method has been used to simulate the transient effects of a moving beam for laser melting of mild steel (EN-43A) taking into account Marangoni and buoyancy convection. The temperature distribution, melt pool geometry, fluid flow velocities and heating/cooling rates have been calculated. Some of the results have been compared with the experimental data

Structure and mechanical properties of parts obtained by selective laser melting of metal powder based on intermetallic compounds Ni3Al

Science.gov (United States)

Smelov, V. G.; Sotov, A. V.; Agapovichev, A. V.; Nosova, E. A.

2018-03-01

The structure and mechanical properties of samples are obtained from metal powder based on intermetallic compound by selective laser melting. The chemical analysis of the raw material and static tensile test of specimens were made. Change in the samples’ structure and mechanical properties after homogenization during four and twenty-four hours were investigated. A small-sized combustion chamber of a gas turbine engine was performed by the selective laser melting method. The print combustion chamber was subjected to the gas-dynamic test in a certain temperature and time range.

Microstructural Evolution and Mechanical Property Development of Selective Laser Melted Copper Alloys

Science.gov (United States)

Ventura, Anthony Patrick

Selective Laser Melting (SLM) is an additive manufacturing technology that utilizes a high-power laser to melt metal powder and form a part layer-by-layer. Over the last 25 years, the technology has progressed from prototyping polymer parts to full scale production of metal component. SLM offers several advantages over traditional manufacturing techniques; however, the current alloy systems that are researched and utilized for SLM do not address applications requiring high electrical and thermal conductivity. This work presents a characterization of the microstructural evolution and mechanical property development of two copper alloys fabricated via SLM and post-process heat treated to address this gap in knowledge. Tensile testing, conductivity measurement, and detailed microstructural characterization was carried out on samples in the as-printed and heat treated conditions. A single phase solid solution strengthened binary alloy, Cu-4.3Sn, was the first alloy studied. Components were selectively laser melted from pre-alloyed Cu-4.3Sn powder and heat treated at 873 K (600 °C) and 1173 K (900 °C) for 1 hour. As-printed samples were around 97 percent dense with a yield strength of 274 MPa, an electrical conductivity of 24.1 %IACS, and an elongation of 5.6%. Heat treatment resulted in lower yield strength with significant increases in ductility due to recrystallization and a decrease in dislocation density. Tensile sample geometry and surface finish also showed a significant effect on measured yield strength but a negligible change in measured ductility. Microstructural characterization indicated that grains primarily grow epitaxially with a sub-micron cellular solidification sub-structure. Nanometer scale tin dioxide particles identified via XRD were found throughout the structure in the tin-rich intercellular regions. The second alloy studied was a high-performance precipitation hardening Cu-Ni-Si alloy, C70250. Pre-alloyed powder was selectively laser melted to

The analysis of the mechanical properties of F75 Co-Cr alloy for use in selective laser melting (SLM manufacturing of removable partial dentures (RPD

Directory of Open Access Journals (Sweden)

D. Jevremovic

2012-04-01

Full Text Available The presented work discusses the applicability of the selective laser melting technique (SLM in manufacture of removable partial denture (RPD frameworks with the emphasis on material properties. The paper presents initial results of a conducted test of the mechanical properties of the F75 Co-Cr dental alloy used with selective laser melting.

Investigation of Selective Laser Melting Surface Alloyed Aluminium Metal Matrix Dispersive Reinforced Layers

Science.gov (United States)

Kamburov, V. V.; Dimitrova, R. B.; Kandeva, M. K.; Sofronov, Y. P.

2018-01-01

The aim of the paper is to investigate the improvement of mechanical properties and in particular wear resistance of laser surface alloyed dispersive reinforced thin layers produced by selective laser melting (SLM) technology. The wear resistance investigation of aluminium matrix composite layers in the conditions of dry friction surface with abrasive particles and nanoindentation tests were carried out. The process parameters (as scan speed) and their impact on the wear resistant layers have been evaluated. The alloyed layers containing metalized SiC particles were studied by Optical and Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray microanalysis (EDX). The obtained experimental results of the laser alloyed thin layers show significant development of their wear resistance and nanohardness due to the incorporated reinforced phase of electroless nickel coated SiC particles.

Microstructure and micro-hardness analyses of titanium alloy Ti-6Al-4V parts manufactured by selective laser melting

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Lancea Camil

2017-01-01

Full Text Available Selective Laser Melting (SLM is one of the powder based additive manufacturing technologies and it is, as well, the most rapidly growing technique in Rapid Prototyping. In this paper is presented a microstructure analysis using Scanning Electron Microscope (LEO 1525 SEM, of Ti6Al4V parts exposed into a corrosion environment. The corrosion environment was generated using a salt chamber with 5% and 10% NaCl concentration and an ACS-Sunrise climatic chamber. The parts were also subjected to tests in order to determine their micro-hardness, followed by a statistical processing of the obtained data. The parts, having a lattice structure, were built on a Selective Laser Melting machine.

The Influence of Selective Laser Melting (SLM) Process Parameters on In-Vitro Cell Response.

Science.gov (United States)

Wysocki, Bartłomiej; Idaszek, Joanna; Zdunek, Joanna; Rożniatowski, Krzysztof; Pisarek, Marcin; Yamamoto, Akiko; Święszkowski, Wojciech

2018-05-30

The use of laser 3D printers is very perspective in the fabrication of solid and porous implants made of various polymers, metals, and its alloys. The Selective Laser Melting (SLM) process, in which consolidated powders are fully melted on each layer, gives the possibility of fabrication personalized implants based on the Computer Aid Design (CAD) model. During SLM fabrication on a 3D printer, depending on the system applied, there is a possibility for setting the amount of energy density (J/mm³) transferred to the consolidated powders, thus controlling its porosity, contact angle and roughness. In this study, we have controlled energy density in a range 8⁻45 J/mm³ delivered to titanium powder by setting various levels of laser power (25⁻45 W), exposure time (20⁻80 µs) and distance between exposure points (20⁻60 µm). The growing energy density within studied range increased from 63 to 90% and decreased from 31 to 13 µm samples density and Ra parameter, respectively. The surface energy 55⁻466 mN/m was achieved with contact angles in range 72⁻128° and 53⁻105° for water and formamide, respectively. The human mesenchymal stem cells (hMSCs) adhesion after 4 h decreased with increasing energy density delivered during processing within each parameter group. The differences in cells proliferation were clearly seen after a 7-day incubation. We have observed that proliferation was decreasing with increasing density of energy delivered to the samples. This phenomenon was explained by chemical composition of oxide layers affecting surface energy and internal stresses. We have noticed that TiO₂, which is the main oxide of raw titanium powder, disintegrated during selective laser melting process and oxygen was transferred into metallic titanium. The typical for 3D printed parts post-processing methods such as chemical polishing in hydrofluoric (HF) or hydrofluoric/nitric (HF/HNO₃) acid solutions and thermal treatments were used to restore surface

The Influence of Selective Laser Melting (SLM Process Parameters on In-Vitro Cell Response

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Bartłomiej Wysocki

2018-05-01

Full Text Available The use of laser 3D printers is very perspective in the fabrication of solid and porous implants made of various polymers, metals, and its alloys. The Selective Laser Melting (SLM process, in which consolidated powders are fully melted on each layer, gives the possibility of fabrication personalized implants based on the Computer Aid Design (CAD model. During SLM fabrication on a 3D printer, depending on the system applied, there is a possibility for setting the amount of energy density (J/mm3 transferred to the consolidated powders, thus controlling its porosity, contact angle and roughness. In this study, we have controlled energy density in a range 8–45 J/mm3 delivered to titanium powder by setting various levels of laser power (25–45 W, exposure time (20–80 µs and distance between exposure points (20–60 µm. The growing energy density within studied range increased from 63 to 90% and decreased from 31 to 13 µm samples density and Ra parameter, respectively. The surface energy 55–466 mN/m was achieved with contact angles in range 72–128° and 53–105° for water and formamide, respectively. The human mesenchymal stem cells (hMSCs adhesion after 4 h decreased with increasing energy density delivered during processing within each parameter group. The differences in cells proliferation were clearly seen after a 7-day incubation. We have observed that proliferation was decreasing with increasing density of energy delivered to the samples. This phenomenon was explained by chemical composition of oxide layers affecting surface energy and internal stresses. We have noticed that TiO2, which is the main oxide of raw titanium powder, disintegrated during selective laser melting process and oxygen was transferred into metallic titanium. The typical for 3D printed parts post-processing methods such as chemical polishing in hydrofluoric (HF or hydrofluoric/nitric (HF/HNO3 acid solutions and thermal treatments were used to restore surface

Property Investigation of Laser Cladded, Laser Melted and Electron Beam Melted Ti-Al6-V4

Science.gov (United States)

2006-05-01

UNCLASSIFIED/UNLIMITED UNCLASSIFIED/UNLIMITED Figure 3: Examples of electron beam melted net shape parts; powder bed [3]. 1.4 Laser Cladding ...description, www.arcam.com. [4] K.-H. Hermann, S. Orban, S. Nowotny, Laser Cladding of Titanium Alloy Ti6242 to Restore Damaged Blades, Proceedings...Property Investigation of Laser Cladded , Laser Melted and Electron Beam Melted Ti-Al6-V4 Johannes Vlcek EADS Deutschland GmbH Corporate Research

Bone ingrowth potential of electron beam and selective laser melting produced trabecular-like implant surfaces with and without a biomimetic coating

NARCIS (Netherlands)

Biemond, J.E.; Hannink, G.; Verdonschot, Nicolaas Jacobus Joseph; Buma, P.

2013-01-01

The bone ingrowth potential of trabecular-like implant surfaces produced by either selective laser melting (SLM) or electron beam melting (EBM), with or without a biomimetic calciumphosphate coating, was examined in goats. For histological analysis and histomorphometry of bone ingrowth depth and

Manufacturing and Characterization of 18Ni Marage 300 Lattice Components by Selective Laser Melting

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Luciano Lamberti

2013-08-01

Full Text Available The spreading use of cellular structures brings the need to speed up manufacturing processes without deteriorating mechanical properties. By using Selective Laser Melting (SLM to produce cellular structures, the designer has total freedom in defining part geometry and manufacturing is simplified. The paper investigates the suitability of Selective Laser Melting for manufacturing steel cellular lattice structures with characteristic dimensions in the micrometer range. Alternative lattice topologies including reinforcing bars in the vertical direction also are considered. The selected lattice structure topology is shown to be superior over other lattice structure designs considered in literature. Compression tests are carried out in order to evaluate mechanical strength of lattice strut specimens made via SLM. Compressive behavior of samples also is simulated by finite element analysis and numerical results are compared with experimental data in order to assess the constitutive behavior of the lattice structure designs considered in this study. Experimental data show that it is possible to build samples of relative density in the 0.2456–0.4367 range. Compressive strength changes almost linearly with respect to relative density, which in turns depends linearly on the number of vertical reinforces. Specific strength increases with cell and strut edge size. Numerical simulations confirm the plastic nature of the instability phenomena that leads the cellular structures to collapse under compression loading.

The study of the laser parameters and environment variables effect on mechanical properties of high compact parts elaborated by selective laser melting 316L powder

International Nuclear Information System (INIS)

Zhang, Baicheng; Dembinski, Lucas; Coddet, Christian

2013-01-01

In this work, a systematic analysis of the main parameters for the selective laser melting (SLM) of a commercial stainless steel 316L powder was conducted to improve the mechanical properties and dimensional accuracy of the fabricated parts. First, the effects of the processing parameters, such as the laser beam scanning velocity, laser power, substrate condition and thickness of the powder layer, on the formation of single tracks for achieving a continuous melting and densification of the material were analysed. Then, the influence of the environmental conditions (gas nature) and of the preheating temperature on the density and dimensional accuracy of the parts was considered. The microstructural features of the SLM SS 316L parts were carefully observed to elucidate the melting-solidification mechanism and the thermal history, which are the basis of the manufacturing process. Finally, the mechanical properties of the corresponding material were also determined

Influence of Process Parameters on the Quality of Aluminium Alloy EN AW 7075 Using Selective Laser Melting (SLM)

Science.gov (United States)

Kaufmann, N.; Imran, M.; Wischeropp, T. M.; Emmelmann, C.; Siddique, S.; Walther, F.

Selective laser melting (SLM) is an additive manufacturing process, forming the desired geometry by selective layer fusion of powder material. Unlike conventional manufacturing processes, highly complex parts can be manufactured with high accuracy and little post processing. Currently, different steel, aluminium, titanium and nickel-based alloys have been successfully processed; however, high strength aluminium alloy EN AW 7075 has not been processed with satisfying quality. The main focus of the investigation is to develop the SLM process for the wide used aluminium alloy EN AW 7075. Before process development, the gas-atomized powder material was characterized in terms of statistical distribution: size and shape. A wide range of process parameters were selected to optimize the process in terms of optimum volume density. The investigations resulted in a relative density of over 99%. However, all laser-melted parts exhibit hot cracks which typically appear in aluminium alloy EN AW 7075 during the welding process. Furthermore the influence of processing parameters on the chemical composition of the selected alloy was determined.

Fabrication and heat treatment of high strength Al-Cu-Mg alloy processed using selective laser melting

Science.gov (United States)

Zhang, Hu; Zhu, Haihong; Nie, Xiaojia; Qi, Ting; Hu, Zhiheng; Zeng, Xiaoyan

2016-04-01

The proposed paper illustrates the fabrication and heat treatment of high strength Al-Cu-Mg alloy produced by selective laser melting (SLM) process. Al-Cu-Mg alloy is one of the heat treatable aluminum alloys regarded as difficult to fusion weld. SLM is an additive manufacturing technique through which components are built by selectively melting powder layers with a focused laser beam. The process is characterized by short laser-powder interaction times and localized high heat input, which leads to steep thermal gradients, rapid solidification and fast cooling. In this research, 3D Al-Cu-Mg parts with relative high density of 99.8% are produced by SLM from gas atomized powders. Room temperature tensile tests reveal a remarkable mechanical behavior: the samples show yield and tensile strengths of about 276 MPa and 402 MPa, respectively, along with fracture strain of 6%. The effect of solution treatment on microstructure and related tensile properties is examined and the results demonstrate that the mechanical behavior of the SLMed Al-Cu-Mg samples can be greatly enhanced through proper heat treatment. After T4 solution treatment at 540°C, under the effect of precipitation strengthening, the tensile strength and the yield strength increase to 532 MPa and 338 MPa, respectively, and the elongation increases to 13%.

Superior creep strength of a nickel-based superalloy produced by selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Pröbstle, M., E-mail: martin.proebstle@fau.de [Department of Materials Science & Engineering Institute I, Friedrich-Alexander-Universität Erlangen-Nürnberg, Martensstraße 5, D-91058 Erlangen (Germany); Neumeier, S.; Hopfenmüller, J.; Freund, L.P. [Department of Materials Science & Engineering Institute I, Friedrich-Alexander-Universität Erlangen-Nürnberg, Martensstraße 5, D-91058 Erlangen (Germany); Niendorf, T. [Institut für Werkstofftechnik (Materials Engineering), Universität Kassel, Mönchebergstr. 3, D-34125 Kassel (Germany); Schwarze, D. [SLM Solutions GmbH, Roggenhorster Straße 9c, D-23556 Lübeck (Germany); Göken, M. [Department of Materials Science & Engineering Institute I, Friedrich-Alexander-Universität Erlangen-Nürnberg, Martensstraße 5, D-91058 Erlangen (Germany)

2016-09-30

The creep properties of a polycrystalline nickel-based superalloy produced via selective laser melting were investigated in this study. All heat treatment conditions of the additively manufactured material show superior creep strength compared to conventional cast and wrought material. The process leads to a microstructure with fine subgrains. In comparison to conventional wrought material no Niobium rich δ phase is necessary to control the grain size and thus more Niobium is available for precipitation hardening and solid solution strengthening resulting in improved creep strength.

Effect of Laser Power and Scan Speed on Melt Pool Characteristics of Commercially Pure Titanium (CP-Ti)

Science.gov (United States)

Kusuma, Chandrakanth; Ahmed, Sazzad H.; Mian, Ahsan; Srinivasan, Raghavan

2017-07-01

Selective laser melting (SLM) is an additive manufacturing technique that creates complex parts by selectively melting metal powder layer-by-layer using a laser. In SLM, the process parameters decide the quality of the fabricated component. In this study, single beads of commercially pure titanium (CP-Ti) were melted on a substrate of the same material using an in-house built SLM machine. Multiple combinations of laser power and scan speed were used for single bead fabrication, while the laser beam diameter and powder layer thickness were kept constant. This experimental study investigated the influence of laser power, scan speed, and laser energy density on the melt pool formation, surface morphology, geometry (width and height), and hardness of solidified beads. In addition, the observed unfavorable effect such as inconsistency in melt pool width formation is discussed. The results show that the quality, geometry, and hardness of solidified melt pool are significantly affected by laser power, scanning speed, and laser energy density.

Design of Wear-Resistant Austenitic Steels for Selective Laser Melting

Science.gov (United States)

Lemke, J. N.; Casati, R.; Lecis, N.; Andrianopoli, C.; Varone, A.; Montanari, R.; Vedani, M.

2018-03-01

Type 316L stainless steel feedstock powder was modified by alloying with powders containing carbide/boride-forming elements to create improved wear-resistant austenitic alloys that can be readily processed by Selective Laser Melting. Fe-based alloys with high C, B, V, and Nb contents were thus produced, resulting in a microstructure that consisted of austenitic grains and a significant amount of hard carbides and borides. Heat treatments were performed to modify the carbide distribution and morphology. Optimal hard-phase spheroidization was achieved by annealing the proposed alloys at 1150 °C for 1 hour followed by water quenching. The total increase in hardness of samples containing 20 pct of C/B-rich alloy powder was of 82.7 pct while the wear resistance could be increased by a factor of 6.

Numerical simulation of complex part manufactured by selective laser melting process

Science.gov (United States)

Van Belle, Laurent

2017-10-01

Selective Laser Melting (SLM) process belonging to the family of the Additive Manufacturing (AM) technologies, enable to build parts layer by layer, from metallic powder and a CAD model. Physical phenomena that occur in the process have the same issues as conventional welding. Thermal gradients generate significant residual stresses and distortions in the parts. Moreover, the large and complex parts to manufacturing, accentuate the undesirable effects. Therefore, it is essential for manufacturers to offer a better understanding of the process and to ensure production reliability of parts with high added value. This paper focuses on the simulation of manufacturing turbine by SLM process in order to calculate residual stresses and distortions. Numerical results will be presented.

Thermal dynamic behavior during selective laser melting of K418 superalloy: numerical simulation and experimental verification

Science.gov (United States)

Chen, Zhen; Xiang, Yu; Wei, Zhengying; Wei, Pei; Lu, Bingheng; Zhang, Lijuan; Du, Jun

2018-04-01

During selective laser melting (SLM) of K418 powder, the influence of the process parameters, such as laser power P and scanning speed v, on the dynamic thermal behavior and morphology of the melted tracks was investigated numerically. A 3D finite difference method was established to predict the dynamic thermal behavior and flow mechanism of K418 powder irradiated by a Gaussian laser beam. A three-dimensional randomly packed powder bed composed of spherical particles was established by discrete element method. The powder particle information including particle size distribution and packing density were taken into account. The volume shrinkage and temperature-dependent thermophysical parameters such as thermal conductivity, specific heat, and other physical properties were also considered. The volume of fluid method was applied to reconstruct the free surface of the molten pool during SLM. The geometrical features, continuity boundaries, and irregularities of the molten pool were proved to be largely determined by the laser energy density. The numerical results are in good agreement with the experiments, which prove to be reasonable and effective. The results provide us some in-depth insight into the complex physical behavior during SLM and guide the optimization of process parameters.

Selective laser melting of Ni-rich NiTi: selection of process parameters and the superelastic response

Science.gov (United States)

Shayesteh Moghaddam, Narges; Saedi, Soheil; Amerinatanzi, Amirhesam; Saghaian, Ehsan; Jahadakbar, Ahmadreza; Karaca, Haluk; Elahinia, Mohammad

2018-03-01

Material and mechanical properties of NiTi shape memory alloys strongly depend on the fabrication process parameters and the resulting microstructure. In selective laser melting, the combination of parameters such as laser power, scanning speed, and hatch spacing determine the microstructural defects, grain size and texture. Therefore, processing parameters can be adjusted to tailor the microstructure and mechanical response of the alloy. In this work, NiTi samples were fabricated using Ni50.8Ti (at.%) powder via SLM PXM by Phenix/3D Systems and the effects of processing parameters were systematically studied. The relationship between the processing parameters and superelastic properties were investigated thoroughly. It will be shown that energy density is not the only parameter that governs the material response. It will be shown that hatch spacing is the dominant factor to tailor the superelastic response. It will be revealed that with the selection of right process parameters, perfect superelasticity with recoverable strains of up to 5.6% can be observed in the as-fabricated condition.

Inducing Stable α + β Microstructures during Selective Laser Melting of Ti-6Al-4V Using Intensified Intrinsic Heat Treatments.

Science.gov (United States)

Barriobero-Vila, Pere; Gussone, Joachim; Haubrich, Jan; Sandlöbes, Stefanie; Da Silva, Julio Cesar; Cloetens, Peter; Schell, Norbert; Requena, Guillermo

2017-03-07

Selective laser melting is a promising powder-bed-based additive manufacturing technique for titanium alloys: near net-shaped metallic components can be produced with high resource-efficiency and cost savings [...].

High resolution laser micro sintering / melting using q-switched and high brilliant laser radiation

Science.gov (United States)

Exner, H.; Streek, A.

2015-03-01

Since the discovery of selective laser sintering/melting, numerous modifications have been made to upgrade or customize this technology for industrial purposes. Laser micro sintering (LMS) is one of those modifications: Powders with particles in the range of a few micrometers are used to obtain products with highly resolved structures. Pulses of a q-switched laser had been considered necessary in order to generate sinter layers from the micrometer scaled metal powders. LMS has been applied with powders from metals as well as from ceramic and cermet feedstock's to generate micro parts. Recent technological progress and the application of high brilliant continuous laser radiation have now allowed an efficient laser sintering/melting of micrometer scaled metal powders. Thereby it is remarkable that thin sinter layers are generated using high continuous laser power. The principles of the process, the state of the art in LMS concerning its advantages and limitations and furthermore the latest results of the recent development of this technology will be presented. Laser Micro Sintering / Laser Micro Melting (LMM) offer a vision for a new dimension of additive fabrication of miniature and precise parts also with application potential in all engineering fields.

Dimensional Accuracy and Surface Roughness Analysis for AlSi10Mg Produced by Selective Laser Melting (SLM

Directory of Open Access Journals (Sweden)

Kamarudin K.

2016-01-01

Full Text Available Selective Laser Melting (SLM is an Additive Manufacturing (AM technique that built 3D part in a layer-by-layer method by melting the top surface layer of a powder bed with a high intensity laser according to sliced 3D CAD data. AlSi10Mg alloy is a traditional cast alloy that is broadly used for die-casting process and used in automotive industry due its good mechanical properties. This paper seeks to investigate the requirement SLM in rapid tooling application. The feasibility study is done by examining the surface roughness and dimensional accuracy as compared to the benchmark part produced through the SLM process with constant parameters. The benchmark produced by SLM shows the potential of SLM in a manufacturing application particularly in moulds.

Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder

International Nuclear Information System (INIS)

Thijs, Lore; Kempen, Karolien; Kruth, Jean-Pierre; Van Humbeeck, Jan

2013-01-01

Graphical abstract: -- Abstract: This study shows that AlSi10Mg parts with an extremely fine microstructure and a controllable texture can be obtained through selective laser melting (SLM). Selective laser melting creates complex functional products by selectively melting powder particles of a powder bed layer after layer using a high-energy laser beam. The high-energy density applied to the material and the additive character of the process result in a unique material structure. To investigate this material structure, cube-shaped SLM parts were made using different scanning strategies and investigated by microscopy, X-ray diffraction and electron backscattered diffraction. The experimental results show that the high thermal gradients occurring during SLM lead to a very fine microstructure with submicron-sized cells. Consequently, the AlSi10Mg SLM products have a high hardness of 127 ± 3 Hv0.5 even without the application of a precipitation hardening treatment. Furthermore, due to the unique solidification conditions and the additive character of the process, a morphological and crystallographic texture is present in the SLM parts. Thanks to the knowledge gathered in this paper on how this texture is formed and how it depends on the process parameters, this texture can be controlled. A strong fibrous 〈1 0 0〉 texture can be altered into a weak cube texture along the building and scanning directions when a rotation of 90° of the scanning vectors within or between the layers is applied

[Energy dispersive spectrum analysis of surface compositions of selective laser melting cobalt-chromium alloy fabricated by different processing parameters].

Science.gov (United States)

Qian, Liang; Zeng, Li; Wei, Bin; Gong, Yao

2015-06-01

To fabricate selective laser melting cobalt-chromium alloy samples by different processing parameters, and to analyze the changes of energy dispersive spectrum(EDS) on their surface. Nine groups were set up by orthogonal experimental design according to different laser powers,scanning speeds and powder feeding rates(laser power:2500-3000 W, scanning speed: 5-15 mm/s, powder feeding rate: 3-6 r/min). Three cylinder specimens(10 mm in diameter and 3 mm in thickness) were fabricated in each group through Rofin DL 035Q laser cladding system using cobalt-chromium alloy powders which were developed independently by our group.Their surface compositions were then measured by EDS analysis. Results of EDS analysis of the 9 groups fabricated by different processing parameters(Co:62.98%-67.13%,Cr:25.56%-28.50%,Si:0.49%-1.23%) were obtained. They were similar to the compositions of cobalt-chromium alloy used in dental practice. According to EDS results, the surface compositions of the selective laser melting cobalt-chromium alloy samples are stable and controllable, which help us gain a preliminary sight into the range of SLM processing parameters. Supported by "973" Program (2012CB910401) and Research Fund of Science and Technology Committee of Shanghai Municipality (12441903001 and 13140902701).

Point, surface and volumetric heat sources in the thermal modelling of selective laser melting

Science.gov (United States)

Yang, Yabin; Ayas, Can

2017-10-01

Selective laser melting (SLM) is a powder based additive manufacturing technique suitable for producing high precision metal parts. However, distortions and residual stresses within products arise during SLM because of the high temperature gradients created by the laser heating. Residual stresses limit the load resistance of the product and may even lead to fracture during the built process. It is therefore of paramount importance to predict the level of part distortion and residual stress as a function of SLM process parameters which requires a reliable thermal modelling of the SLM process. Consequently, a key question arises which is how to describe the laser source appropriately. Reasonable simplification of the laser representation is crucial for the computational efficiency of the thermal model of the SLM process. In this paper, first a semi-analytical thermal modelling approach is described. Subsequently, the laser heating is modelled using point, surface and volumetric sources, in order to compare the influence of different laser source geometries on the thermal history prediction of the thermal model. The present work provides guidelines on appropriate representation of the laser source in the thermal modelling of the SLM process.

Inducing Stable α + β Microstructures during Selective Laser Melting of Ti-6Al-4V Using Intensified Intrinsic Heat Treatments

Directory of Open Access Journals (Sweden)

Pere Barriobero-Vila

2017-03-01

Full Text Available Selective laser melting is a promising powder-bed-based additive manufacturing technique for titanium alloys: near net-shaped metallic components can be produced with high resource-efficiency and cost savings [...

Implementation of a thermomechanical model for the simulation of selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Hodge, N. E. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Ferencz, R. M. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Solberg, J. M. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

2014-07-01

Selective laser melting (SLM) is an additive manufacturing process in which multiple, successive layers of metal powders are heated via laser in order to build a part. Modeling of SLM requires consideration of both heat transfer and solid mechanics. The present work describes continuum modeling of SLM as envisioned for eventual support of part-scale modeling of this fabrication process to determine end-state information such as residual stresses and distortion. The determination of the evolving temperatures is dependent on the material, the state of the material (powder or solid), the specified heating, and the configuration. Similarly, the current configuration is dependent on the temperatures, the powder-solid state, and the constitutive models. A multi-physics numerical formulation is required to solve such problems. This article describes the problem formulation, numerical method, and constitutive parameters necessary to solve such a problem. Additionally, various verification and example problems are simulated in the parallel, multi-physics finite element code Diablo, and the results presented herein.

Computationally efficient thermal-mechanical modelling of selective laser melting

Science.gov (United States)

Yang, Yabin; Ayas, Can

2017-10-01

The Selective laser melting (SLM) is a powder based additive manufacturing (AM) method to produce high density metal parts with complex topology. However, part distortions and accompanying residual stresses deteriorates the mechanical reliability of SLM products. Modelling of the SLM process is anticipated to be instrumental for understanding and predicting the development of residual stress field during the build process. However, SLM process modelling requires determination of the heat transients within the part being built which is coupled to a mechanical boundary value problem to calculate displacement and residual stress fields. Thermal models associated with SLM are typically complex and computationally demanding. In this paper, we present a simple semi-analytical thermal-mechanical model, developed for SLM that represents the effect of laser scanning vectors with line heat sources. The temperature field within the part being build is attained by superposition of temperature field associated with line heat sources in a semi-infinite medium and a complimentary temperature field which accounts for the actual boundary conditions. An analytical solution of a line heat source in a semi-infinite medium is first described followed by the numerical procedure used for finding the complimentary temperature field. This analytical description of the line heat sources is able to capture the steep temperature gradients in the vicinity of the laser spot which is typically tens of micrometers. In turn, semi-analytical thermal model allows for having a relatively coarse discretisation of the complimentary temperature field. The temperature history determined is used to calculate the thermal strain induced on the SLM part. Finally, a mechanical model governed by elastic-plastic constitutive rule having isotropic hardening is used to predict the residual stresses.

Densification behavior of gas and water atomized 316L stainless steel powder during selective laser melting

Science.gov (United States)

Li, Ruidi; Shi, Yusheng; Wang, Zhigang; Wang, Li; Liu, Jinhui; Jiang, Wei

2010-04-01

The densification during selective laser melting (SLM) process is an important factor determining the final application of SLM-part. In the present work, the densifications under different processing conditions were investigated and the densification mechanisms were elucidated. It was found that the higher laser power, lower scan speed, narrower hatch spacing and thinner layer thickness could enable a much smoother melting surface and consequently a higher densification. The gas atomized powder possessed better densification than water atomized powder, due to the lower oxygen content and higher packing density of gas atomized powder. A large number of regular-shaped pores can be generated at a wider hatch spacing, even if the scanning track is continuous and wetted very well. The densification mechanisms were addressed and the methods for building dense metal parts were also proposed as follows: inhibiting the balling phenomenon, increasing the overlap ratio of scanning tracks and reducing the micro-cracks.

Tailoring Selective Laser Melting Process Parameters for NiTi Implants

Science.gov (United States)

Bormann, Therese; Schumacher, Ralf; Müller, Bert; Mertmann, Matthias; de Wild, Michael

2012-12-01

Complex-shaped NiTi constructions become more and more essential for biomedical applications especially for dental or cranio-maxillofacial implants. The additive manufacturing method of selective laser melting allows realizing complex-shaped elements with predefined porosity and three-dimensional micro-architecture directly out of the design data. We demonstrate that the intentional modification of the applied energy during the SLM-process allows tailoring the transformation temperatures of NiTi entities within the entire construction. Differential scanning calorimetry, x-ray diffraction, and metallographic analysis were employed for the thermal and structural characterizations. In particular, the phase transformation temperatures, the related crystallographic phases, and the formed microstructures of SLM constructions were determined for a series of SLM-processing parameters. The SLM-NiTi exhibits pseudoelastic behavior. In this manner, the properties of NiTi implants can be tailored to build smart implants with pre-defined micro-architecture and advanced performance.

Investigation on Porosity and Microhardness of 316L Stainless Steel Fabricated by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Shahir Mohd Yusuf

2017-02-01

Full Text Available This study investigates the porosity and microhardness of 316L stainless steel samples fabricated by selective laser melting (SLM. The porosity content was measured using the Archimedes method and the advanced X-ray computed tomography (XCT scan. High densification level (≥99% with a low average porosity content (~0.82% were obtained from the Archimedes method. The highest porosity content in the XCT-scanned sample was ~0.61. However, the pores in the SLM samples for both cases (optical microscopy and XCT were not uniformly distributed. The higher average microhardness values in the SLM samples compared to the wrought manufactured counterpart are attributed to the fine microstructures from the localised melting and rapid solidification rate of the SLM process.

Hot working behavior of selective laser melted and laser metal deposited Inconel 718

Science.gov (United States)

Bambach, Markus; Sizova, Irina

2018-05-01

The production of Nickel-based high-temperature components is of great importance for the transport and energy sector. Forging of high-temperature alloys often requires expensive dies, multiple forming steps and leads to forged parts with tolerances that require machining to create the final shape and a large amount of scrap. Additive manufacturing offers the possibility to print the desired shapes directly as net-shape components, requiring only little additional effort in machining. Especially for high-temperature alloys carrying a large amount of energy per unit mass, additive manufacturing could be more energy-efficient than forging if the energy contained in the machining scrap exceeds the energy needed for powder production and laser processing. However, the microstructure and performance of 3d-printed parts will not reach the level of forged material unless further expensive processes such as hot-isostatic pressing are used. Using the design freedom and possibilities to locally engineer material, additive manufacturing could be combined with forging operations to novel process chains, offering the possibility to reduce the number of forging steps and to create near-net shape forgings with desired local properties. Some innovative process chains combining additive manufacturing and forging have been patented recently, but almost no scientific knowledge on the workability of 3D printed preforms exists. The present study investigates the flow stress and microstructure evolution during hot working of pre-forms produced by laser powder deposition and selective laser melting (Figure 1) and puts forward a model for the flow stress.

Experimental Research on Selective Laser Melting AlSi10Mg Alloys: Process, Densification and Performance

Science.gov (United States)

Chen, Zhen; Wei, Zhengying; Wei, Pei; Chen, Shenggui; Lu, Bingheng; Du, Jun; Li, Junfeng; Zhang, Shuzhe

2017-12-01

In this work, a set of experiments was designed to investigate the effect of process parameters on the relative density of the AlSi10Mg parts manufactured by SLM. The influence of laser scan speed v, laser power P and hatch space H, which were considered as the dominant parameters, on the powder melting and densification behavior was also studied experimentally. In addition, the laser energy density was introduced to evaluate the combined effect of the above dominant parameters, so as to control the SLM process integrally. As a result, a high relative density (> 97%) was obtained by SLM at an optimized laser energy density of 3.5-5.5 J/mm2. Moreover, a parameter-densification map was established to visually select the optimum process parameters for the SLM-processed AlSi10Mg parts with elevated density and required mechanical properties. The results provide an important experimental guidance for obtaining AlSi10Mg components with full density and gradient functional porosity by SLM.

Fracture behaviour of a magnesium–aluminium alloy treated by selective laser surface melting treatment

International Nuclear Information System (INIS)

Taltavull, C.; López, A.J.; Torres, B.; Rams, J.

2014-01-01

Highlights: • β-Mg 17 Al 12 presents fragile fracture behavior decreasing the ductility of AZ91D. • SLSM treatment only modifies the β-Mg 17 Al 12 phase whilst α-Mg remains unaltered. • In-situ SEM bending test allows to observe and data record of the crack propagation. • Eutectic microestructure of modified β-phase presents ductile fracture behaviour. • Fracture toughness of laser treated specimen is 40% greater than as-received alloy. - Abstract: Fracture behaviour of AZ91D magnesium alloy is dominated by the brittle fracture of the β-Mg 17 Al 12 phase so its modification is required to improve the toughness of this alloy. The novel laser treatment named as Selective Laser Surface Melting (SLSM) is characterized by the microstructural modification of the β-Mg 17 Al 12 phase without altering the α-Mg matrix. We have studied the effect of the selected microstructural modification induced by the laser treatment in the fracture behaviour of the alloy has been studied using in situ Scanning Electron Microscopy bending test. This test configuration allows the in situ observation of the crack progression and the record of the load–displacement curve. It has been observed that the microstructural modification introduced by SLSM causes an increase of 40% of the fracture toughness of the treated specimen. This phenomenon can be related with the transition from brittle to ductile fracture behaviour of the laser modified β-phase

Additive manufacturing of ITER first wall panel parts by two approaches: Selective laser melting and electron beam melting

International Nuclear Information System (INIS)

Zhong, Yuan; Rännar, Lars-Erik; Wikman, Stefan; Koptyug, Andrey; Liu, Leifeng; Cui, Daqing; Shen, Zhijian

2017-01-01

Highlights: • A novel way using additive manufacturing to fabricated ITER First Wall Panel parts is proposed. • ITER First Wall Panel parts successfully manufactured by both SLM and EBM are compared. • Physical and mechanical properties of SLM and EBM SS316L are clearly compared. • Problems encountered for large scale part building were discussed and possible solutions are given. - Abstract: Fabrication of ITER First Wall (FW) Panel parts by two additive manufacturing (AM) technologies, selective laser melting (SLM) and electron beam melting (EBM), was supported by Fusion for Energy (F4E). For the first time, AM is applied to manufacture ITER In-Vessel parts with complex design. Fully dense SS316L was prepared by both SLM and EBM after developing optimized laser/electron beam parameters. Characterizations on the density, magnetic permeability, microstructure, defects and inclusions were carried out. Tensile properties, Charpy-impact properties and fatigue properties of SLM and EBM SS316L were also compared. ITER FW Panel parts were successfully fabricated by both SLM and EBM in a one-step building process. The SLM part has smoother surface, better size accuracy while the EBM part takes much less time to build. Issues with removing support structures might be solved by slightly changing the design of the internal cooling system. Further investigation of the influence of neutron irradiation on materials properties between the two AM technologies is needed.

Additive manufacturing of ITER first wall panel parts by two approaches: Selective laser melting and electron beam melting

Energy Technology Data Exchange (ETDEWEB)

Zhong, Yuan [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, SE-106 91 Stockholm (Sweden); Rännar, Lars-Erik [Department of Quality Technology, Mechanical Engineering and Mathematics, Sports Tech Research Centre, Mid Sweden University, SE-831 25 Östersund (Sweden); Wikman, Stefan [Fusion for Energy, Torres Diagonal Litoral B3, Josep Pla 2, 08019 Barcelona (Spain); Koptyug, Andrey [Department of Quality Technology, Mechanical Engineering and Mathematics, Sports Tech Research Centre, Mid Sweden University, SE-831 25 Östersund (Sweden); Liu, Leifeng; Cui, Daqing [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, SE-106 91 Stockholm (Sweden); Shen, Zhijian, E-mail: shen@mmk.su.se [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, SE-106 91 Stockholm (Sweden)

2017-03-15

Highlights: • A novel way using additive manufacturing to fabricated ITER First Wall Panel parts is proposed. • ITER First Wall Panel parts successfully manufactured by both SLM and EBM are compared. • Physical and mechanical properties of SLM and EBM SS316L are clearly compared. • Problems encountered for large scale part building were discussed and possible solutions are given. - Abstract: Fabrication of ITER First Wall (FW) Panel parts by two additive manufacturing (AM) technologies, selective laser melting (SLM) and electron beam melting (EBM), was supported by Fusion for Energy (F4E). For the first time, AM is applied to manufacture ITER In-Vessel parts with complex design. Fully dense SS316L was prepared by both SLM and EBM after developing optimized laser/electron beam parameters. Characterizations on the density, magnetic permeability, microstructure, defects and inclusions were carried out. Tensile properties, Charpy-impact properties and fatigue properties of SLM and EBM SS316L were also compared. ITER FW Panel parts were successfully fabricated by both SLM and EBM in a one-step building process. The SLM part has smoother surface, better size accuracy while the EBM part takes much less time to build. Issues with removing support structures might be solved by slightly changing the design of the internal cooling system. Further investigation of the influence of neutron irradiation on materials properties between the two AM technologies is needed.

[Research progress in CoCr metal-ceramic alloy fabricated by selective laser melting].

Science.gov (United States)

Yan, X; Lin, H

2018-02-09

Cobalt-chromium alloys have been applied to dental porcelain fused to metal (PFM) restorations over the past decades owing to their excellent corrosion resistance, good biocompatibility and low price. The production of CoCr metal-ceramic restorations has always been based on traditional lost-wax casting techniques. However, in recent years, selective laser melting (SLM) is becoming more and more highly valued by dental laboratories and dental practitioners due to its individuation, precision and efficiency. This paper mainly reviews the recent researches on the production process of copings, microstructure, mechanical property, metal-ceramic bond strength, fit of copings, corrosion resistance and biocompatibility of SLM CoCr metal-ceramic alloy.

Corrosion resistance characteristics of a Ti-6Al-4V alloy scaffold that is fabricated by electron beam melting and selective laser melting for implantation in vivo.

Science.gov (United States)

Zhao, Bingjing; Wang, Hong; Qiao, Ning; Wang, Chao; Hu, Min

2017-01-01

The purpose of this study is to determine the corrosion resistance of Ti-6Al-4V alloy fabricated with electron beam melting and selective laser melting for implantation in vivo. Ti-6Al-4V alloy specimens were fabricated with electron beam melting (EBM) and selective laser melting (SLM). A wrought form of Ti-6Al-4V alloy was used as a control. Surface morphology observation, component analysis, corrosion resistance experimental results, electrochemical impedance spectroscopy, crevice corrosion resistance experimental results, immersion test and metal ions precipitation analysis were processed, respectively. The thermal stability of EBM specimen was the worst, based on the result of open circuit potential (OCP) result. The result of electrochemical impedance spectroscopy indicated that the corrosion resistance of the SLM specimen was the best under the low electric potential. The result of potentiodynamic polarization suggested that the corrosion resistance of the SLM specimen was the best under the low electric potential (1.5V).The crevice corrosion resistance of the EBM specimen was the best. The corrosion resistance of SLM specimen was the best, based on the result of immersion test. The content of Ti, Al and V ions of EBM, SLM and wrought specimens was very low. In general, the scaffolds that were fabricated with EBM and SLM had good corrosion resistance, and were suitable for implantation in vivo. Copyright © 2016 Elsevier B.V. All rights reserved.

Surface Roughness of a 3D-Printed Ni-Cr Alloy Produced by Selective Laser Melting: Effect of Process Parameters.

Science.gov (United States)

Hong, Min-Ho; Son, Jun Sik; Kwon, Tae-Yub

2018-03-01

The selective laser melting (SLM) process parameters, which directly determine the melting behavior of the metallic powders, greatly affect the nanostructure and surface roughness of the resulting 3D object. This study investigated the effect of various laser process parameters (laser power, scan rate, and scan line spacing) on the surface roughness of a nickel-chromium (Ni-Cr) alloy that was three-dimensionally (3D) constructed using SLM. Single-line formation tests were used to determine the optimal laser power of 200 W and scan rate of 98.8 mm/s, which resulted in beads with an optimal profile. In the subsequent multi-layer formation tests, the 3D object with the smoothest surface (Ra = 1.3 μm) was fabricated at a scan line spacing of 60 μm (overlap ratio = 73%). Narrow scan line spacing (and thus large overlap ratios) was preferred over wide scan line spacing to reduce the surface roughness of the 3D body. The findings of this study suggest that the laser power, scan rate, and scan line spacing are the key factors that control the surface quality of Ni-Cr alloys produced by SLM.

Thermomechanical characterization of Ni-rich NiTi fabricated by selective laser melting

International Nuclear Information System (INIS)

Saedi, Soheil; Turabi, Ali Sadi; Karaca, Haluk; Andani, Mohsen Taheri; Haberland, Christoph; Elahinia, Mohammad

2016-01-01

This study presents the shape memory behavior of as-fabricated and solution annealed Ni 50.8 Ti 49.2 alloys fabricated using the selective laser melting (SLM) technique. Results were compared to the initial ingot that was used to fabricate powders. Optical microscopy was employed to reveal the microstructure. The shape memory effect under constant compressive stress and isothermal compressive stress cycling tests were utilized to investigate the shape memory characteristics of the initial ingot and fabricated alloys. It was revealed that the SLM method and post heat treatments can be used to tailor the microstructure and shape memory response. Partial superelasticity was observed after the SLM process. Solutionizing the fabricated samples increased the strength and improved the superelasticity but slightly decreased the recoverable strain. (paper)

Optimization of Selective Laser Melting by Evaluation Method of Multiple Quality Characteristics

Science.gov (United States)

Khaimovich, A. I.; Stepanenko, I. S.; Smelov, V. G.

2018-01-01

Article describes the adoption of the Taguchi method in selective laser melting process of sector of combustion chamber by numerical and natural experiments for achieving minimum temperature deformation. The aim was to produce a quality part with minimum amount of numeric experiments. For the study, the following optimization parameters (independent factors) were chosen: the laser beam power and velocity; two factors for compensating the effect of the residual thermal stresses: the scale factor of the preliminary correction of the part geometry and the number of additional reinforcing elements. We used an orthogonal plan of 9 experiments with a factor variation at three levels (L9). As quality criterias, the values of distortions for 9 zones of the combustion chamber and the maximum strength of the material of the chamber were chosen. Since the quality parameters are multidirectional, a grey relational analysis was used to solve the optimization problem for multiple quality parameters. As a result, according to the parameters obtained, the combustion chamber segments of the gas turbine engine were manufactured.

Permeability Study of Austenitic Stainless Steel Surfaces Produced by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Emmanuel Segura-Cardenas

2017-11-01

Full Text Available Selective laser melting (SLM is emerging as a versatile process for fabricating different metal components with acceptable mechanical properties and geometrical accuracy. The process has been used in the manufacturing of several parts (e.g., aerospace or biomedical components, and offers the capability to tailor the performance of several surface and mechanical properties. In this work, permeability properties and surface roughness of stainless steel (SS316L surfaces were evaluated through experimentation with three different laser scanning patterns (chessboard, meander, and stripe, and different sloping angles between the fabricated surface and the laser beam incident on the process. Results showed that for each scanning pattern, the roughness decreased as the sloping angle increased consistently in all experimental trials. Furthermore, in the case of the permeability evaluation, the manufactured surfaces showed changes in properties for each series of experiments performed with different scanning patterns. The chessboard pattern showed a change of 67° to 107° in contact angle, while the meander and stripe patterns showed a variation in contact angle in a range of 65° to 85°. The different scanning strategies in the SLM process resulted in an alternative method for surface enhancement with different hydrophobicity properties, valuable for designing the most appropriate permeability characteristics for specific applications.

Manufacturing Feasibility and Forming Properties of Cu-4Sn in Selective Laser Melting.

Science.gov (United States)

Mao, Zhongfa; Zhang, David Z; Wei, Peitang; Zhang, Kaifei

2017-03-24

Copper alloys, combined with selective laser melting (SLM) technology, have attracted increasing attention in aerospace engineering, automobile, and medical fields. However, there are some difficulties in SLM forming owing to low laser absorption and excellent thermal conductivity. It is, therefore, necessary to explore a copper alloy in SLM. In this research, manufacturing feasibility and forming properties of Cu-4Sn in SLM were investigated through a systematic experimental approach. Single-track experiments were used to narrow down processing parameter windows. A Greco-Latin square design with orthogonal parameter arrays was employed to control forming qualities of specimens. Analysis of variance was applied to establish statistical relationships, which described the effects of different processing parameters (i.e., laser power, scanning speed, and hatch space) on relative density (RD) and Vickers hardness of specimens. It was found that Cu-4Sn specimens were successfully manufactured by SLM for the first time and both its RD and Vickers hardness were mainly determined by the laser power. The maximum value of RD exceeded 93% theoretical density and the maximum value of Vickers hardness reached 118 HV 0.3/5. The best tensile strength of 316-320 MPa is inferior to that of pressure-processed Cu-4Sn and can be improved further by reducing defects.

Analysis of picosecond pulsed laser melted graphite

International Nuclear Information System (INIS)

Steinbeck, J.; Braunstein, G.; Speck, J.; Dresselhaus, M.S.; Huang, C.Y.; Malvezzi, A.M.; Bloembergen, N.

1986-01-01

A Raman microprobe and high resolution TEM have been used to analyze the resolidified region of liquid carbon generated by picosecond pulse laser radiation. From the relative intensities of the zone center Raman-allowed mode for graphite at 1582 cm -1 and the disorder-induced mode at 1360 cm -1 , the average graphite crystallite size in the resolidified region is determined as a function of position. By comparison with Rutherford backscattering spectra and Raman spectra from nonosecond pulsed laser melting experiments, the disorder depth for picosecond pulsed laser melted graphite is determined as a function of irradiating energy density. Comparisons of TEM micrographs for nanosecond and picosecond pulsed laser melting experiments show that the structure of the laser disordered regions in graphite are similar and exhibit similar behavior with increasing laser pulse fluence

Microstructure and Properties of AlSi10Mg Powder for Selective Laser Melting

Directory of Open Access Journals (Sweden)

TANG Pengjun

2018-02-01

Full Text Available The AlSi10Mg powder was prepared by supersonic gas atomization. After classified, the powder was fabricated into block by selective laser melting (SLM. The microstructure, phase, and evolutions of powder and block were investigated by optical microscope, scanning electron microscope and X-Ray Diffraction. The tensile properties of SLM block were tested by tensile experiments at room temperature. The results show that the size distribution of AlSi10Mg powder after classified can meet the requirements of SLM technology. The powder always is spherical and spherical-like. Meanwhile, the microstructure of powders is fine and uniform, which contain α(Al matrix and (α+Si eutectic. In addition, the melt pool boundaries of SLM block are legible. The microstructure is also uniform and densified, the relative density approaches to 99.5%. On the other hand, only α(Al and few Silicon phase are detected in this condition, due to the most alloying elements are dissolved in α(Al matrix. At room temperature, the ultimate tensile strength of SLM block reaches up to 442 MPa.

Phase composition and microstructure of WC-Co alloys obtained by selective laser melting

Science.gov (United States)

Khmyrov, Roman S.; Shevchukov, Alexandr P.; Gusarov, Andrey V.; Tarasova, Tatyana V.

2018-03-01

Phase composition and microstructure of initial WC, BK8 (powder alloy 92 wt.% WC-8 wt.% Co), Co powders, ball-milled powders with four different compositions (1) 25 wt.% WC-75 wt.% Co, (2) 30 wt.% BK8-70 wt.% Co, (3) 50 wt.% WC-50 wt.% Co, (4) 94 wt.% WC-6 wt.% Co, and bulk alloys obtained by selective laser melting (SLM) from as-milled powders in as-melted state and after heat treatment were investigated by scanning electron microscopy and X-ray diffraction analysis. Initial and ball-milled powders consist of WC, hexagonal α-Co and face-centered cubic β-Co. The SLM leads to the formation of major new phases W3Co3C, W4Co2C and face-centered cubic β-Co-based solid solution. During the heat treatment, there occurs partial decomposition of the face-centered cubic β-Co-based solid solution with the formation of W2C and hexagonal α-Co solid solution. The microstructure of obtained bulk samples, in general, corresponds to the observed phase composition.

Comparison of Microstructure and Mechanical Properties of Scalmalloy® Produced by Selective Laser Melting and Laser Metal Deposition.

Science.gov (United States)

Awd, Mustafa; Tenkamp, Jochen; Hirtler, Markus; Siddique, Shafaqat; Bambach, Markus; Walther, Frank

2017-12-23

The second-generation aluminum-magnesium-scandium (Al-Mg-Sc) alloy, which is often referred to as Scalmalloy ® , has been developed as a high-strength aluminum alloy for selective laser melting (SLM). The high-cooling rates of melt pools during SLM establishes the thermodynamic conditions for a fine-grained crack-free aluminum structure saturated with fine precipitates of the ceramic phase Al₃-Sc. The precipitation allows tensile and fatigue strength of Scalmalloy ® to exceed those of AlSi10Mg by ~70%. Knowledge about properties of other additive manufacturing processes with slower cooling rates is currently not available. In this study, two batches of Scalmalloy ® processed by SLM and laser metal deposition (LMD) are compared regarding microstructure-induced properties. Microstructural strengthening mechanisms behind enhanced strength and ductility are investigated by scanning electron microscopy (SEM). Fatigue damage mechanisms in low-cycle (LCF) to high-cycle fatigue (HCF) are a subject of study in a combined strategy of experimental and statistical modeling for calculation of Woehler curves in the respective regimes. Modeling efforts are supported by non-destructive defect characterization in an X-ray computed tomography (µ-CT) platform. The investigations show that Scalmalloy ® specimens produced by LMD are prone to extensive porosity, contrary to SLM specimens, which is translated to ~30% lower fatigue strength.

Investigation of the microstructure and surface morphology of a Ti6Al4V plate fabricated by vacuum selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Sato, Yuji; Tsukamoto, Masahiro; Masuno, Shinichiro; Abe, Nobuyuki [Osaka University, Joining and Welding Research Institute, Ibaraki, Osaka (Japan); Yamashita, Yorihiro [Industrial Research Institute of Ishikawa, Kanazawa, Ishikawa (Japan); Yamashita, Kensuke; Tanigawa, Daichi [Osaka University, Graduate School of Engineering, Suita, Osaka (Japan)

2016-04-15

As an additive manufacturing technology, the selective laser melting (SLM) process is useful to directly form complicated shapes. The SLM process in a vacuum has been used to fabricate three-dimensional Ti6Al4V (Ti64) plates because this method can control the phase transformation. To investigate the laser melting and solidification dynamics, the formation of a Ti64 plate by SLM in a vacuum was captured by a high-speed video camera. Due to the effects of temperature and scanning speed on the phase transformation, the crystal orientation was evaluated with X-ray diffraction. A phase transformation of the crystal orientation occurred as the baseplate temperature was heated up from 50 to 150 C. (orig.)

Investigation of the microstructure and surface morphology of a Ti6Al4V plate fabricated by vacuum selective laser melting

International Nuclear Information System (INIS)

Sato, Yuji; Tsukamoto, Masahiro; Masuno, Shinichiro; Abe, Nobuyuki; Yamashita, Yorihiro; Yamashita, Kensuke; Tanigawa, Daichi

2016-01-01

As an additive manufacturing technology, the selective laser melting (SLM) process is useful to directly form complicated shapes. The SLM process in a vacuum has been used to fabricate three-dimensional Ti6Al4V (Ti64) plates because this method can control the phase transformation. To investigate the laser melting and solidification dynamics, the formation of a Ti64 plate by SLM in a vacuum was captured by a high-speed video camera. Due to the effects of temperature and scanning speed on the phase transformation, the crystal orientation was evaluated with X-ray diffraction. A phase transformation of the crystal orientation occurred as the baseplate temperature was heated up from 50 to 150 C. (orig.)

Microstructure of selective laser melted CM247LC nickel-based superalloy and its evolution through heat treatment

International Nuclear Information System (INIS)

Divya, V.D.; Muñoz-Moreno, R.; Messé, O.M.D.M.; Barnard, J.S.; Baker, S.; Illston, T.; Stone, H.J.

2016-01-01

The selective laser melting of high temperature alloys is of great interest to the aerospace industry as it offers the prospect of producing more complex geometries than can be achieved with other manufacturing methods. In this study, the microstructure of the nickel-based superalloy, CM247LC, has been characterised following selective laser melting and after a post deposition heat treatment below the γ′ solvus temperature. In the as-deposited state, scanning electron microscopy with electron backscatter diffraction revealed a fine, cellular microstructure with preferential alignment of 〈001〉 along the build direction. A high dislocation density was seen at the periphery of the cells, indicating substantial localised deformation of the material. Fine primary MC carbides were also observed in the inter-cellular regions. High-resolution transmission electron microscopy identified the occurrence of very fine γ′ precipitates, approximately 5 nm in diameter, dispersed within the gamma phase. After heat treatment, the elongated cell colonies were observed to partially coalesce, accompanied by a decrease in dislocation density, producing columnar grains along the build direction. Cuboidal γ′ precipitates approximately 500 nm in diameter were observed to form in the recrystallised grains, accompanied by larger γ′ precipitates on the grain boundaries.

Microstructure of selective laser melted CM247LC nickel-based superalloy and its evolution through heat treatment

Energy Technology Data Exchange (ETDEWEB)

Divya, V.D., E-mail: dv272@cam.ac.uk [Department of Materials Science and Metallurgy, University of Cambridge, 27 Charles Babbage Road, Cambridge CB3 0FS (United Kingdom); Muñoz-Moreno, R.; Messé, O.M.D.M.; Barnard, J.S. [Department of Materials Science and Metallurgy, University of Cambridge, 27 Charles Babbage Road, Cambridge CB3 0FS (United Kingdom); Baker, S.; Illston, T. [Materials Solutions, Unit 8, Great Western Business Park, McKenzie Way, Worcester WR4 9GN (United Kingdom); Stone, H.J. [Department of Materials Science and Metallurgy, University of Cambridge, 27 Charles Babbage Road, Cambridge CB3 0FS (United Kingdom)

2016-04-15

The selective laser melting of high temperature alloys is of great interest to the aerospace industry as it offers the prospect of producing more complex geometries than can be achieved with other manufacturing methods. In this study, the microstructure of the nickel-based superalloy, CM247LC, has been characterised following selective laser melting and after a post deposition heat treatment below the γ′ solvus temperature. In the as-deposited state, scanning electron microscopy with electron backscatter diffraction revealed a fine, cellular microstructure with preferential alignment of 〈001〉 along the build direction. A high dislocation density was seen at the periphery of the cells, indicating substantial localised deformation of the material. Fine primary MC carbides were also observed in the inter-cellular regions. High-resolution transmission electron microscopy identified the occurrence of very fine γ′ precipitates, approximately 5 nm in diameter, dispersed within the gamma phase. After heat treatment, the elongated cell colonies were observed to partially coalesce, accompanied by a decrease in dislocation density, producing columnar grains along the build direction. Cuboidal γ′ precipitates approximately 500 nm in diameter were observed to form in the recrystallised grains, accompanied by larger γ′ precipitates on the grain boundaries.

Evaluation of single tracks of 17-4PH steel manufactured at different power densities and scanning speeds by selective laser melting

CSIR Research Space (South Africa)

Moller, Hein

2016-11-01

Full Text Available In Selective Laser Melting, the initial units produced are single tracks that overlap to create a single layer; from the sequence of layers, a 3D object is manufactured. The properties of the parts produced by SLM depend heavily on the properties...

Computational Simulation of Thermal and Spattering Phenomena and Microstructure in Selective Laser Melting of Inconel 625

Science.gov (United States)

Özel, Tuğrul; Arısoy, Yiğit M.; Criales, Luis E.

Computational modelling of Laser Powder Bed Fusion (L-PBF) processes such as Selective laser Melting (SLM) can reveal information that is hard to obtain or unobtainable by in-situ experimental measurements. A 3D thermal field that is not visible by the thermal camera can be obtained by solving the 3D heat transfer problem. Furthermore, microstructural modelling can be used to predict the quality and mechanical properties of the product. In this paper, a nonlinear 3D Finite Element Method based computational code is developed to simulate the SLM process with different process parameters such as laser power and scan velocity. The code is further improved by utilizing an in-situ thermal camera recording to predict spattering which is in turn included as a stochastic heat loss. Then, thermal gradients extracted from the simulations applied to predict growth directions in the resulting microstructure.

On the Selective Laser Melting (SLM of the AlSi10Mg Alloy: Process, Microstructure, and Mechanical Properties

Directory of Open Access Journals (Sweden)

Francesco Trevisan

2017-01-01

Full Text Available The aim of this review is to analyze and to summarize the state of the art of the processing of aluminum alloys, and in particular of the AlSi10Mg alloy, obtained by means of the Additive Manufacturing (AM technique known as Selective Laser Melting (SLM. This process is gaining interest worldwide, thanks to the possibility of obtaining a freeform fabrication coupled with high mechanical properties related to a very fine microstructure. However, SLM is very complex, from a physical point of view, due to the interaction between a concentrated laser source and metallic powders, and to the extremely rapid melting and the subsequent fast solidification. The effects of the main process variables on the properties of the final parts are analyzed in this review: from the starting powder properties, such as shape and powder size distribution, to the main process parameters, such as laser power and speed, layer thickness, and scanning strategy. Furthermore, a detailed overview on the microstructure of the AlSi10Mg material, with the related tensile and fatigue properties of the final SLM parts, in some cases after different heat treatments, is presented.

On the Selective Laser Melting (SLM) of the AlSi10Mg Alloy: Process, Microstructure, and Mechanical Properties.

Science.gov (United States)

Trevisan, Francesco; Calignano, Flaviana; Lorusso, Massimo; Pakkanen, Jukka; Aversa, Alberta; Ambrosio, Elisa Paola; Lombardi, Mariangela; Fino, Paolo; Manfredi, Diego

2017-01-18

The aim of this review is to analyze and to summarize the state of the art of the processing of aluminum alloys, and in particular of the AlSi10Mg alloy, obtained by means of the Additive Manufacturing (AM) technique known as Selective Laser Melting (SLM). This process is gaining interest worldwide, thanks to the possibility of obtaining a freeform fabrication coupled with high mechanical properties related to a very fine microstructure. However, SLM is very complex, from a physical point of view, due to the interaction between a concentrated laser source and metallic powders, and to the extremely rapid melting and the subsequent fast solidification. The effects of the main process variables on the properties of the final parts are analyzed in this review: from the starting powder properties, such as shape and powder size distribution, to the main process parameters, such as laser power and speed, layer thickness, and scanning strategy. Furthermore, a detailed overview on the microstructure of the AlSi10Mg material, with the related tensile and fatigue properties of the final SLM parts, in some cases after different heat treatments, is presented.

Physical properties and microstructure study of stainless steel 316L alloy fabricated by selective laser melting

Science.gov (United States)

Islam, Nurul Kamariah Md Saiful; Harun, Wan Sharuzi Wan; Ghani, Saiful Anwar Che; Omar, Mohd Asnawi; Ramli, Mohd Hazlen; Ismail, Muhammad Hussain

2017-12-01

Selective Laser Melting (SLM) demonstrates the 21st century's manufacturing infrastructure in which powdered raw material is melted by a high energy focused laser, and built up layer-by-layer until it forms three-dimensional metal parts. SLM process involves a variation of process parameters which affects the final material properties. 316L stainless steel compacts through the manipulation of building orientation and powder layer thickness parameters were manufactured by SLM. The effect of the manipulated parameters on the relative density and dimensional accuracy of the 316L stainless steel compacts, which were in the as-build condition, were experimented and analysed. The relationship between the microstructures and the physical properties of fabricated 316L stainless steel compacts was investigated in this study. The results revealed that 90° building orientation has higher relative density and dimensional accuracy than 0° building orientation. Building orientation was found to give more significant effect in terms of dimensional accuracy, and relative density of SLM compacts compare to build layer thickness. Nevertheless, the existence of large number and sizes of pores greatly influences the low performances of the density.

Immobilisation of an antibacterial drug to Ti6Al4V components fabricated using selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Vaithilingam, Jayasheelan [Additive Manufacturing and 3D Printing Research Group, School of Engineering, University of Nottingham, Nottingham NG7 2RD (United Kingdom); Kilsby, Samuel [Department of Chemistry, Loughborough University, Loughborough LE11 3TU (United Kingdom); Goodridge, Ruth D., E-mail: Ruth.Goodridge@nottingham.ac.uk [Additive Manufacturing and 3D Printing Research Group, School of Engineering, University of Nottingham, Nottingham NG7 2RD (United Kingdom); Christie, Steven D.R. [Department of Chemistry, Loughborough University, Loughborough LE11 3TU (United Kingdom); Edmondson, Steve [School of Materials, The University of Manchester, Manchester M13 9PL (United Kingdom); Hague, Richard J.M. [Additive Manufacturing and 3D Printing Research Group, School of Engineering, University of Nottingham, Nottingham NG7 2RD (United Kingdom)

2014-09-30

Graphical abstract: The potential integration of selective laser melting (SLM) with surface modification using self-assembled monolayers for biomedical application has been investigated. Ciprofloxacin{sup ®} was functionalised to the SLM fabricated Ti6Al4V surface. Sustained release of the drug under in-vitro condition was witnessed. The inhibition zones showed the eluted drug was active against Staphylococcus aureus (a) and Escherichia coli (b) upon its release from the SLM fabricated part. - Highlights: • Parts fabricated using selective laser melting were coated with Ciprofloxacin{sup ®}. • The total amount of drug coated was approximately 1 μg/cm{sup 2}. • The coating was highly stable under oxidative conditions. • In-vitro studies showed a sustained release of the drug for over 42 days. • Ciprofloxacin{sup ®} eluted from the Ti6Al4V surface inhibited bacterial growth. - Abstract: Bacterial infections from biomedical implants and surgical devices are a major problem in orthopaedic, dental and vascular surgery. Although the sources of contaminations that lead to bacterial infections are known, it is not possible to control or avoid such infections completely. In this study, an approach to immobilise Ciprofloxacin{sup ®} (an antibacterial drug) to phosphonic acid based self-assembled monolayers (SAMs) adsorbed on a selectively laser melted (SLM) Ti6Al4V structure, has been presented. X-ray photoelectron spectroscopy (XPS) and static water contact angle measurements confirmed the attachment of SAMs and the drug. Results showed that Ciprofloxacin{sup ®} is highly stable under the oxidative conditions used in this study. In-vitro stability was estimated by immersing the Ciprofloxacin{sup ®} immobilised substrates in 10 mM of Tris–HCl buffer (pH-7.4) for 42 days. The Tris–HCl buffer was analysed using UV–vis spectrophotometry at 7, 14, 28 and 42 day time intervals to determine the release of the immobilised drug. The drug was observed to

Microstructure and mechanical properties of Al-12Si produced by selective laser melting

Science.gov (United States)

Fefelov, A. S.; Merkushev, A. G.; Chikova, O. A.

2017-10-01

Al-12Si specimens are produced by selective laser melting (SLM) from gas atomized powders. Installation for the production of powder is original. All specimens were prepared using the EOSINT M 280 device. A fine cellular structure is observed with residual free Si along the cellular boundaries. Room temperature tensile tests reveal remarkable mechanical behavior: the samples show yield and tensile strengths of about 102 MPa and 425 MPa, respectively, along with fracture strain of 12%. The study of crack surface morphology was shown by the example of a sample. Except the spherical pores, the interface of the molten pool also appears on the fracture surface, which indicates a mixture of fragile and ductile fracture. Additionally, the agglomerated silicon group appears also on the fracture surface.

Fabrication of friction-reducing texture surface by selective laser melting of ink-printed (SLM-IP) copper (Cu) nanoparticles(NPs)

Science.gov (United States)

Wang, Xinjian; Liu, Junyan; Wang, Yang; Fu, Yanan

2017-02-01

This paper reports a process of selective laser melting of ink-printed (SLM-IP) copper (Cu) nanoparticles(NPs) for the fabrication of full dense Cu friction-reducing texture on the metallic surface in ambient condition. This technique synthesizes pure Cu by chemical reduction route using an organic solvent during laser melting in the atmosphere environment, and provides a flexible additive manufacture approach to form complex friction-reduction texture on the metallic surface. Microtextures of ring and disc arrays have been fabricated on the stainless steel surface by SLM-IP Cu NPs. The friction coefficient has been measured under the lubricating condition of the oil. Disc texture surface (DTS) has a relatively low friction coefficient compared with ring texture surface (RTS), Cu film surface (Cu-FS) and the untreated substrate. The study suggests a further research on SLM-IP approach for complex microstructure or texture manufacturing, possibly realizing its advantage of flexibility.

Relationship of Powder Feedstock Variability to Microstructure and Defects in Selective Laser Melted Alloy 718

Science.gov (United States)

Smith, T. M.; Kloesel, M. F.; Sudbrack, C. K.

2017-01-01

Powder-bed additive manufacturing processes use fine powders to build parts layer by layer. For selective laser melted (SLM) Alloy 718, the powders that are available off-the-shelf are in the 10-45 or 15-45 micron size range. A comprehensive investigation of sixteen powders from these typical ranges and two off-nominal-sized powders is underway to gain insight into the impact of feedstock on processing, durability and performance of 718 SLM space-flight hardware. This talk emphasizes an aspect of this work: the impact of powder variability on the microstructure and defects observed in the as-fabricated and full heated material, where lab-scale components were built using vendor recommended parameters. These typical powders exhibit variation in composition, percentage of fines, roughness, morphology and particle size distribution. How these differences relate to the melt-pool size, porosity, grain structure, precipitate distributions, and inclusion content will be presented and discussed in context of build quality and powder acceptance.

Functionalisation of Ti6Al4V components fabricated using selective laser melting with a bioactive compound

Energy Technology Data Exchange (ETDEWEB)

Vaithilingam, Jayasheelan [Additive Manufacturing and 3D Printing Research Group, School of Engineering, The University of Nottingham, Nottingham NG7 2RD (United Kingdom); Kilsby, Samuel [Department of Chemistry, Loughborough University, Loughborough LE11 3TU (United Kingdom); Goodridge, Ruth D., E-mail: Ruth.Goodridge@nottingham.ac.uk [Additive Manufacturing and 3D Printing Research Group, School of Engineering, The University of Nottingham, Nottingham NG7 2RD (United Kingdom); Christie, Steven D.R. [Department of Chemistry, Loughborough University, Loughborough LE11 3TU (United Kingdom); Edmondson, Steve [School of Materials, The University of Manchester, Manchester M13 9PL (United Kingdom); Hague, Richard J.M. [Additive Manufacturing and 3D Printing Research Group, School of Engineering, The University of Nottingham, Nottingham NG7 2RD (United Kingdom)

2015-01-01

Surface modification of an implant with a biomolecule is used to improve its biocompatibility and to reduce post-implant complications. In this study, a novel approach has been used to functionalise phosphonic acid monolayers with a drug. Ti6Al4V components fabricated using selective laser melting (SLM) were functionalised with Paracetamol (a pharmaceutically relevant biomolecule) using phosphonic acid based self-assembled monolayers (SAMs). The attachment, stability of the monolayers on the SLM fabricated surface and functionalisation of SAMs with Paracetamol were studied using X-ray photoelectron spectroscopy (XPS) and surface wettability measurements. The obtained results confirmed that SAMs were stable on the Ti6Al4V surface for over four weeks and then began to desorb from the surface. The reaction used to functionalise the phosphonic acid monolayers with Paracetamol was noted to be successful. Thus, the proposed method has the potential to immobilise drugs/proteins to SAM coated surfaces and improve their biocompatibility and reduce post-implant complications. - Graphical abstract: A significant change in the contact angle confirming the immobilisation of Paracetamol. (a) Before self-assembled monolayer (SAM) attachment, (b) after SAM attachment and (c) after the immobilisation of Paracetamol to the SAMs. - Highlights: • Ti6Al4V parts were fabricated using selective laser melting (SLM). • Monolayers used to modify the SLM surface were stable for over 28 days (in-vitro). • Surface roughness did not have a significant impact on the monolayer stability. • Paracetamol was successfully immobilised to the adsorbed monolayers. • Caution required before selecting Paracetamol as a model drug.

Functionalisation of Ti6Al4V components fabricated using selective laser melting with a bioactive compound

International Nuclear Information System (INIS)

Vaithilingam, Jayasheelan; Kilsby, Samuel; Goodridge, Ruth D.; Christie, Steven D.R.; Edmondson, Steve; Hague, Richard J.M.

2015-01-01

Surface modification of an implant with a biomolecule is used to improve its biocompatibility and to reduce post-implant complications. In this study, a novel approach has been used to functionalise phosphonic acid monolayers with a drug. Ti6Al4V components fabricated using selective laser melting (SLM) were functionalised with Paracetamol (a pharmaceutically relevant biomolecule) using phosphonic acid based self-assembled monolayers (SAMs). The attachment, stability of the monolayers on the SLM fabricated surface and functionalisation of SAMs with Paracetamol were studied using X-ray photoelectron spectroscopy (XPS) and surface wettability measurements. The obtained results confirmed that SAMs were stable on the Ti6Al4V surface for over four weeks and then began to desorb from the surface. The reaction used to functionalise the phosphonic acid monolayers with Paracetamol was noted to be successful. Thus, the proposed method has the potential to immobilise drugs/proteins to SAM coated surfaces and improve their biocompatibility and reduce post-implant complications. - Graphical abstract: A significant change in the contact angle confirming the immobilisation of Paracetamol. (a) Before self-assembled monolayer (SAM) attachment, (b) after SAM attachment and (c) after the immobilisation of Paracetamol to the SAMs. - Highlights: • Ti6Al4V parts were fabricated using selective laser melting (SLM). • Monolayers used to modify the SLM surface were stable for over 28 days (in-vitro). • Surface roughness did not have a significant impact on the monolayer stability. • Paracetamol was successfully immobilised to the adsorbed monolayers. • Caution required before selecting Paracetamol as a model drug

The Laser Damage Threshold for Materials and the Relation Between Solid-Melt and Melt-Vapor Interface Velocities

International Nuclear Information System (INIS)

Khalil, Osama Mostafa

2010-01-01

Numerous experiments have demonstrated and analytic theories have predicted that there is a threshold for pulsed laser ablation of a wide range of materials. Optical surface damage threshold is a very complex and important application of high-power lasers. Optical damage may also be considered to be the initial phase of laser ablation. In this work it was determined the time required and the threshold energy of a layer of thickness to heat up. We used the Finite Difference method to simulate the process of laser-target interaction in three cases. Namely, the case before melting begins using a continuous wave (c.w) laser source and a pulsed laser source, the case after the first change of state (from solid to melt), and the case after the second change of state (from melt to vapor). And also study the relation between the solid-melt and melt-vapor interface velocities to have a commonsense of the laser ablation process.

Selective Laser Melting of Hot Gas Turbine Components: Materials, Design and Manufacturing Aspects

DEFF Research Database (Denmark)

Goutianos, Stergios

2017-01-01

are built additively to nearly net shape. This allows the fabrication of arbitrary complex geometries that cannot be made by conventional manufacturing techniques. However, despite the powerful capabilities of SLM, a number of issues (e.g. part orientation, support structures, internal stresses), have......Selective Laser Melting (SLM) allows the design and manufacturing of novel parts and structures with improved performance e.g. by incorporating complex and more efficient cooling schemes in hot gas turbine parts. In contrast to conventional manufacturing of removing material, with SLM parts...... to be considered in order to manufacture cost-effective and high quality parts at an industrial scale. These issues are discussed in the present work from an engineering point of view with the aim to provide simple quidelines to produce high quality SLM parts....

Microstructure and mechanical properties of stainless steel/calcium silicate composites manufactured by selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Zheng, Zeng [School of Materials Science and Engineering, Tongji University, Shanghai 201804 (China); Shanghai Key Lab. of D& A for Metal-Functional Materials, Shanghai 201804 (China); Wang, Lianfeng [School of Materials Science and Engineering, Tongji University, Shanghai 201804 (China); Shanghai Aerospace Equipments Manufacturer, Shanghai 200240 (China); Jia, Min [Shanghai Aircraft Manufacturing Co., Ltd, Shanghai 200436 (China); Cheng, Lingyu [Shanghai Aerospace Equipments Manufacturer, Shanghai 200240 (China); Yan, Biao, E-mail: 84016@tongji.edu.cn [School of Materials Science and Engineering, Tongji University, Shanghai 201804 (China); Shanghai Key Lab. of D& A for Metal-Functional Materials, Shanghai 201804 (China)

2017-02-01

Selective laser melting (SLM) is raised as one kind of additive manufacturing (AM) which is based on the discrete-stacking concept. This technique can fabricate advanced composites with desirable properties directly from 3D CAD data. In this research, 316L stainless steel (316L SS) and different fractions of calcium silicate (CaSiO{sub 3}) composites (weight fractions of calcium silicate are 0%, 5%,10% and 15%, respectively) were prepared by SLM technique with a purpose to develop biomedical metallic materials. The relative density, tensile, microhardness and elastic modulus of the composites were tested, their microstructures and fracture morphologies were observed using optical microscope (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). It was found that the addition of CaSiO{sub 3} particles influenced the microstructure and mechanical properties of specimens significantly. The CaSiO{sub 3} precipitates from the overlap of adjacent tracks and became the origin of the defects. The tensile strength of specimens range 320–722 MPa. The microhardness and elastic modulus are around 250 HV and 215 GPa respectively. These composites were ductile materials and the fracture mode of the composites was mixed mode of ductile and brittle fracture. The 316L SS/CaSiO{sub 3} composites can be a potential biomedical metallic materials in the medical field. - Highlights: • 316L SS/CaSiO{sub 3} composites were fabricated by selective laser melting. • Microstructure, mechanical properties, corrosion resistance of samples was studied. • Composites is a ductile material and mixed mode of ductile and brittle fracture. • Composites is a potential biomedical metallic materials in the medical field.

Fatigue performance evaluation of selective laser melted Ti–6Al–4V

Energy Technology Data Exchange (ETDEWEB)

Edwards, P. [Boeing Research and Technology, The Boeing Company, Seattle, WA (United States); Ramulu, M., E-mail: ramulum@u.washington.edu [Department of Mechanical Engineering, University of Washington, Seattle, WA (United States)

2014-03-01

Additive Manufacturing of titanium components holds promise to deliver benefits such as reduced cost, weight and carbon emissions during both manufacture and use. To capitalize on these benefits, it must be shown that the mechanical performance of parts produced by Additive Manufacturing can meet design requirements that are typically based on wrought material performance properties. Of particular concern for safety critical structures are the fatigue properties of parts produced by Additive Manufacturing. This research evaluates the fatigue properties of Ti–6Al–4V specimens produced by the Selective Laser Melting additive manufacturing process. It was found that the fatigue life is significantly lower compared to wrought material. This reduction in fatigue performance was attributed to a variety of issues, such as microstructure, porosity, surface finish and residual stress. There was also found to be a high degree of anisotropy in the fatigue performance associated with the specimen build orientation.

Fatigue performance evaluation of selective laser melted Ti–6Al–4V

International Nuclear Information System (INIS)

Edwards, P.; Ramulu, M.

2014-01-01

Additive Manufacturing of titanium components holds promise to deliver benefits such as reduced cost, weight and carbon emissions during both manufacture and use. To capitalize on these benefits, it must be shown that the mechanical performance of parts produced by Additive Manufacturing can meet design requirements that are typically based on wrought material performance properties. Of particular concern for safety critical structures are the fatigue properties of parts produced by Additive Manufacturing. This research evaluates the fatigue properties of Ti–6Al–4V specimens produced by the Selective Laser Melting additive manufacturing process. It was found that the fatigue life is significantly lower compared to wrought material. This reduction in fatigue performance was attributed to a variety of issues, such as microstructure, porosity, surface finish and residual stress. There was also found to be a high degree of anisotropy in the fatigue performance associated with the specimen build orientation

Selective laser melting-enabled electrospinning: Introducing complexity within electrospun membranes.

Science.gov (United States)

Paterson, Thomas E; Beal, Selina N; Santocildes-Romero, Martin E; Sidambe, Alfred T; Hatton, Paul V; Asencio, Ilida Ortega

2017-06-01

Additive manufacturing technologies enable the creation of very precise and well-defined structures that can mimic hierarchical features of natural tissues. In this article, we describe the development of a manufacturing technology platform to produce innovative biodegradable membranes that are enhanced with controlled microenvironments produced via a combination of selective laser melting techniques and conventional electrospinning. This work underpins the manufacture of a new generation of biomaterial devices that have significant potential for use as both basic research tools and components of therapeutic implants. The membranes were successfully manufactured and a total of three microenvironment designs (niches) were chosen for thorough characterisation. Scanning electron microscopy analysis demonstrated differences in fibre diameters within different areas of the niche structures as well as differences in fibre density. We also showed the potential of using the microfabricated membranes for supporting mesenchymal stromal cell culture and proliferation. We demonstrated that mesenchymal stromal cells grow and populate the membranes penetrating within the niche-like structures. These findings demonstrate the creation of a very versatile tool that can be used in a variety of tissue regeneration applications including bone healing.

Investigation into the influence of laser energy input on selective laser melted thin-walled parts by response surface method

Science.gov (United States)

Liu, Yang; Zhang, Jian; Pang, Zhicong; Wu, Weihui

2018-04-01

Selective laser melting (SLM) provides a feasible way for manufacturing of complex thin-walled parts directly, however, the energy input during SLM process, namely derived from the laser power, scanning speed, layer thickness and scanning space, etc. has great influence on the thin wall's qualities. The aim of this work is to relate the thin wall's parameters (responses), namely track width, surface roughness and hardness to the process parameters considered in this research (laser power, scanning speed and layer thickness) and to find out the optimal manufacturing conditions. Design of experiment (DoE) was used by implementing composite central design to achieve better manufacturing qualities. Mathematical models derived from the statistical analysis were used to establish the relationships between the process parameters and the responses. Also, the effects of process parameters on each response were determined. Then, a numerical optimization was performed to find out the optimal process set at which the quality features are at their desired values. Based on this study, the relationship between process parameters and SLMed thin-walled structure was revealed and thus, the corresponding optimal process parameters can be used to manufactured thin-walled parts with high quality.

Porous niobium coatings fabricated with selective laser melting on titanium substrates: Preparation, characterization, and cell behavior.

Science.gov (United States)

Zhang, Sheng; Cheng, Xian; Yao, Yao; Wei, Yehui; Han, Changjun; Shi, Yusheng; Wei, Qingsong; Zhang, Zhen

2015-08-01

Nb, an expensive and refractory element with good wear resistance and biocompatibility, is gaining more attention as a new metallic biomaterial. However, the high price of the raw material, as well as the high manufacturing costs because of Nb's strong oxygen affinity and high melting point have limited the widespread use of Nb and its compounds. To overcome these disadvantages, porous Nb coatings of various thicknesses were fabricated on Ti substrate via selective laser melting (SLM), which is a 3D printing technique that uses computer-controlled high-power laser to melt the metal. The morphology and microstructure of the porous Nb coatings, which had pores ranging from 15 to 50 μm in size, were characterized with scanning electron microscopy (SEM). The average hardness of the coating, which was measured with the linear intercept method, was 392±37 HV. In vitro tests of the porous Nb coating which was monitored with SEM, immunofluorescence, and CCK-8 counts of cells, exhibited excellent cell morphology, attachment, and growth. The simulated body fluid test also proved the bioactivity of the Nb coating. Therefore, these new porous Nb coatings could potentially be used for enhanced early biological fixation to bone tissue. In addition, this study has shown that SLM technique could be used to fabricate coatings with individually tailored shapes and/or porosities from group IVB and VB biomedical metals and their alloys on stainless steel, Co-Cr, and other traditional biomedical materials without wasting raw materials. Copyright © 2015 Elsevier B.V. All rights reserved.

Simultaneously enhanced strength and ductility for 3D-printed stainless steel 316L by selective laser melting

Science.gov (United States)

Sun, Zhongji; Tan, Xipeng; Tor, Shu Beng; Chua, Chee Kai

2018-04-01

Laser-based powder-bed fusion additive manufacturing or three-dimensional printing technology has gained tremendous attention due to its controllable, digital, and automated manufacturing process, which can afford a refined microstructure and superior strength. However, it is a major challenge to additively manufacture metal parts with satisfactory ductility and toughness. Here we report a novel selective laser melting process to simultaneously enhance the strength and ductility of stainless steel 316L by in-process engineering its microstructure into a crystallographic texture. We find that the tensile strength and ductility of SLM-built stainless steel 316L samples could be enhanced by 16% and 40% respectively, with the engineered textured microstructure compared to the common textured microstructure. This is because the favorable nano-twinning mechanism was significantly more activated in the textured stainless steel 316L samples during plastic deformation. In addition, kinetic simulations were performed to unveil the relationship between the melt pool geometry and crystallographic texture. The new additive manufacturing strategy of engineering the crystallographic texture can be applied to other metals and alloys with twinning-induced plasticity. This work paves the way to additively manufacture metal parts with high strength and high ductility.

Corrosion resistance characteristics of a Ti-6Al-4V alloy scaffold that is fabricated by electron beam melting and selective laser melting for implantation in vivo

Energy Technology Data Exchange (ETDEWEB)

Zhao, Bingjing; Wang, Hong [Department of Stomatology, General Hospital of the PLA, Beijing (China); Department of Stomatology, The Second Affiliated Stomatological Hospital of Liaoning Medical University (China); Qiao, Ning [College of Materials Science and Engineering, Beijing University of Chemical Technology, Beijing (China); Wang, Chao [School of Medicine, Nankai University, Tianjin 300071 (China); Hu, Min, E-mail: humin48@vip.163.com [Department of Stomatology, General Hospital of the PLA, Beijing (China)

2017-01-01

The purpose of this study is to determine the corrosion resistance of Ti-6Al-4V alloy fabricated with electron beam melting and selective laser melting for implantation in vivo. Ti-6Al-4V alloy specimens were fabricated with electron beam melting (EBM) and selective laser melting (SLM). A wrought form of Ti-6Al-4V alloy was used as a control. Surface morphology observation, component analysis, corrosion resistance experimental results, electrochemical impedance spectroscopy, crevice corrosion resistance experimental results, immersion test and metal ions precipitation analysis were processed, respectively. The thermal stability of EBM specimen was the worst, based on the result of open circuit potential (OCP) result. The result of electrochemical impedance spectroscopy indicated that the corrosion resistance of the SLM specimen was the best under the low electric potential. The result of potentiodynamic polarization suggested that the corrosion resistance of the SLM specimen was the best under the low electric potential (< 1.5 V) and EBM specimen was the best under the high electric potential (> 1.5 V).The crevice corrosion resistance of the EBM specimen was the best. The corrosion resistance of SLM specimen was the best, based on the result of immersion test. The content of Ti, Al and V ions of EBM, SLM and wrought specimens was very low. In general, the scaffolds that were fabricated with EBM and SLM had good corrosion resistance, and were suitable for implantation in vivo. - Highlights: • EBM and SLM Ti-6Al-4V alloy have good corrosion resistance, and both of them can be applied in vivo. • SLM Ti-6Al-4V alloy was more suitable for implantation in vivo than that of EBM Ti-6Al-4V alloy. • The crevice corrosion resistance of the EBM specimen is the best. • EBM and SLM specimens can form oxide film.

Microstructure and tensile properties of Ti-6Al-4V alloys manufactured by selective laser melting with optimized processing parameters

Science.gov (United States)

Wang, L.; Ma, C.; Huang, J.; Ding, H. Y.; Chu, M. Q.

2017-11-01

Selective laser melting (SLM) is a precise additive manufacturing process that the metallic powders without binder are melted layer by layer to complex components using a high bright fiber laser. In the paper, Ti-6Al-4V alloy was fabricated by SLM and its microstructure and mechanical properties were investigated in order to evaluate the SLM process. The results show that the microstructure exists anisotropy between the horizontal and vertical section due to the occurrence of epitaxial growth, and the former microstructure seems equal-axis and the latter is column. Moreover, there is little difference in tensile test between the horizontal and vertical sections. Furthermore, the tensile properties of fabricated Ti-6Al-4V alloy by SLM are higher than the forged standard ones. However, the fatigue results show that there are some scatters, which need further investigation to define the fatigue initiation.

Influence of small particles inclusion on selective laser melting of Ti-6Al-4V powder

Science.gov (United States)

Gong, Haijun; Dilip, J. J. S.; Yang, Li; Teng, Chong; Stucker, Brent

2017-12-01

The particle size distribution and powder morphology of metallic powders have an important effect on powder bed fusion based additive manufacturing processes, such as selective laser melting (SLM). The process development and parameter optimization require a fundamental understanding of the influence of powder on SLM. This study introduces a pre-alloyed titanium alloy Ti-6Al-4V powder, which has a certain amount of small particles, for SLM. The influence of small particle inclusion is investigated through microscopy of surface topography, elemental and microstructural analysis, and mechanical testing, compared to the Ti-6Al-4V powder provided by SLM machine vendor. It is found that the small particles inclusion in Ti-6Al-4V powder has a noticeable effect on extra laser energy absorption, which may develop imperfections and deteriorate the SLM fatigue performance.

A Comparison of Biocompatibility of a Titanium Alloy Fabricated by Electron Beam Melting and Selective Laser Melting.

Science.gov (United States)

Wang, Hong; Zhao, Bingjing; Liu, Changkui; Wang, Chao; Tan, Xinying; Hu, Min

2016-01-01

Electron beam melting (EBM) and selective laser melting (SLM) are two advanced rapid prototyping manufacturing technologies capable of fabricating complex structures and geometric shapes from metallic materials using computer tomography (CT) and Computer-aided Design (CAD) data. Compared to traditional technologies used for metallic products, EBM and SLM alter the mechanical, physical and chemical properties, which are closely related to the biocompatibility of metallic products. In this study, we evaluate and compare the biocompatibility, including cytocompatibility, haemocompatibility, skin irritation and skin sensitivity of Ti6Al4V fabricated by EBM and SLM. The results were analysed using one-way ANOVA and Tukey's multiple comparison test. Both the EBM and SLM Ti6Al4V exhibited good cytobiocompatibility. The haemolytic ratios of the SLM and EBM were 2.24% and 2.46%, respectively, which demonstrated good haemocompatibility. The EBM and SLM Ti6Al4V samples showed no dermal irritation when exposed to rabbits. In a delayed hypersensitivity test, no skin allergic reaction from the EBM or the SLM Ti6Al4V was observed in guinea pigs. Based on these results, Ti6Al4V fabricated by EBM and SLM were good cytobiocompatible, haemocompatible, non-irritant and non-sensitizing materials. Although the data for cell adhesion, proliferation, ALP activity and the haemolytic ratio was higher for the SLM group, there were no significant differences between the different manufacturing methods.

Evaluating Acoustic Emission Signals as an in situ process monitoring technique for Selective Laser Melting (SLM)

Energy Technology Data Exchange (ETDEWEB)

Fisher, Karl A. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Candy, Jim V. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Guss, Gabe [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Mathews, M. J. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

2016-10-14

In situ real-time monitoring of the Selective Laser Melting (SLM) process has significant implications for the AM community. The ability to adjust the SLM process parameters during a build (in real-time) can save time, money and eliminate expensive material waste. Having a feedback loop in the process would allow the system to potentially ‘fix’ problem regions before a next powder layer is added. In this study we have investigated acoustic emission (AE) phenomena generated during the SLM process, and evaluated the results in terms of a single process parameter, of an in situ process monitoring technique.

Influence of repetitive pulsed laser irradiation on the surface characteristics of an aluminum alloy in the melting regime

International Nuclear Information System (INIS)

Choi, Sung Ho; Jhang, Kyung Young

2015-01-01

We have investigated the influence of repetitive near-infrared (NIR) pulsed laser shots in the melting regime on the surface characteristics of an aluminum 6061-T6 alloy. Characteristics of interest include surface morphology, surface roughness, and surface hardness in the melted zone as well as the size of the melted zone. For this study, the proper pulse energy for inducing surface melting at one shot is selected using numerical simulations that calculate the variation in temperature at the laser beam spot for various input pulse energies in order to find the proper pulse energy for raising the temperature to the melting point. In this study, 130 mJ was selected as the input energy for a Nd:YAG laser pulse with a duration of 5 ns. The size of the melted zone measured using optical microscopy (OM) increased logarithmically with an increasing shot number. The surface morphology observed by scanning electron microscopy (SEM) clearly showed a re-solidified microstructure evolution after surface melting. The surface roughness and hardness were measured by atomic force microscopy (AFM) and nano-indentation, respectively. The surface roughness showed almost no variation due to the surface texturing after laser shots over 10. The hardness inside the melted zone was lower than that outside the zone because the β'' phase was transformed to a β phase or dissolved into a matrix.

Comparison of high-intensity sound and mechanical vibration for cleaning porous titanium cylinders fabricated using selective laser melting.

Science.gov (United States)

Seiffert, Gary; Hopkins, Carl; Sutcliffe, Chris

2017-01-01

Orthopedic components, such as the acetabular cup in total hip joint replacement, can be fabricated using porous metals, such as titanium, and a number of processes, such as selective laser melting. The issue of how to effectively remove loose powder from the pores (residual powder) of such components has not been addressed in the literature. In this work, we investigated the feasibility of two processes, acoustic cleaning using high-intensity sound inside acoustic horns and mechanical vibration, to remove residual titanium powder from selective laser melting-fabricated cylinders. With acoustic cleaning, the amount of residual powder removed was not influenced by either the fundamental frequency of the horn used (75 vs. 230 Hz) or, for a given horn, the number of soundings (between 1 and 20). With mechanical vibration, the amount of residual powder removed was not influenced by the application time (10 vs. 20 s). Acoustic cleaning was found to be more reliable and effective in removal of residual powder than cleaning with mechanical vibration. It is concluded that acoustic cleaning using high-intensity sound has significant potential for use in the final preparation stages of porous metal orthopedic components. © 2015 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 117-123, 2017. © 2015 The Authors Journal of Biomedical Materials Research Part B: Applied Biomaterials Published by Wiley Periodicals, Inc.

Characterization of 316L Steel Cellular Dodecahedron Structures Produced by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Konda Gokuldoss Prashanth

2016-10-01

Full Text Available The compression behavior of different 316L steel cellular dodecahedron structures with different density values were studied. The 316L steel structures produced using the selective laser melting process has four different geometries: single unit cells with and without the addition of base plates beneath and on top, and sandwich structures with multiple unit cells with different unit cell sizes. The relation between the relative compressive strength and the relative density was compared using different Gibson-Ashby models and with other published reports. The different aspects of the deformation and the mechanical properties were evaluated and the deformation at distinct loading levels was recorded. Finite element method (FEM simulations were carried out with the defined structures and the mechanical testing results were compared. The calculated theory, simulation estimation, and the observed experimental results are in good agreement.

Modeling of the thermal physical process and study on the reliability of linear energy density for selective laser melting

Science.gov (United States)

Xiang, Zhaowei; Yin, Ming; Dong, Guanhua; Mei, Xiaoqin; Yin, Guofu

2018-06-01

A finite element model considering volume shrinkage with powder-to-dense process of powder layer in selective laser melting (SLM) is established. Comparison between models that consider and do not consider volume shrinkage or powder-to-dense process is carried out. Further, parametric analysis of laser power and scan speed is conducted and the reliability of linear energy density as a design parameter is investigated. The results show that the established model is an effective method and has better accuracy allowing for the temperature distribution, and the length and depth of molten pool. The maximum temperature is more sensitive to laser power than scan speed. The maximum heating rate and cooling rate increase with increasing scan speed at constant laser power and increase with increasing laser power at constant scan speed as well. The simulation results and experimental result reveal that linear energy density is not always reliable using as a design parameter in the SLM.

Cold Spray Deposition of Freestanding Inconel Samples and Comparative Analysis with Selective Laser Melting

Science.gov (United States)

Bagherifard, Sara; Roscioli, Gianluca; Zuccoli, Maria Vittoria; Hadi, Mehdi; D'Elia, Gaetano; Demir, Ali Gökhan; Previtali, Barbara; Kondás, Ján; Guagliano, Mario

2017-10-01

Cold spray offers the possibility of obtaining almost zero-porosity buildups with no theoretical limit to the thickness. Moreover, cold spray can eliminate particle melting, evaporation, crystallization, grain growth, unwanted oxidation, undesirable phases and thermally induced tensile residual stresses. Such characteristics can boost its potential to be used as an additive manufacturing technique. Indeed, deposition via cold spray is recently finding its path toward fabrication of freeform components since it can address the common challenges of powder-bed additive manufacturing techniques including major size constraints, deposition rate limitations and high process temperature. Herein, we prepared nickel-based superalloy Inconel 718 samples with cold spray technique and compared them with similar samples fabricated by selective laser melting method. The samples fabricated using both methods were characterized in terms of mechanical strength, microstructural and porosity characteristics, Vickers microhardness and residual stresses distribution. Different heat treatment cycles were applied to the cold-sprayed samples in order to enhance their mechanical characteristics. The obtained data confirm that cold spray technique can be used as a complementary additive manufacturing method for fabrication of high-quality freestanding components where higher deposition rate, larger final size and lower fabrication temperatures are desired.

The Influence of Selective Laser Melting Parameters on Density and Mechanical Properties of AlSi10Mg

Directory of Open Access Journals (Sweden)

Raus A. A.

2016-01-01

Full Text Available Selective Laser Melting (SLM is one of the most effective powder bed technique in the additive Manufacturing (AM which able to fabricate functional metal parts directly from 3D Computer Aided Design (CAD file data. In this paper, the influence of SLM parameters, such as laser power, scanning speed and hatching distance on the density of AlSi10Mg samples are investigated using one factor at a time (OFAT. Furthermore, the optimum results are used to fabricate samples for hardness, tensile strength, and impact toughness test. It is revealed that AlSi10Mg parts fabricated by SLM achieving the best density of 99.13% at the value of 350 watts laser power, 1650 mm/s scanning speed and hatching distance 0.13mm, whereby resulted comparable and even better mechanical properties to those of conventionally HDPC A360F and HDPC A360T6 alloys although without any comprehensive post processing methods.

Cellular scanning strategy for selective laser melting: Evolution of optimal grid-based scanning path & parametric approach to thermal homogeneity

DEFF Research Database (Denmark)

Mohanty, Sankhya; Tutum, Cem Celal; Hattel, Jesper Henri

2013-01-01

Selective laser melting, as a rapid manufacturing technology, is uniquely poised to enforce a paradigm shift in the manufacturing industry by eliminating the gap between job- and batch-production techniques. Products from this process, however, tend to show an increased amount of defects such as ...... strategy has been developed for processing the standard sample, one unit cell at a time, using genetic algorithms, with an objective of reducing thermal asymmetries. © 2013 SPIE....

Intragranular cellular segregation network structure strengthening 316L stainless steel prepared by selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Zhong, Yuan; Liu, Leifeng [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, 10691 Stockholm (Sweden); Wikman, Stefan [Fusion for Energy, Torres Diagonal Litoral B3, Josep Pla 2, 08019 Barcelona (Spain); Cui, Daqing [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, 10691 Stockholm (Sweden); Shen, Zhijian, E-mail: shen@mmk.su.se [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, 10691 Stockholm (Sweden)

2016-03-15

A feasibility study was performed to fabricate ITER In-Vessel components by Selective Laser Melting (SLM) supported by Fusion for Energy (F4E). Almost fully dense 316L stainless steel (SS316L) components were prepared from gas-atomized powder and with optimized SLM processing parameters. Tensile tests and Charpy-V tests were carried out at 22 °C and 250 °C and the results showed that SLM SS316L fulfill the RCC-MR code. Microstructure characterization reveals the presence of hierarchical macro-, micro- and nano-structures in as-built samples that were very different from SS316L microstructures prepared by other established methods. The formation of a characteristic intragranular cellular segregation network microstructure appears to contribute to the increase of yield strength without losing ductility. Silicon oxide nano-inclusions were formed during the SLM process that generated a micro-hardness fluctuation in the building direction. The combined influence of a cellular microstructure and the nano-inclusions constraints the size of ductile dimples to nano-scale. The crack propagation is hindered by a pinning effect that improves the defect-tolerance of the SLM SS316L. This work proves that it was possible to manufacture SS316L with properties suitable for ITER First Wall panels. Further studies on irradiation properties of SLM SS316L and manufacturing of larger real-size components are needed. - Highlights: • The mechanical properties of SS316L made by selective laser melting fulfill RCC-MR. • SLM SS316L consists hierarchical structures of high heterogeneity. • Silicon rich oxide nano-inclusions are formed unexpectedly during SLM process. • Cellular structure and oxide nano-inclusions strengthen SLM SS316L.

On the texture, phase and tensile properties of commercially pure Ti produced via selective laser melting assisted by static magnetic field.

Science.gov (United States)

Kang, Nan; Yuan, Hao; Coddet, Pierre; Ren, Zhongming; Bernage, Charles; Liao, Hanlin; Coddet, Christian

2017-01-01

Tensile strength and ductility of Selective Laser Melting (SLM) processed commercially pure Ti (CP-Ti) were simultaneous enhanced by preforming the melting/solidification processes under Static Magnetic Field (SMF). The effects of SMF on microstructure and tensile properties were examined. The SMF-SLMed CP-Ti sample presents a microstructure of fine acicular martensitic α'-Ti and lath-shaped α-Ti. Meanwhile, the texture structure of SLMed CP-Ti was eliminated after adding a SMF. The SMF-SLM process offers new avenues to ameliorate the microstructure and improve the mechanical properties of SLMed sample. Copyright © 2016 Elsevier B.V. All rights reserved.

Process Optimization and Microstructure Characterization of Ti6Al4V Manufactured by Selective Laser Melting

Science.gov (United States)

junfeng, Li; zhengying, Wei

2017-11-01

Process optimization and microstructure characterization of Ti6Al4V manufactured by selective laser melting (SLM) were investigated in this article. The relative density of sampled fabricated by SLM is influenced by the main process parameters, including laser power, scan speed and hatch distance. The volume energy density (VED) was defined to account for the combined effect of the main process parameters on the relative density. The results shown that the relative density changed with the change of VED and the optimized process interval is 55˜60J/mm3. Furthermore, compared with laser power, scan speed and hatch distance by taguchi method, it was found that the scan speed had the greatest effect on the relative density. Compared with the microstructure of the cross-section of the specimen at different scanning speeds, it was found that the microstructures at different speeds had similar characteristics, all of them were needle-like martensite distributed in the β matrix, but with the increase of scanning speed, the microstructure is finer and the lower scan speed leads to coarsening of the microstructure.

Manufacturing of individual biodegradable bone substitute implants using selective laser melting technique.

Science.gov (United States)

Lindner, Markus; Hoeges, Simon; Meiners, Wilhelm; Wissenbach, Konrad; Smeets, Ralf; Telle, Rainer; Poprawe, Reinhart; Fischer, Horst

2011-06-15

The additive manufacturing technique selective laser melting (SLM) has been successfully proved to be suitable for applications in implant manufacturing. SLM is well known for metal parts and offers direct manufacturing of three-dimensional (3D) parts with high bulk density on the base of individual 3D data, including computer tomography models of anatomical structures. Furthermore, an interconnecting porous structure with defined and reproducible pore size can be integrated during the design of the 3D virtual model of the implant. The objective of this study was to develop the SLM processes for a biodegradable composite material made of β-tricalcium phosphate (β-TCP) and poly(D, L)-lactide (PDLLA). The development of a powder composite material (β-TCP/PDLLA) suitable for the SLM process was successfully performed. The microstructure of the manufactured samples exhibit a homogeneous arrangement of ceramic and polymer. The four-point bending strength was up to 23 MPa. The X-ray diffraction (XRD) analysis of the samples confirmed β-TCP as the only present crystalline phase and the gel permeations chromatography (GPC) analysis documented a degradation of the polymer caused by the laser process less than conventional manufacturing processes. We conclude that SLM presents a new possibility to manufacture individual biodegradable implants made of β-TCP/PDLLA. Copyright © 2011 Wiley Periodicals, Inc.

Low-Cycle Fatigue Behaviour of AISI 18Ni300 Maraging Steel Produced by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Ricardo Branco

2018-01-01

Full Text Available Selective laser melting has received a great deal of attention in recent years. Nevertheless, research has been mainly focused on the technical issues and their relationship with the final microstructure and monotonic properties. Fatigue behaviour has rarely been addressed, and the emphasis has been placed on high-cycle regimes. The aim of this paper is, therefore, to study, in a systematic manner, the cyclic plastic behaviour of AISI 18Ni300 maraging steel manufactured by selective laser melting. For this purpose, low-cycle fatigue tests, under fully-reversed strain-controlled conditions, with strain amplitudes ranging from 0.3% to 1.0%, were performed. After testing, fracture surfaces were examined by scanning electron microscopy to identify the main fatigue damage mechanisms. The analysis of results showed a non-Masing material, with a slight strain-softening behaviour, and non-linear response in both the elastic and plastic regimes. In addition, this steel exhibited a very low transition life of about 35 reversals, far below the values of conventional materials with equivalent monotonic mechanical properties, which can be attributed to the combination of high strength and low ductility. The total strain energy density, irrespective of strain amplitude, revealed itself to be a quite stable parameter throughout the lifetime. Finally, the SEM analysis showed for almost all the tested samples cracks initiated from the surface and inner defects which propagated through the rest of the cross section. A ductile/brittle fracture, with a predominance of brittle fracture, was observed in the samples, owing to the presence of defects which make it easier to spread the microcracks.

Vapor-melt Ratio in Laser Fine Cutting of Slot Arrays

International Nuclear Information System (INIS)

Wang Xuyue; Meng Qingxuan; Kang Renke; Xu Wenji; Guo Dongming; Wang Lianji

2011-01-01

In order to improve cut quality for slot arrays, a new method of laser fine cutting under the consideration of the ratio of vapor to melt is presented. Laser cutting of 6063 aluminum alloy sheet, 0.5 mm in thickness, was carried out on a JK701H Nd:YAG pulse laser cutting system. The effects of vapor-melt ratio on kerf width, surface roughness and recast layer were studied which relate cutting qualities. Observation on the cut samples with different vapor-melt ratios (0.687, 1.574, 3.601 varied with laser power increasing, and 1.535, 3.601, 7.661 with decreasing of beam cutting speed) shows that high vapor-melt ratio improves laser cut quality clearly. Kerf width 0.2 mm of smooth area on kerf top area and thickness 2.03 μm of recast layer are obtained. No dross was found on the kerf bottom and the percentage of the smooth area is up to 40% out of whole kerf side. The research on vapor-melt ratio provides a deeper understanding of laser cutting and improves laser cut quality effectively.

Improving the fatigue performance of porous metallic biomaterials produced by Selective Laser Melting.

Science.gov (United States)

Van Hooreweder, Brecht; Apers, Yanni; Lietaert, Karel; Kruth, Jean-Pierre

2017-01-01

This paper provides new insights into the fatigue properties of porous metallic biomaterials produced by additive manufacturing. Cylindrical porous samples with diamond unit cells were produced from Ti6Al4V powder using Selective Laser Melting (SLM). After measuring all morphological and quasi-static properties, compression-compression fatigue tests were performed to determine fatigue strength and to identify important fatigue influencing factors. In a next step, post-SLM treatments were used to improve the fatigue life of these biomaterials by changing the microstructure and by reducing stress concentrators and surface roughness. In particular, the influence of stress relieving, hot isostatic pressing and chemical etching was studied. Analytical and numerical techniques were developed to calculate the maximum local tensile stress in the struts as function of the strut diameter and load. With this method, the variability in the relative density between all samples was taken into account. The local stress in the struts was then used to quantify the exact influence of the applied post-SLM treatments on the fatigue life. A significant improvement of the fatigue life was achieved. Also, the post-SLM treatments, procedures and calculation methods can be applied to different types of porous metallic structures and hence this paper provides useful tools for improving fatigue performance of metallic biomaterials. Additive Manufacturing (AM) techniques such as Selective Laser Melting (SLM) are increasingly being used for producing customized porous metallic biomaterials. These biomaterials are regularly used for biomedical implants and hence a long lifetime is required. In this paper, a set of post-built surface and heat treatments is presented that can be used to significantly improve the fatigue life of porous SLM-Ti6Al4V samples. In addition, a novel and efficient analytical local stress method was developed to accurately quantify the influence of the post

Coatings with laser melt injection of ceramic particles

NARCIS (Netherlands)

de Hosson, J.T.M.; Ocelik, V.; de Oliveira, U.; Seal, S; Dahotre, NB; Moore, JJ; Suryanarayana, C; Agarwal, A

2003-01-01

The conditions for a successful Laser Melt Injection (LMI) of SiC and WC particles into the melt pool of Al8Si and Ti6Al4V alloys were studied experimentally and theoretically by FEM calculations. The laser employed is a high power Nd:YAG The formation of a relatively thick aluminium oxide layer on

Defect, Microstructure, and Mechanical Property of Ti-6Al-4V Alloy Fabricated by High-Power Selective Laser Melting

Science.gov (United States)

Cao, Sheng; Chen, Zhuoer; Lim, Chao Voon Samuel; Yang, Kun; Jia, Qingbo; Jarvis, Tom; Tomus, Dacian; Wu, Xinhua

2017-12-01

To improve the selective laser melting (SLM) productivity, a high laser power and accordingly adjusted parameters are employed to facilitate a high build rate. Three distinct processing strategies with incremental build rate are developed for SLM Ti-6Al-4V. Various types of defects are investigated. Further studies were carried out by heat-treatment and hot isostatic pressing to evaluate the influence of microstructure and porosity on mechanical properties. The anisotropic mechanical property in horizontally and vertically build samples were observed, which was attributable to the columnar grains and spatial arrangement of defects. Regardless of anisotropy, a post-SLM heat-treatment at 800°C for 2 h produces a combined high strength and ductility.

Plate-impact loading of cellular structures formed by selective laser melting

International Nuclear Information System (INIS)

Winter, R E; Cotton, M; Harris, E J; Maw, J R; Chapman, D J; Eakins, D E; McShane, G

2014-01-01

Porous materials are of great interest because of improved energy absorption over their solid counterparts. Their properties, however, have been difficult to optimize. Additive manufacturing has emerged as a potential technique to closely define the structure and properties of porous components, i.e. density, strut width and pore size; however, the behaviour of these materials at very high impact energies remains largely unexplored. We describe an initial study of the dynamic compression response of lattice materials fabricated through additive manufacturing. Lattices consisting of an array of intersecting stainless steel rods were fabricated into discs using selective laser melting. The resulting discs were impacted against solid stainless steel targets at velocities ranging from 300 to 700 m s −1 using a gas gun. Continuum CTH simulations were performed to identify key features in the measured wave profiles, while 3D simulations, in which the individual cells were modelled, revealed details of microscale deformation during collapse of the lattice structure. The validated computer models have been used to provide an understanding of the deformation processes in the cellular samples. The study supports the optimization of cellular structures for application as energy absorbers. (paper)

A Review of Selective Laser Melted NiTi Shape Memory Alloy

Science.gov (United States)

Khoo, Zhong Xun; Shen, Yu Fang

2018-01-01

NiTi shape memory alloys (SMAs) have the best combination of properties among the different SMAs. However, the limitations of conventional manufacturing processes and the poor manufacturability of NiTi have critically limited its full potential applicability. Thus, additive manufacturing, commonly known as 3D printing, has the potential to be a solution in fabricating complex NiTi smart structures. Recently, a number of studies on Selective Laser Melting (SLM) of NiTi were conducted to explore the various aspects of SLM-produced NiTi. Compared to producing conventional metals through the SLM process, the fabrication of NiTi SMA is much more challenging. Not only do the produced parts require a high density that leads to good mechanical properties, strict composition control is needed as well for the SLM NiTi to possess suitable phase transformation characteristics. Additionally, obtaining a good shape memory effect from the SLM NiTi samples is another challenging task that requires further understanding. This paper presents the results of the effects of energy density and SLM process parameters on the properties of SLM NiTi. Its shape memory properties and potential applications were then reviewed and discussed. PMID:29596320

Porous niobium coatings fabricated with selective laser melting on titanium substrates: Preparation, characterization, and cell behavior

Energy Technology Data Exchange (ETDEWEB)

Zhang, Sheng [Science and Technology on Power Beam Processes Laboratory, Beijing Aeronautical Manufacturing Technology Research Institute (BAMTRI), Beijing 100024 (China); State Key Lab of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074 (China); Cheng, Xian; Yao, Yao; Wei, Yehui [Department of Stomatology, Union Hospital, Tongji Medical College, Huazhong University of Science and Technology, Wuhan 430022 (China); Han, Changjun; Shi, Yusheng [State Key Lab of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074 (China); Wei, Qingsong, E-mail: wqs_xn@163.com [State Key Lab of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074 (China); Zhang, Zhen, E-mail: zhangzhentitanium@163.com [State Key Lab of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074 (China); Department of Stomatology, Union Hospital, Tongji Medical College, Huazhong University of Science and Technology, Wuhan 430022 (China)

2015-08-01

Nb, an expensive and refractory element with good wear resistance and biocompatibility, is gaining more attention as a new metallic biomaterial. However, the high price of the raw material, as well as the high manufacturing costs because of Nb's strong oxygen affinity and high melting point have limited the widespread use of Nb and its compounds. To overcome these disadvantages, porous Nb coatings of various thicknesses were fabricated on Ti substrate via selective laser melting (SLM), which is a 3D printing technique that uses computer-controlled high-power laser to melt the metal. The morphology and microstructure of the porous Nb coatings, which had pores ranging from 15 to 50 μm in size, were characterized with scanning electron microscopy (SEM). The average hardness of the coating, which was measured with the linear intercept method, was 392 ± 37 HV. In vitro tests of the porous Nb coating which was monitored with SEM, immunofluorescence, and CCK-8 counts of cells, exhibited excellent cell morphology, attachment, and growth. The simulated body fluid test also proved the bioactivity of the Nb coating. Therefore, these new porous Nb coatings could potentially be used for enhanced early biological fixation to bone tissue. In addition, this study has shown that SLM technique could be used to fabricate coatings with individually tailored shapes and/or porosities from group IVB and VB biomedical metals and their alloys on stainless steel, Co–Cr, and other traditional biomedical materials without wasting raw materials. - Highlights: • Porous Nb coating was firstly fabricated on Ti substrate by SLM technique. • Morphology, microstructure and hardness of the coating were characterized. • In vitro test of the coating showed good cell attachment, morphology and growth.

Porous niobium coatings fabricated with selective laser melting on titanium substrates: Preparation, characterization, and cell behavior

International Nuclear Information System (INIS)

Zhang, Sheng; Cheng, Xian; Yao, Yao; Wei, Yehui; Han, Changjun; Shi, Yusheng; Wei, Qingsong; Zhang, Zhen

2015-01-01

Nb, an expensive and refractory element with good wear resistance and biocompatibility, is gaining more attention as a new metallic biomaterial. However, the high price of the raw material, as well as the high manufacturing costs because of Nb's strong oxygen affinity and high melting point have limited the widespread use of Nb and its compounds. To overcome these disadvantages, porous Nb coatings of various thicknesses were fabricated on Ti substrate via selective laser melting (SLM), which is a 3D printing technique that uses computer-controlled high-power laser to melt the metal. The morphology and microstructure of the porous Nb coatings, which had pores ranging from 15 to 50 μm in size, were characterized with scanning electron microscopy (SEM). The average hardness of the coating, which was measured with the linear intercept method, was 392 ± 37 HV. In vitro tests of the porous Nb coating which was monitored with SEM, immunofluorescence, and CCK-8 counts of cells, exhibited excellent cell morphology, attachment, and growth. The simulated body fluid test also proved the bioactivity of the Nb coating. Therefore, these new porous Nb coatings could potentially be used for enhanced early biological fixation to bone tissue. In addition, this study has shown that SLM technique could be used to fabricate coatings with individually tailored shapes and/or porosities from group IVB and VB biomedical metals and their alloys on stainless steel, Co–Cr, and other traditional biomedical materials without wasting raw materials. - Highlights: • Porous Nb coating was firstly fabricated on Ti substrate by SLM technique. • Morphology, microstructure and hardness of the coating were characterized. • In vitro test of the coating showed good cell attachment, morphology and growth

Selective laser melting of carbon/AlSi10Mg composites: Microstructure, mechanical and electronical properties

Energy Technology Data Exchange (ETDEWEB)

Zhao, Xiao; Song, Bo, E-mail: bosong@hust.edu.cn; Fan, Wenrui; Zhang, Yuanjie; Shi, Yusheng

2016-04-25

Carbon nanotubes/AlSi10Mg composites has drawn lots of attention in structural engineering and functional device applications due to its extraordinary high elastic modulus and mechanical strength as well as excellent electrical and thermal conductivities. In this study, the CNTs/AlSi10Mg composites was firstly prepared and then processed by selective laser melting. The powder preparation, SLM process, and microstructure evolution, properties were clarified. The results showed that CNTs were decomposed due to the direct interaction with the laser beam. The SLMed composites displayed a similar microstructure to that of SLMed AlSi10Mg. The common brittleness phase Al{sub 4}C{sub 3} didn't form, and the carbon dispersion strengthening was observed. The electrical resistivity of the composites was reduced significantly and the hardness was improved. - Highlights: • Carbon nanotubes/AlSi10Mg powder were prepared by slurry ball milling process. • Carbon nanotubes/AlSi10Mg composites were firstly prepared by SLM. • The electrical resistivity of the composites was significantly reduced and hardness was improved.

Comparison of Selective Laser Melted Titanium and Magnesium Implants Coated with PCL

Science.gov (United States)

Matena, Julia; Petersen, Svea; Gieseke, Matthias; Teske, Michael; Beyerbach, Martin; Kampmann, Andreas; Escobar, Hugo Murua; Gellrich, Nils-Claudius; Haferkamp, Heinz; Nolte, Ingo

2015-01-01

Degradable implant material for bone remodeling that corresponds to the physiological stability of bone has still not been developed. Promising degradable materials with good mechanical properties are magnesium and magnesium alloys. However, excessive gas production due to corrosion can lower the biocompatibility. In the present study we used the polymer coating polycaprolactone (PCL), intended to lower the corrosion rate of magnesium. Additionally, improvement of implant geometry can increase bone remodeling. Porous structures are known to support vessel ingrowth and thus increase osseointegration. With the selective laser melting (SLM) process, defined open porous structures can be created. Recently, highly reactive magnesium has also been processed by SLM. We performed studies with a flat magnesium layer and with porous magnesium implants coated with polymers. The SLM produced magnesium was compared with the titanium alloy TiAl6V4, as titanium is already established for the SLM-process. For testing the biocompatibility, we used primary murine osteoblasts. Results showed a reduced corrosion rate and good biocompatibility of the SLM produced magnesium with PCL coating. PMID:26068455

Mechanical properties of regular hexahedral lattice structure formed by selective laser melting

International Nuclear Information System (INIS)

Sun, Jianfeng; Yang, Yongqiang; Wang, Di

2013-01-01

The Ti–6Al–4V lattice structure is widely used in the aerospace field. This research first designs a regular hexahedral unit, processes the lattice structure composed of the Ti–6Al–4V units by selective laser melting technology, obtains the experimental fracture load and the compression deformation of them through compression tests, then conducts a simulation of the unit and the lattice structure through ANSYS to analyze the failure point. Later, according to the force condition of the point, the model of maximum load is built, through which the analytical formula of the fracture load of the unit and the lattice structure are obtained. The results of groups of experiments demonstrate that there exists an exponential relationship between the practical fracture load and the porosity of the lattice structure. There also exists a trigonometric function relationship between the compression deformation and the porosity of the lattice structure. The fracture analysis indicates that fracture of the units and lattice structure is brittle fracture due to cleavage fracture. (paper)

A novel coping metal material CoCrCu alloy fabricated by selective laser melting with antimicrobial and antibiofilm properties

Energy Technology Data Exchange (ETDEWEB)

Ren, Ling [Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016 (China); Memarzadeh, Kaveh [Institute of Dentistry, Barts and The London School of Medicine & Dentistry, Queen Mary University of London, Newark Street, London E1 2AT (United Kingdom); Zhang, Shuyuan; Sun, Ziqing; Yang, Chunguang [Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016 (China); Ren, Guogang [University of Hertfordshire, Hatfield AL10 9AB (United Kingdom); Allaker, Robert P., E-mail: r.p.allaker@qmul.ac.uk [Institute of Dentistry, Barts and The London School of Medicine & Dentistry, Queen Mary University of London, Newark Street, London E1 2AT (United Kingdom); Yang, Ke, E-mail: kyang@imr.ac.cn [Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016 (China)

2016-10-01

Objective: The aim of this study was to fabricate a novel coping metal CoCrCu alloy using a selective laser melting (SLM) technique with antimicrobial and antibiofilm activities and to investigate its microstructure, mechanical properties, corrosion resistance and biocompatibility. Methods: Novel CoCrCu alloy was fabricated using SLM from a mixture of commercial CoCr based alloy and elemental Cu powders. SLM CoCr without Cu served as control. Antibacterial activity was analyzed using standard antimicrobial tests, and antibiofilm properties were investigated using confocal laser scanning microscope. Cu distribution and microstructure were determined using scanning electron microscope, optical microscopy and X-ray diffraction. Corrosion resistance was evaluated by potential dynamic polarization and biocompatibility measured using an MTT assay. Results: SLM CoCrCu alloys were found to be bactericidal and able to inhibit biofilm formation. Other factors such as microstructure, mechanical properties, corrosion resistance and biocompatibility were similar to those of SLM CoCr alloys. Significance: The addition of appropriate amounts of Cu not only maintains normal beneficial properties of CoCr based alloys, but also provides SLM CoCrCu alloys with excellent antibacterial and antibiofilm capabilities. This material has the potential to be used as a coping metal for dental applications. - Highlights: • Novel CoCrCu alloys were fabricated by using selective laser melting (SLM). • SLM CoCrCu alloys showed satisfied antimicrobial and antibiofilm activities. • SLM CoCrCu alloys have no cytotoxic effect on normal cells. • Other properties of SLM CoCrCu alloys were similar to SLM CoCr alloys. • SLM CoCrCu alloys have the potential to be used as coping metals.

A novel coping metal material CoCrCu alloy fabricated by selective laser melting with antimicrobial and antibiofilm properties

International Nuclear Information System (INIS)

Ren, Ling; Memarzadeh, Kaveh; Zhang, Shuyuan; Sun, Ziqing; Yang, Chunguang; Ren, Guogang; Allaker, Robert P.; Yang, Ke

2016-01-01

Objective: The aim of this study was to fabricate a novel coping metal CoCrCu alloy using a selective laser melting (SLM) technique with antimicrobial and antibiofilm activities and to investigate its microstructure, mechanical properties, corrosion resistance and biocompatibility. Methods: Novel CoCrCu alloy was fabricated using SLM from a mixture of commercial CoCr based alloy and elemental Cu powders. SLM CoCr without Cu served as control. Antibacterial activity was analyzed using standard antimicrobial tests, and antibiofilm properties were investigated using confocal laser scanning microscope. Cu distribution and microstructure were determined using scanning electron microscope, optical microscopy and X-ray diffraction. Corrosion resistance was evaluated by potential dynamic polarization and biocompatibility measured using an MTT assay. Results: SLM CoCrCu alloys were found to be bactericidal and able to inhibit biofilm formation. Other factors such as microstructure, mechanical properties, corrosion resistance and biocompatibility were similar to those of SLM CoCr alloys. Significance: The addition of appropriate amounts of Cu not only maintains normal beneficial properties of CoCr based alloys, but also provides SLM CoCrCu alloys with excellent antibacterial and antibiofilm capabilities. This material has the potential to be used as a coping metal for dental applications. - Highlights: • Novel CoCrCu alloys were fabricated by using selective laser melting (SLM). • SLM CoCrCu alloys showed satisfied antimicrobial and antibiofilm activities. • SLM CoCrCu alloys have no cytotoxic effect on normal cells. • Other properties of SLM CoCrCu alloys were similar to SLM CoCr alloys. • SLM CoCrCu alloys have the potential to be used as coping metals.

Studies of pulsed laser melting and rapid solidification using amorphous silicon

International Nuclear Information System (INIS)

Lowndes, D.H.; Wood, R.F.

1984-06-01

Pulsed-laser melting of ion implantation-amorphized silicon layers, and subsequent solidification were studied. Measurements of the onset of melting of amorphous silicon layers and of the duration of melting, and modified melting model calculations demonstrated that the thermal conductivity, K/sub a/, of amorphous silicon is very low (K/sub a/ approx. = 0.02 W/cm-K). K/sub a/ is also the dominant parameter determining the dynamical response of amorphous silicon to pulsed laser radiation. TEM indicates that bulk (volume) nucleation occurs directly from the highly undercooled liquid silicon that can be prepared by pulsed laser melting of amorphous silicon layers at low laser energy densities. A modified thermal melting model is presented. The model calculations demonstrate that the release of latent heat by bulk nucleation occurring during the melt-in process is essential to obtaining agreement with observed depths of melting. These calculations also show that this release of latent heat accompanying bulk nucleation can result in the existence of buried molten layers of silicon in the interior of the sample after the surface has solidified. The bulk nucleation implies that the liquid-to-amorphous phase transition (produced using picosecond or uv nanosecond laser pulses) cannot be explained using purely thermodynamic considerations

Microstructure analysis of magnesium alloy melted by laser irradiation

International Nuclear Information System (INIS)

Liu, S.Y.; Hu, J.D.; Yang, Y.; Guo, Z.X.; Wang, H.Y.

2005-01-01

The effects of laser surface melting (LSM) on microstructure of magnesium alloy containing Al8.57%, Zn 0.68%, Mn0.15%, Ce0.52% were investigated. In the present work, a pulsed Nd:YAG laser was used to melt and rapidly solidify the surface of the magnesium alloy with the objective of changing microstructure and improving the corrosion resistance. The results indicate that laser-melted layer contains the finer dendrites and behaviors good resistance corrosion compared with the untreated layer. Furthermore, the absorption coefficient of the magnesium alloy has been estimated according to the numeral simulation of the thermal conditions. The formation process of fine microstructure in melted layers was investigated based on the experimental observation and the theoretical analysis. Some simulation results such as the re-solidification velocities are obtained. The phase constitutions of the melted layers determined by X-ray diffraction were β-Mg 17 Al 12 and α-Mg as well as some phases unidentified

Challenges in Laser Sintering of Melt-Processable Thermoset Imide Resin

Science.gov (United States)

Chuang, Kathy C.; Gornet, Timothy; Koerner, Hilmar

2016-01-01

Polymer Laser Sintering (LS) is an additive manufacturing technique that builds 3D models layer by layer using a laser to selectively melt cross sections in powdered polymeric materials, following sequential slices of the CAD model. LS generally uses thermoplastic polymeric powders, such as polyamides (i.e. Nylon), and the resultant 3D objects are often weaker in their strength compared to traditionally processed materials, due to the lack of polymer inter-chain connection in the z-direction. The objective of this project is to investigate the possibility of printing a melt-processable RTM370 imide resin powder terminated with reactive phenylethynyl groups by LS, followed by a postcure in order to promote additional crosslinking to achieve higher temperature (250-300 C) capability. A preliminary study to build tensile specimens by LS and the corresponding DSC and rheology study of RTM370 during LS process is presented.

Heat treatment of Ti6Al4V produced by Selective Laser Melting: Microstructure and mechanical properties

International Nuclear Information System (INIS)

Vrancken, Bey; Thijs, Lore; Kruth, Jean-Pierre; Van Humbeeck, Jan

2012-01-01

Highlights: ► Responses of SLM-produced and wrought Ti6Al4V to heat treatment are compared. ► Temperature is found to be the controlling parameter for treatments in the α + β range. ► Ductility could be improved by a factor of 85%, from 7.27% to 13.59%. ► An optimal heat treatment for SLM produced Ti6Al4V is proposed. - Abstract: The present work shows that optimization of mechanical properties via heat treatment of parts produced by Selective Laser Melting (SLM) is profoundly different compared to conventionally processed Ti6Al4V. In order to obtain optimal mechanical properties, specific treatments are necessary due to the specific microstructure resulting from the SLM process. SLM is an additive manufacturing technique through which components are built by selectively melting powder layers with a focused laser beam. The process is characterized by short laser-powder interaction times and localized high heat input, which leads to steep thermal gradients, rapid solidification and fast cooling. In this research, the effect of several heat treatments on the microstructure and mechanical properties of Ti6Al4V processed by SLM is studied. A comparison is made with the effect of these treatments on hot forged and subsequently mill annealed Ti6Al4V with an original equiaxed microstructure. For SLM produced parts, the original martensite α′ phase is converted to a lamellar mixture of α and β for heat treating temperatures below the β-transus (995 °C), but features of the original microstructure are maintained. Treated above the β-transus, extensive grain growth occurs and large β grains are formed which transform to lamellar α + β upon cooling. Post treating at 850 °C for 2 h, followed by furnace cooling increased the ductility of SLM parts to 12.84 ± 1.36%, compared to 7.36 ± 1.32% for as-built parts.

Microstructure and mechanical behavior of porous Ti-6Al-4V parts obtained by selective laser melting.

Science.gov (United States)

Sallica-Leva, E; Jardini, A L; Fogagnolo, J B

2013-10-01

Rapid prototyping allows titanium porous parts with mechanical properties close to that of bone tissue to be obtained. In this article, porous parts of the Ti-6Al-4V alloy with three levels of porosity were obtained by selective laser melting with two different energy inputs. Thermal treatments were performed to determine the influence of the microstructure on the mechanical properties. The porous parts were characterized by both optical and scanning electron microscopy. The effective modulus, yield and ultimate compressive strength were determined by compressive tests. The martensitic α' microstructure was observed in all of the as-processed parts. The struts resulting from the processing conditions investigated were thinner than those defined by CAD models, and consequently, larger pores and a higher experimental porosity were achieved. The use of the high-energy input parameters produced parts with higher oxygen and nitrogen content, their struts that were even thinner and contained a homogeneous porosity distribution. Greater mechanical properties for a given relative density were obtained using the high-energy input parameters. The as-quenched martensitic parts showed yield and ultimate compressive strengths similar to the as-processed parts, and these were greater than those observed for the fully annealed samples that had the lamellar microstructure of the equilibrium α+β phases. The effective modulus was not significantly influenced by the thermal treatments. A comparison between these results and those of porous parts with similar geometry obtained by selective electron beam melting shows that the use of a laser allows parts with higher mechanical properties for a given relative density to be obtained. Copyright © 2013 Elsevier Ltd. All rights reserved.

Microstructure and mechanical properties of selective laser melted Ti6Al4V alloy

Science.gov (United States)

Losertová, M.; Kubeš, V.

2017-11-01

The present work was focused on the properties of porous Ti6Al4V specimens processed by selective laser melting (SLM) and tested in tension and compression before and after heat treatment. The SLM samples were annealed at 955 °C, water quenched and aged at 600 °C with following air cooling. The values of the mechanical tests showed that the samples exhibited high mechanical properties. The anisotropy of tensile and compressive strength was observed, which was related to the occurrence of voids. The plastic properties of specimens were improved by means of the heat treatment that led to the transformation of martensitic to lamellar structure composed of α + β phases. The microstructure of SLM samples were evaluated before and after the heat treatment. The brittle nature of failures of non-heat treated samples can be explained by synergy of martensite presence, microcracks and residual stresses produced by SLM.

Bioactive treatment promotes osteoblast differentiation on titanium materials fabricated by selective laser melting technology.

Science.gov (United States)

Tsukanaka, Masako; Fujibayashi, Shunsuke; Takemoto, Mitsuru; Matsushita, Tomiharu; Kokubo, Tadashi; Nakamura, Takashi; Sasaki, Kiyoyuki; Matsuda, Shuichi

2016-01-01

Selective laser melting (SLM) technology is useful for the fabrication of porous titanium implants with complex shapes and structures. The materials fabricated by SLM characteristically have a very rough surface (average surface roughness, Ra=24.58 µm). In this study, we evaluated morphologically and biochemically the specific effects of this very rough surface and the additional effects of a bioactive treatment on osteoblast proliferation and differentiation. Flat-rolled titanium materials (Ra=1.02 µm) were used as the controls. On the treated materials fabricated by SLM, we observed enhanced osteoblast differentiation compared with the flat-rolled materials and the untreated materials fabricated by SLM. No significant differences were observed between the flat-rolled materials and the untreated materials fabricated by SLM in their effects on osteoblast differentiation. We concluded that the very rough surface fabricated by SLM had to undergo a bioactive treatment to obtain a positive effect on osteoblast differentiation.

A novel process for production of spherical PBT powders and their processing behavior during laser beam melting

Energy Technology Data Exchange (ETDEWEB)

Schmidt, Jochen, E-mail: jochen.schmidt@fau.de; Sachs, Marius; Fanselow, Stephanie; Wirth, Karl-Ernst; Peukert, Wolfgang [Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Particle Technology, Cauerstr. 4, D-91058 Erlangen (Germany); Zhao, Meng; Wudy, Katrin; Drexler, Maximilian; Drummer, Dietmar [Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Polymer Technology, Am Weichselgarten 9, D-91058 Erlangen (Germany)

2016-03-09

Additive manufacturing processes like laser beam melting of polymers are established for production of prototypes and individualized parts. The transfer to other areas of application and to serial production is currently hindered by the limited availability of polymer powders with good processability. Within this contribution a novel process route for the production of spherical polymer micron-sized particles of good flowability has been established and applied to produce polybutylene terephthalate (PBT) powders. Moreover, the applicability of the PBT powders in selective laser beam melting and the dependencies of process parameters on device properties will be outlined. First, polymer micro particles are produced by a novel wet grinding method. To improve the flowability the produced particles the particle shape is optimized by rounding in a heated downer reactor. A further improvement of flowability of the cohesive spherical PBT particles is realized by dry coating. An improvement of flowability by a factor of about 5 is achieved by subsequent rounding of the comminution product and dry-coating as proven by tensile strength measurements of the powders. The produced PBT powders were characterized with respect to their processability. Therefore thermal, rheological, optical and bulk properties were analyzed. Based on these investigations a range of processing parameters was derived. Parameter studies on thin layers, produced in a selective laser melting system, were conducted. Hence appropriate parameters for processing the PBT powders by laser beam melting, like building chamber temperature, scan speed and laser power have been identified.

A novel process for production of spherical PBT powders and their processing behavior during laser beam melting

International Nuclear Information System (INIS)

Schmidt, Jochen; Sachs, Marius; Fanselow, Stephanie; Wirth, Karl-Ernst; Peukert, Wolfgang; Zhao, Meng; Wudy, Katrin; Drexler, Maximilian; Drummer, Dietmar

2016-01-01

Additive manufacturing processes like laser beam melting of polymers are established for production of prototypes and individualized parts. The transfer to other areas of application and to serial production is currently hindered by the limited availability of polymer powders with good processability. Within this contribution a novel process route for the production of spherical polymer micron-sized particles of good flowability has been established and applied to produce polybutylene terephthalate (PBT) powders. Moreover, the applicability of the PBT powders in selective laser beam melting and the dependencies of process parameters on device properties will be outlined. First, polymer micro particles are produced by a novel wet grinding method. To improve the flowability the produced particles the particle shape is optimized by rounding in a heated downer reactor. A further improvement of flowability of the cohesive spherical PBT particles is realized by dry coating. An improvement of flowability by a factor of about 5 is achieved by subsequent rounding of the comminution product and dry-coating as proven by tensile strength measurements of the powders. The produced PBT powders were characterized with respect to their processability. Therefore thermal, rheological, optical and bulk properties were analyzed. Based on these investigations a range of processing parameters was derived. Parameter studies on thin layers, produced in a selective laser melting system, were conducted. Hence appropriate parameters for processing the PBT powders by laser beam melting, like building chamber temperature, scan speed and laser power have been identified.

Development Algorithm of the Technological Process of Manufacturing Gas Turbine Parts by Selective Laser Melting

Science.gov (United States)

Sotov, A. V.; Agapovichev, A. V.; Smelov, V. G.; Kyarimov, R. R.

2018-01-01

The technology of the selective laser melting (SLM) allows making products from powders of aluminum, titanium, heat-resistant alloys and stainless steels. Today the use of SLM technology develops at manufacture of the functional parts. This in turn requires development of a methodology projection of technological processes (TP) for manufacturing parts including databases of standard TP. Use of a technique will allow to exclude influence of technologist’s qualification on made products quality, and also to reduce labor input and energy consumption by development of TP due to use of the databases of standard TP integrated into a methodology. As approbation of the developed methodology the research of influence of the modes of a laser emission on a roughness of a surface of synthesized material was presented. It is established that the best values of a roughness of exemplars in the longitudinal and transversal directions make 1.98 μm and 3.59 μm respectively. These values of a roughness were received at specific density of energy 6.25 J/mm2 that corresponds to power and the speed of scanning of 200 W and 400 mm/s, respectively, and a hatch distance of 0.08 mm.

Strength analysis and modeling of cellular lattice structures manufactured using selective laser melting for tooling applications

DEFF Research Database (Denmark)

Mahshid, Rasoul; Hansen, Hans Nørgaard; Loft Højbjerre, Klaus

2016-01-01

Additive manufacturing is rapidly developing and gaining popularity for direct metal fabrication systems like selective laser melting (SLM). The technology has shown significant improvement for high-quality fabrication of lightweight design-efficient structures such as conformal cooling channels...... in injection molding tools and lattice structures. This research examines the effect of cellular lattice structures on the strength of workpieces additively manufactured from ultra high-strength steel powder. Two commercial SLM machines are used to fabricate cellular samples based on four architectures— solid......, hollow, lattice structure and rotated lattice structure. Compression test is applied to the specimens while they are deformed. The analytical approach includes finite element (FE), geometrical and mathematical models for prediction of collapse strength. The results from the the models are verified...

Influence of Selective Laser Melting Processing Parameters of Co-Cr-W Powders on the Roughness of Exterior Surfaces

Science.gov (United States)

Baciu, M. A.; Baciu, E. R.; Bejinariu, C.; Toma, S. L.; Danila, A.; Baciu, C.

2018-06-01

Selective Laser Melting (SLM) represents an Additive Manufacturing method widely used in medical practice, mainly in dental medicine. The powder of 59% Co, 25% Cr, 2.5% W alloy (Starbond CoS Powder 55, S&S Scheftner C, Germany) was processed (SLM) on a Realizer SLM 50 device (SLM Solution, Germany). After laser processing and simple sanding with Al2O3 or two-phase sanding (Al2O3 and glass balls), measurements of surface roughness were conducted. This paper presents the influences exercised by laser power (P = 60 W, 80 W and 100 W), the scanning speed (vscan = 333 mm/s, 500 mm/s and 1000 mm/s) and exposure time (te = 20 µs, 40 µs and 60 µs) on the roughness of surfaces obtained by SLM processing. Based on the experimental results obtained for roughness (Ra), some recommendations regarding the choice of favorable combinations among the values of technological parameters under study in order to obtain the surface quality necessary for subsequent applications of the processed parts (SLM) have been made.

A Lightweight Structure Redesign Method Based on Selective Laser Melting

Directory of Open Access Journals (Sweden)

Li Tang

2016-11-01

Full Text Available The purpose of this paper is to present a new design method of lightweight parts fabricated by selective laser melting (SLM based on the “Skin-Frame” and to explore the influence of fabrication defects on SLM parts with different sizes. Some standard lattice parts were designed according to the Chinese GB/T 1452-2005 standard and manufactured by SLM. Then these samples were tested in an MTS Insight 30 compression testing machine to study the trends of the yield process with different structure sizes. A set of standard cylinder samples were also designed according to the Chinese GB/T 228-2010 standard. These samples, which were made of iron-nickel alloy (IN718, were also processed by SLM, and then tested in the universal material testing machine INSTRON 1346 to obtain their tensile strength. Furthermore, a lightweight redesigned method was researched. Then some common parts such as a stopper and connecting plate were redesigned using this method. These redesigned parts were fabricated and some application tests have already been performed. The compression testing results show that when the minimum structure size is larger than 1.5 mm, the mechanical characteristics will hardly be affected by process defects. The cylinder parts were fractured by the universal material testing machine at about 1069.6 MPa. These redesigned parts worked well in application tests, with both the weight and fabrication time of these parts reduced more than 20%.

Osseointegration of three-dimensional designed titanium implants manufactured by selective laser melting.

Science.gov (United States)

Shaoki, Algabri; Xu, Jia-Yun; Sun, Haipeng; Chen, Xian-Shuai; Ouyang, Jianglin; Zhuang, Xiu-Mei; Deng, Fei-Long

2016-10-27

The selective laser melting (SLM) technique is a recent additive manufacturing (AM) technique. Several studies have reported success in the SLM-based production of biocompatible orthopaedic implants and three-dimensional bone defect constructs. In this study, we evaluated the surface properties and biocompatibility of an SLM titanium implant in vitro and compared them with those of a machined (MA) titanium control surface. In addition, we evaluated the osseointegration capability of the SLM implants in vivo and compared it with those of MA and Nobel-speedy (Nobel-S) implants. SLM microtopographical surface analysis revealed porous and high roughness with varied geometry compared with a smooth surface in MA Ti samples but with similar favourable wettability. Osteoblast proliferation and alkaline phosphatase activity were significantly enhanced on the SLM surface. Histological analysis of the bone-implant contact ratio revealed no significant difference among SLM, MA, and Nobel-S implants. Micro-CT assessment indicated that there was no significant difference in bone volume fraction around the implant among SLM implants and other types of surface modification implants. The removal torque value measurement of SLM implants was significantly lower that of than Nobel-S implants P manufacturing technique.

Surface chemistry of Ti6Al4V components fabricated using selective laser melting for biomedical applications

Energy Technology Data Exchange (ETDEWEB)

Vaithilingam, Jayasheelan, E-mail: Jayasheelan.Vaithilingam@nottingham.ac.uk [Additive Manufacturing and 3D Printing Research Group, EPSRC Centre for Innovative Manufacturing in Additive Manufacturing, School of Engineering, The University of Nottingham, Nottingham NG7 2RD (United Kingdom); Prina, Elisabetta [School of Pharmacy, Centre for Biomolecular Sciences, The University of Nottingham, Nottingham NG7 2RD (United Kingdom); Goodridge, Ruth D.; Hague, Richard J.M. [Additive Manufacturing and 3D Printing Research Group, EPSRC Centre for Innovative Manufacturing in Additive Manufacturing, School of Engineering, The University of Nottingham, Nottingham NG7 2RD (United Kingdom); Edmondson, Steve [School of Materials, The University of Manchester, Manchester M13 9PL (United Kingdom); Rose, Felicity R.A.J. [School of Pharmacy, Centre for Biomolecular Sciences, The University of Nottingham, Nottingham NG7 2RD (United Kingdom); Christie, Steven D.R. [Department of Chemistry, Loughborough University, Loughborough LE11 3TU (United Kingdom)

2016-10-01

Selective laser melting (SLM) has previously been shown to be a viable method for fabricating biomedical implants; however, the surface chemistry of SLM fabricated parts is poorly understood. In this study, X-ray photoelectron spectroscopy (XPS) was used to determine the surface chemistries of (a) SLM as-fabricated (SLM-AF) Ti6Al4V and (b) SLM fabricated and mechanically polished (SLM-MP) Ti6Al4V samples and compared with (c) traditionally manufactured (forged) and mechanically polished Ti6Al4V samples. The SLM–AF surface was observed to be porous with an average surface roughness (Ra) of 17.6 ± 3.7 μm. The surface chemistry of the SLM-AF was significantly different to the FGD-MP surface with respect to elemental distribution and their existence on the outermost surface. Sintered particles on the SLM-AF surface were observed to affect depth profiling of the sample due to a shadowing effect during argon ion sputtering. Surface heterogeneity was observed for all three surfaces; however, vanadium was witnessed only on the mechanically polished (SLM-MP and FGD-MP) surfaces. The direct and indirect 3T3 cell cytotoxicity studies revealed that the cells were viable on the SLM fabricated Ti6Al4V parts. The varied surface chemistry of the SLM-AF and SLM-MP did not influence the cell behaviour. - Highlights: • Surface chemistry of selective laser melted (SLM) Ti6Al4V parts was compared with conventionally forged Ti6Al4V parts. • The surface elemental compositions of the SLM as-fabricated surfaces were significantly different to the forged surface. • Surface oxide-layer of the SLM as-fabricated was thicker than the polished SLM surfaces and the forged Ti6Al4V surfaces.

Simulation on the Effects of Surfactants and Observed Thermocapillary Motion for Laser Melting Physics

Science.gov (United States)

Nourgaliev, Robert; Barney, Rebecca; Weston, Brian; Delplanque, Jean-Pierre; McCallen, Rose

2017-11-01

A newly developed, robust, high-order in space and time, Newton-Krylov based reconstructed discontinuous Galerkin (rDG) method is used to model and analyze thermocapillary convection in melt pools. The application of interest is selective laser melting (SLM) which is an Additive Manufacturing (AM, 3D metal laser printing) process. These surface tension driven flows are influenced by temperature gradients and surfactants (impurities), and are known as the Marangoni flow. They have been experimentally observed in melt pools for welding applications, and are thought to influence the microstructure of the re-solidified material. We study the effects of the laser source configuration (power, beam size and scanning speed), as well as surfactant concentrations. Results indicate that the surfactant concentration influences the critical temperature, which governs the direction of the surface thermocapillary traction. When the surface tension traction changes sign, very complex flow patterns emerge, inducing hydrodynamic instability under certain conditions. These in turn would affect the melt pool size (depth) and shape, influencing the resulting microstructure, properties, and performance of a finished product part produced using 3D metal laser printing technologies. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. Information management release number LLNL-ABS-735908.

Effects of Oxygen Content on Tensile and Fatigue Performance of Ti-6Al-4 V Manufactured by Selective Laser Melting

Science.gov (United States)

Quintana, Oscar A.; Tong, Weidong

2017-12-01

We investigated the selective laser melting (SLM) process for development of Ti-6Al-4 V solid material with oxygen content corresponding to the extra low interstitial (ELI) and non-ELI conditions. The microstructure, chemistry, and tensile properties of samples in as-built and hot isostatically pressed (HIPed) condition were evaluated for both material types, while fatigue performance was evaluated by rotating bending fatigue tests on both smooth and notched SLM ELI and non-ELI Ti-6Al-4 V samples in HIPed condition.

Research on the mechanical behaviour of an airplane component made by selective laser melting technology

Directory of Open Access Journals (Sweden)

Păcurar Răzvan

2017-01-01

Full Text Available The main objective of the presented research consists in the redesign of an airplane component to decrease its weight, without affecting the mechanical behaviour of the component, at the end. Femap NX Nastran and ANSYS FEA programs were used for the shape optimization and for the estimation of the mechanical behaviour of a fixing clamp that was used to sustain the hydraulic pipes that are passing through an airplane fuselage, taking into consideration two types of raw materials – Ti6Al4V and AlSi12 powder from which this component could be manufactured by using the selective laser melting (SLM technology. Based on the obtained results, the airplane component was finally manufactured from titanium alloy using the SLM 250 HL equipment that is available at SLM Solutions GmbH company from Luebeck, in Germany.

Constitutive and failure behaviour in selective laser melted stainless steel for microlattice structures

International Nuclear Information System (INIS)

Li, Peifeng

2015-01-01

The emerging selective laser melting (SLM) technology makes possible the manufacturing of metallic microlattice structures with better tailorability of properties. This work investigated the constitutive formulation of the parent material and the failure mechanism in the SLM stainless steel microlattice structure. The constitutive behaviour of SLM stainless steel was quantitatively formulated using the Johnson–Cook hardening model. A finite element model incorporating the constitutive formula was developed and experimentally validated to predict the localised stress evolution in an SLM stainless steel microlattice structure subjected to uniaxial compression. The predicted stresses were then linked to the fracture process in the SLM steel observed by scanning electron microscope. It was found that the tensile and compressive stress state is localised in the strut members of the microlattice, and determines the macroscopic cracking mode. The tensile opening and shear cracking dominate the tension and compression zones, respectively. However, the microscopic examination on the fracture surfaces reveals the formation of substantial slip bands in both the tension and compression zones, implying that the ductile fracture in the SLM stainless steel is transgranular

Layered surface structure of gas-atomized high Nb-containing TiAl powder and its impact on laser energy absorption for selective laser melting

Science.gov (United States)

Zhou, Y. H.; Lin, S. F.; Hou, Y. H.; Wang, D. W.; Zhou, P.; Han, P. L.; Li, Y. L.; Yan, M.

2018-05-01

Ti45Al8Nb alloy (in at.%) is designed to be an important high-temperature material. However, its fabrication through laser-based additive manufacturing is difficult to achieve. We present here that a good understanding of the surface structure of raw material (i.e. Ti45Al8Nb powder) is important for optimizing its process by selective laser melting (SLM). Detailed X-ray photoelectron spectroscopy (XPS) depth profiling and transmission electron microscopy (TEM) analyses were conducted to determine the surface structure of Ti45Al8Nb powder. An envelope structure (∼54.0 nm in thickness) was revealed for the powder, consisting of TiO2 + Nb2O5 (as the outer surface layer)/Al2O3 + Nb2O5 (as the intermediate layer)/Al2O3 (as the inner surface layer)/Ti45Al8Nb (as the matrix). During SLM, this layered surface structure interacted with the incident laser beam and improved the laser absorptivity of Ti45Al8Nb powder by ∼32.21%. SLM experiments demonstrate that the relative density of the as-printed parts can be realized to a high degree (∼98.70%), which confirms good laser energy absorption. Such layered surface structure with appropriate phase constitution is essential for promoting SLM of the Ti45Al8Nb alloy.

Biodegradation Resistance and Bioactivity of Hydroxyapatite Enhanced Mg-Zn Composites via Selective Laser Melting.

Science.gov (United States)

Shuai, Cijun; Zhou, Yuanzhuo; Yang, Youwen; Feng, Pei; Liu, Long; He, Chongxian; Zhao, Mingchun; Yang, Sheng; Gao, Chengde; Wu, Ping

2017-03-17

Mg-Zn alloys have attracted great attention as implant biomaterials due to their biodegradability and biomechanical compatibility. However, their clinical application was limited due to the too rapid degradation. In the study, hydroxyapatite (HA) was incorporated into Mg-Zn alloy via selective laser melting. Results showed that the degradation rate slowed down due to the decrease of grain size and the formation of protective layer of bone-like apatite. Moreover, the grain size continually decreased with increasing HA content, which was attributed to the heterogeneous nucleation and increased number of nucleation particles in the process of solidification. At the same time, the amount of bone-like apatite increased because HA could provide favorable areas for apatite nucleation. Besides, HA also enhanced the hardness due to the fine grain strengthening and second phase strengthening. However, some pores occurred owing to the agglomerate of HA when its content was excessive, which decreased the biodegradation resistance. These results demonstrated that the Mg-Zn/HA composites were potential implant biomaterials.

Research on High Layer Thickness Fabricated of 316L by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Shuo Wang

2017-09-01

Full Text Available Selective laser melting (SLM is a potential additive manufacturing (AM technology. However, the application of SLM was confined due to low efficiency. To improve efficiency, SLM fabrication with a high layer thickness and fine powder was systematically researched, and the void areas and hollow powders can be reduced by using fine powder. Single-track experiments were used to narrow down process parameter windows. Multi-layer fabrication relative density can be reached 99.99% at the exposure time-point distance-hatch space of 120 μs-40 μm-240 μm. Also, the building rate can be up to 12 mm3/s, which is about 3–10 times higher than the previous studies. Three typical defects were found by studying deeply, including the un-melted defect between the molten pools, the micro-pore defect within the molten pool, and the irregular distribution of the splashing phenomenon. Moreover, the microstructure is mostly equiaxed crystals and a small amount of columnar crystals. The averages of ultimate tensile strength, yield strength, and elongation are 625 MPa, 525 MPa, and 39.9%, respectively. As exposure time increased from 80 μs to 200 μs, the grain size is gradually grown up from 0.98 μm to 2.23 μm, the grain aspect ratio is close to 1, and the tensile properties are shown as a downward trend. The tensile properties of high layer thickness fabricated are not significantly different than those with a coarse-powder layer thickness of low in previous research.

Research on High Layer Thickness Fabricated of 316L by Selective Laser Melting.

Science.gov (United States)

Wang, Shuo; Liu, Yude; Shi, Wentian; Qi, Bin; Yang, Jin; Zhang, Feifei; Han, Dong; Ma, Yingyi

2017-09-08

Selective laser melting (SLM) is a potential additive manufacturing (AM) technology. However, the application of SLM was confined due to low efficiency. To improve efficiency, SLM fabrication with a high layer thickness and fine powder was systematically researched, and the void areas and hollow powders can be reduced by using fine powder. Single-track experiments were used to narrow down process parameter windows. Multi-layer fabrication relative density can be reached 99.99% at the exposure time-point distance-hatch space of 120 μs-40 μm-240 μm. Also, the building rate can be up to 12 mm³/s, which is about 3-10 times higher than the previous studies. Three typical defects were found by studying deeply, including the un-melted defect between the molten pools, the micro-pore defect within the molten pool, and the irregular distribution of the splashing phenomenon. Moreover, the microstructure is mostly equiaxed crystals and a small amount of columnar crystals. The averages of ultimate tensile strength, yield strength, and elongation are 625 MPa, 525 MPa, and 39.9%, respectively. As exposure time increased from 80 μs to 200 μs, the grain size is gradually grown up from 0.98 μm to 2.23 μm, the grain aspect ratio is close to 1, and the tensile properties are shown as a downward trend. The tensile properties of high layer thickness fabricated are not significantly different than those with a coarse-powder layer thickness of low in previous research.

Holographic measurement of distortion during laser melting: Additive distortion from overlapping pulses

Science.gov (United States)

Haglund, Peter; Frostevarg, Jan; Powell, John; Eriksson, Ingemar; Kaplan, Alexander F. H.

2018-03-01

Laser - material interactions such as welding, heat treatment and thermal bending generate thermal gradients which give rise to thermal stresses and strains which often result in a permanent distortion of the heated object. This paper investigates the thermal distortion response which results from pulsed laser surface melting of a stainless steel sheet. Pulsed holography has been used to accurately monitor, in real time, the out-of-plane distortion of stainless steel samples melted on one face by with both single and multiple laser pulses. It has been shown that surface melting by additional laser pulses increases the out of plane distortion of the sample without significantly increasing the melt depth. The distortion differences between the primary pulse and subsequent pulses has also been analysed for fully and partially overlapping laser pulses.

Characterisation of a complex thin walled structure fabricated by selective laser melting using a ferritic oxide dispersion strengthened steel

Energy Technology Data Exchange (ETDEWEB)

Boegelein, Thomas, E-mail: t.boegelein@liv.ac.uk; Louvis, Eleftherios; Dawson, Karl; Tatlock, Gordon J.; Jones, Andy R.

2016-02-15

Oxide dispersion strengthened (ODS) alloys exhibit superior mechanical and physical properties due to the presence of nanoscopic Y(Al, Ti) oxide precipitates, but their manufacturing process is complex. The present study is aimed at further investigation of the application of an alternative, Additive Manufacturing (AM) technique, Selective Laser Melting (SLM), to the production of consolidated ODS alloy components. Mechanically alloyed PM2000 (ODS-FeCrAl) powders have been consolidated and a fine dispersion of Y-containing precipitates were observed in an as built thin-walled component, but these particles were typically poly-crystalline and contained a variety of elements including O, Al, Ti, Cr and Fe. Application of post-build heat treatments resulted in the modification of particle structures and compositions; in the annealed condition most precipitates were transformed to single crystal yttrium aluminium oxides. During the annealing treatment, precipitate distributions homogenised and localised variations in number density were diminished. The resulting volume fractions of those precipitates were 25–40% lower than have been reported in conventionally processed PM2000, which was attributed to Y-rich slag-like surface features and inclusions formed during SLM. - Highlights: • A wall structure was grown from ODS steel powder using selective laser melting. • A fine dispersion of nano-precipitates was apparent in as-build material. • Precipitates were multi-phased containing several elements, e.g. O, Ti, Al, Fe, Cr, Y. • Post-build annealing changed those into typically single-crystalline Y–Al–O. • The anneal also reduced and stabilised the volume fraction of precipitates to ~ 0.006.

Influence of pre-heating on the surface modification of powder-metallurgy processed cold-work tool steel during laser surface melting

Energy Technology Data Exchange (ETDEWEB)

Šturm, Roman, E-mail: roman.sturm@fs.uni-lj.si [University of Ljubljana, Faculty of Mechanical Engineering, Aškerčeva 6, 1000 Ljubljana (Slovenia); Štefanikova, Maria [University of Ljubljana, Faculty of Mechanical Engineering, Aškerčeva 6, 1000 Ljubljana (Slovenia); Steiner Petrovič, Darja [Institute of Metals and Technology, Lepi pot 11, 1000 Ljubljana (Slovenia)

2015-01-15

Graphical abstract: - Highlights: • Heat-treatment protocol for laser surface melting of cold-work tool steel is proposed. • The laser melted steel surface is hardened, and morphologically modified. • The pre-heating of substrate creates a crack-and pore-free steel surface. • The optimum pre-heating temperature is determined to be 350 °C. • Using pre-heating the quantity of retained austenite is reduced. - Abstract: In this study we determine the optimal parameters for surface modification using the laser surface melting of powder-metallurgy processed, vanadium-rich, cold-work tool steel. A combination of steel pre-heating, laser surface melting and a subsequent heat treatment creates a hardened and morphologically modified surface of the selected high-alloy tool steel. The pre-heating of the steel prior to the laser surface melting ensures a crack- and pore-free modified surface. Using a pre-heating temperature of 350 °C, the extremely fine microstructure, which typically evolves during the laser-melting, became slightly coarser and the volume fraction of retained austenite was reduced. In the laser-melted layer the highest values of microhardness were achieved in the specimens where a subsequent heat treatment at 550 °C was applied. The performed thermodynamic calculations were able to provide a very valuable assessment of the liquidus temperature and, especially, a prediction of the chemical composition as well as the precipitation and dissolution sequence for the carbides.

Microstructure and properties of high chrome steel roller after laser surface melting

International Nuclear Information System (INIS)

Li Meiyan; Wang Yong; Han Bin; Zhao Weimin; Han Tao

2009-01-01

Laser surface melting of high chrome steels was achieved by a 5 kW continuous wave CO 2 laser. The microstructure of the laser surface-melted steels was investigated by scanning electron microscopy, transmission electron microscopy and X-ray diffractometry, and the hardness profiles were determined by a Vickers hardness tester. The corrosion behavior in 3.5% NaCl solution was studied by electrochemical corrosion equipment. The large carbides of high chrome steels are completely dissolved and ultrafine dendrites of austenite with submicroscopic M 23 C 6 carbides precipitation are formed in the melted zone. The austenite in the melted zone has a high tempering stability. The corrosion resistance of the laser surface-melted steels is significantly improved due to the dissolution of carbides and the increase of the alloying elements in the solid solution as well as the large amount of austenite.

Fundamental Aspects of Selective Melting Additive Manufacturing Processes

Energy Technology Data Exchange (ETDEWEB)

van Swol, Frank B. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Miller, James E. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

2014-12-01

Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

[Bond strengths of customized titanium brackets manufactured by selective laser melting].

Science.gov (United States)

Zou, Dao-xing; Wang, Ze-min; Guo, Hong-ming; Li, Song; Bai, Yu-xing

2013-07-01

To investigate the bond strengths of customized titanium bracket manufactured by selective laser melting. Eighty human premolars which had been extracted for orthodontic purpose were collected and divided randomly (by random table) into two groups (customized bracket group and 3M bracket group, 40 molars in each group). The 35% phosphoric acid was used for etching and the brackets were bonded with 3M Unitek bonding adhesive. All bonded specimens were placed in saline for 24 hours at room temperature and were tested on DWD3050 electronic testing machine to determine the shear bond strength and tensile bond strength. After debonding, the adhesive remnant indexes (ARI) were recorded. The shear bond strengths of customized brackets was 6.80 (6.20, 8.32) MPa, which was significantly lower than that of the 3M brackets [10.46 (9.72, 11.48) MPa] (Z = -3.463, P < 0.05). And the tensile bond strengths of customized brackets was (6.93 ± 1.21) MPa, which was significantly higher than that of the 3M brackets [(5.88 ± 1.23) MPa] (t = 2.81, P < 0.05). No significant difference was found in the ARI between two different kinds of the brackets. The shear bond strength and tensile bond strength of both kinds of brackets were enough for clinic application.

Selective laser melting of an Al86Ni6Y4.5Co2La1.5 metallic glass: Processing, microstructure evolution and mechanical properties

International Nuclear Information System (INIS)

Li, X.P.; Kang, C.W.; Huang, H.; Zhang, L.C.; Sercombe, T.B.

2014-01-01

In this study, single line scans at different laser powers were carried out using selective laser meting (SLM) equipment on a pre-fabricated porous Al 86 Ni 6 Y 4.5 Co 2 La 1.5 metallic glass (MG) preform. The densification, microstructural evolution, phase transformation and mechanical properties of the scan tracks were systematically investigated. It was found that the morphology of the scan track was influenced by the energy distribution of the laser beam and the heat transfer competition between convection and conduction in the melt pool. Due to the Gaussian distribution of laser energy and heat transfer process, different regions of the scan track experienced different thermal histories, resulting in a gradient microstructure and mechanical properties. Higher laser powers caused higher thermal stresses, which led to the formation of cracks; while low power reduced the strength of the laser track, also inducing cracking. The thermal fluctuation at high laser power produced an inhomogeneous chemical distribution which gave rise to severe crystallization of the MG, despite the high cooling rate. The crystallization occurred both within the heat affected zone (HAZ) and at the edge of melt pool. However, by choosing an appropriate laser power crack-free scan tracks could be produced with no crystallization. This work provides the necessary fundamental understanding that will lead to the fabrication of large-size, crack-free MG with high density, controllable microstructure and mechanical properties using SLM

Influence of Powder Surface Contamination in the Ni-Based Superalloy Alloy718 Fabricated by Selective Laser Melting and Hot Isostatic Pressing

Directory of Open Access Journals (Sweden)

Yen-Ling Kuo

2017-09-01

Full Text Available The aim of this study was to gain a deep understanding of the microstructure-mechanical relationship between solid-state sintering and full-melting processes. The IN718 superalloy was fabricated by hot isostatic pressing (HIP and selective laser melting (SLM. Continuous precipitates were clearly localized along the prior particle boundary (PPB in the HIP materials, while SLM materials showed a microstructure free of PPB. The mechanical properties of specimens that underwent SLM + solution treatment and aging were comparable to those of conventional wrought specimens both at room temperature and 650 °C. However, a drop was observed in the ductility of HIP material at 650 °C. The brittle particles along the PPB were found to affect the HIP materials’ creep life and ductility during solid-state sintering.

Microstructure and properties of high chrome steel roller after laser surface melting

Energy Technology Data Exchange (ETDEWEB)

Li Meiyan, E-mail: lmy_102411@163.com [College of Electromechanical Engineering, China University of Petroleum, 271 Bei' er Road, Dongying 257061 (China); Wang Yong; Han Bin; Zhao Weimin; Han Tao [College of Electromechanical Engineering, China University of Petroleum, 271 Bei' er Road, Dongying 257061 (China)

2009-06-15

Laser surface melting of high chrome steels was achieved by a 5 kW continuous wave CO{sub 2} laser. The microstructure of the laser surface-melted steels was investigated by scanning electron microscopy, transmission electron microscopy and X-ray diffractometry, and the hardness profiles were determined by a Vickers hardness tester. The corrosion behavior in 3.5% NaCl solution was studied by electrochemical corrosion equipment. The large carbides of high chrome steels are completely dissolved and ultrafine dendrites of austenite with submicroscopic M{sub 23}C{sub 6} carbides precipitation are formed in the melted zone. The austenite in the melted zone has a high tempering stability. The corrosion resistance of the laser surface-melted steels is significantly improved due to the dissolution of carbides and the increase of the alloying elements in the solid solution as well as the large amount of austenite.

Effect of Build Angle on Surface Properties of Nickel Superalloys Processed by Selective Laser Melting

Science.gov (United States)

Covarrubias, Ernesto E.; Eshraghi, Mohsen

2018-03-01

Aerospace, automotive, and medical industries use selective laser melting (SLM) to produce complex parts through solidifying successive layers of powder. This additive manufacturing technique has many advantages, but one of the biggest challenges facing this process is the resulting surface quality of the as-built parts. The purpose of this research was to study the surface properties of Inconel 718 alloys fabricated by SLM. The effect of build angle on the surface properties of as-built parts was investigated. Two sets of sample geometries including cube and rectangular artifacts were considered in the study. It was found that, for angles between 15° and 75°, theoretical calculations based on the "stair-step" effect were consistent with the experimental results. Downskin surfaces showed higher average roughness values compared to the upskin surfaces. No significant difference was found between the average roughness values measured from cube and rectangular test artifacts.

Tailoring the texture of IN738LC processed by selective laser melting (SLM) by specific scanning strategies

Energy Technology Data Exchange (ETDEWEB)

Geiger, Fabian [General Electric Switzerland GmbH – GE Power, CH-5401 Baden (Switzerland); Kunze, Karsten, E-mail: karsten.kunze@scopem.ethz.ch [ETH Zurich, Scientific Center of Optical and Electron Microscopy (ScopeM), CH-8093 Zürich (Switzerland); Etter, Thomas [General Electric Switzerland GmbH – GE Power, CH-5401 Baden (Switzerland)

2016-04-20

Selective laser melting (SLM) is an emerging technology of additive manufacturing, which is used to directly produce metallic parts from thin powder layers. This study aims at correlating laser scanning strategies with the resulting textures and corresponding anisotropy of the elastic behavior of bulk materials. Tensile test specimens made of the γ’-containing Ni-base superalloy IN738LC were built with the loading direction oriented either parallel (z-specimens) or perpendicular to the build-up direction (xy-specimens). Their bulk mechanical properties were determined at room temperature and at 850 °C. Specimens were investigated in the ‘as-built’ condition and after recrystallization heat treatment. SEM-based electron backscatter diffraction (EBSD) was applied to measure their crystallographic preferred orientations (texture) and to correlate the anisotropy of Young's modulus with the texture of the material. It is shown that the applied laser scanning strategies allow to tailor the crystallographic texture locally. The possibility to switch from transverse anisotropic to transverse isotropic properties and reverse is demonstrated for triple layered tensile samples. A recrystallization heat treatment reduces the degree of crystallographic texture and thus the elastic anisotropy by abundant annealing twinning. Predictions of Young's modulus calculated from the measured textures compare well with the data from tensile tests.

[Effects of repeated firing on microleakage of selective laser melting ceramic crowns].

Science.gov (United States)

Zhong, Qun; Peng, Yan; Wu, Xue-Ying; Weng, Jia-Wei

2016-12-01

To investigate the effects of repeated firing on microleakage of selective laser melting ceramic crowns. Fifty molars were randomly divided into 2 groups (25 teeth in each group). Teeth in group A received a chamfer finish line preparation, whereas teeth in group B received a shoulder finish line. After SLM metal crowns were fabricated, all the crowns received initial oxidation step, opaque firing, dentin firing and glaze firing, then crowns in each group were randomly divided into 5 sub-groups according to different time of clinical firings. Glass ionomer was applied for bonding. After 5000 thermocycles ranging from 5degrees centigrade to 55degrees centigrade, all the specimens was evaluated by dye penetration and then microleakage was examined under light microscopy. The data were analyzed with SPSS 20.0 software package. Microleakage between all specimens of group A were not statistically significant (P>0.05) whereas that of group B were statistically significant (P<0.05); After the fifth time of clinical firing, microleakage of specimens in group B(B5) were significantly higher than that of group A(A5). Repeated firings had no significant influence on marginal microleakage of SLM ceramic crowns whereas the crowns of chamfer finish lines result in better clinical performance after repeated firings.

Experimental investigation on densification behavior and surface roughness of AlSi10Mg powders produced by selective laser melting

Science.gov (United States)

Wang, Lin-zhi; Wang, Sen; Wu, Jiao-jiao

2017-11-01

Effects of laser energy density (LED) on densities and surface roughness of AlSi10Mg samples processed by selective laser melting were studied. The densification behaviors of the SLM manufactured AlSi10Mg samples at different LEDs were characterized by a solid densitometer, an industrial X-ray and CT detection system. A field emission scanning electron microscope, an automatic optical measuring system, and a surface profiler were used for measurements of surface roughness. The results show that relatively high density can be obtained with the point distance of 80-105 μm and the exposure time of 140-160 μs. The LED has an important influence on the surface morphology of the forming part, too high LED may lead to balling effect, while too low LED tends to produce defects, such as porosity and microcrack, and then affect surface roughness and porosities of the parts finally.

Adaptation and micro-structure of Co-Cr alloy maxillary complete denture base plates fabricated by selective laser melting technique.

Science.gov (United States)

Ye, Ye; Jiao, Ting; Zhu, Jiarui; Sun, Jian

2018-01-24

The purpose of the study was to evaluate the adaptation and micro-structure of Co-Cr alloy maxillary complete denture base plates fabricated by the selective laser melting (SLM) technique. Twenty pairs of edentulous casts were randomly and evenly divided into two groups, and manufacturing of the Co-Cr alloy maxillary complete denture base was conducted either by the SLM technique or by the conventional method. The base-cast sets were transversally sectioned into three sections at the distal canines, mesial of the first molars and the posterior palatal zone. The gap between the metal base and cast was measured in these three sections with a stereoscopic microscope, and the data were analysed using t tests. A total of five specimens of 5 mm diameter were fabricated with the Co-Cr alloy by SLM and the traditional casting technology. A scanning electron microscope (SEM) was used to evaluate the differences in microstructure between these specimens. There was no statistical difference between the three sections in all four groups (P > 0.05). At the region of the canines, the clearance value for the SLM Co-Cr alloy group was larger than that of the conventional method group (P  0.05). The SLM Co-Cr alloy has a denser microstructure behaviour and less casting defect than the cast Co-Cr alloy. The SLM technique showed initial feasibility for the manufacture of dental bases of complete dentures, but large sample studies are needed to prove its reliability in clinical applications. The mechanical properties and microstructure of the denture frameworks prepared by selective laser melting indicate that these dentures are appropriate for clinical use.

Ti-6Al-4V Additively Manufactured by Selective Laser Melting with Superior Mechanical Properties

Science.gov (United States)

Xu, W.; Sun, S.; Elambasseril, J.; Liu, Q.; Brandt, M.; Qian, M.

2015-03-01

The Achilles' heel of additively manufactured Ti-6Al-4V by selective laser melting (SLM) is its inferior mechanical properties compared with its wrought (forged) counterparts. Acicular α' martensite resulted from rapid cooling by SLM is primarily responsible for high strength but inadequate tensile ductility achieved in the as-fabricated state. This study presents a solution to eliminating the adverse effect of the nonequilibrium α' martensite. This is achieved by enabling in situ martensite decomposition into a novel ultrafine (200-300 nm) lamellar ( α + β) microstructure via the selection of an array of processing variables including the layer thickness, energy density, and focal offset distance. The resulting tensile elongation reached 11.4% while the yield strength was kept above 1100 MPa. These properties compare favorably with those of mill-annealed Ti-6Al-4V consisting of globular α and β. The fatigue life of SLM-fabricated Ti-6Al-4V with an ultrafine lamellar ( α + β) structure has approached that of the mill-annealed counterparts and is much superior to that of SLM-fabricated Ti-6Al-4V with α' martensite.

The Transverse Rupture Strength in Ti-6Al-4V Alloy Manufactured by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Lai Pang-Hsin

2015-01-01

Full Text Available The objective of this study was to investigate the transverse rupture strength and apparent hardness of selective laser melted Ti-6Al-4V alloys manufactured in the vertical (V and horizontal (H directions. The microstructure and the distribution of alloy elements were examined by optical microscope and electron probe microanalysis, respectively. The results show that the columnar α′ grains are formed along the building direction, and the elemental distributions of Ti, Al, and V are homogeneous in the alloy. The building direction does not sufficiently affect the density and apparent hardness. However, the transverse rupture strengths (TRS are obviously dominated by the building directions investigated in this study. The TRS of an H specimen is significantly superior to that of a V specimen by 48%. This phenomenon can be mainly attributed to the presence of disc-shaped pores.

[Comparative adaptation of crowns of selective laser melting and wax-lost-casting method].

Science.gov (United States)

Li, Guo-qiang; Shen, Qing-yi; Gao, Jian-hua; Wu, Xue-ying; Chen, Li; Dai, Wen-an

2012-07-01

To investigate the marginal adaptation of crowns fabricated by selective laser melting (SLM) and wax-lost-casting method, so as to provide an experimental basis for clinic. Co-Cr alloy full crown were fabricated by SLM and wax-lost-casting for 24 samples in each group. All crowns were cemented with zinc phosphate cement and cut along longitudinal axis by line cutting machine. The gap between crown tissue surface and die was measured by 6-point measuring method with scanning electron microscope (SEM). The marginal adaptation of crowns fabricated by SLM and wax-lost-casting were compared statistically. The gap between SLM crowns were (36.51 ± 2.94), (49.36 ± 3.31), (56.48 ± 3.35), (42.20 ± 3.60) µm, and wax-lost-casting crowns were (68.86 ± 5.41), (58.86 ± 6.10), (70.62 ± 5.79), (69.90 ± 6.00) µm. There were significant difference between two groups (P casting method and SLM method provide acceptable marginal adaptation in clinic, and the marginal adaptation of SLM is better than that of wax-lost-casting method.

Influence of Annealing on Mechanical Properties of Al-20Si Processed by Selective Laser Melting

Directory of Open Access Journals (Sweden)

Pan Ma

2014-01-01

Full Text Available The microstructure and mechanical properties of Al-20Si produced by selective laser melting (SLM are investigated for different heat treatment conditions. As a result of the high cooling rate during processing, the as-built SLM material displays a microstructure consisting of a supersaturated Al(Si solid solution along with heavily refined eutectic Si and Si particles. The Si particles become coarser, and the eutectic Si gradually changes its morphology from fibrous to plate-like shape with increasing annealing temperature. The microstructural variations occurring during heat treatment significantly affect the mechanical behavior of the samples. The yield and ultimate strengths decrease from 374 and 506 MPa for the as-built SLM material to 162 and 252 MPa for the sample annealed at 673 K, whereas the ductility increases from 1.6 to 8.7%. This offers the possibility to tune microstructure and corresponding properties of the Al-20Si SLM parts to meet specific requirements.

Biodegradation Resistance and Bioactivity of Hydroxyapatite Enhanced Mg-Zn Composites via Selective Laser Melting

Directory of Open Access Journals (Sweden)

Cijun Shuai

2017-03-01

Full Text Available Mg-Zn alloys have attracted great attention as implant biomaterials due to their biodegradability and biomechanical compatibility. However, their clinical application was limited due to the too rapid degradation. In the study, hydroxyapatite (HA was incorporated into Mg-Zn alloy via selective laser melting. Results showed that the degradation rate slowed down due to the decrease of grain size and the formation of protective layer of bone-like apatite. Moreover, the grain size continually decreased with increasing HA content, which was attributed to the heterogeneous nucleation and increased number of nucleation particles in the process of solidification. At the same time, the amount of bone-like apatite increased because HA could provide favorable areas for apatite nucleation. Besides, HA also enhanced the hardness due to the fine grain strengthening and second phase strengthening. However, some pores occurred owing to the agglomerate of HA when its content was excessive, which decreased the biodegradation resistance. These results demonstrated that the Mg-Zn/HA composites were potential implant biomaterials.

Comparison of high‐intensity sound and mechanical vibration for cleaning porous titanium cylinders fabricated using selective laser melting

Science.gov (United States)

Seiffert, Gary; Sutcliffe, Chris

2015-01-01

Abstract Orthopedic components, such as the acetabular cup in total hip joint replacement, can be fabricated using porous metals, such as titanium, and a number of processes, such as selective laser melting. The issue of how to effectively remove loose powder from the pores (residual powder) of such components has not been addressed in the literature. In this work, we investigated the feasibility of two processes, acoustic cleaning using high‐intensity sound inside acoustic horns and mechanical vibration, to remove residual titanium powder from selective laser melting‐fabricated cylinders. With acoustic cleaning, the amount of residual powder removed was not influenced by either the fundamental frequency of the horn used (75 vs. 230 Hz) or, for a given horn, the number of soundings (between 1 and 20). With mechanical vibration, the amount of residual powder removed was not influenced by the application time (10 vs. 20 s). Acoustic cleaning was found to be more reliable and effective in removal of residual powder than cleaning with mechanical vibration. It is concluded that acoustic cleaning using high‐intensity sound has significant potential for use in the final preparation stages of porous metal orthopedic components. © 2015 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 117–123, 2017. PMID:26426906

On the role of heat and mass transfer into laser processability during selective laser melting AlSi12 alloy based on a randomly packed powder-bed

Science.gov (United States)

Wang, Lianfeng; Yan, Biao; Guo, Lijie; Gu, Dongdong

2018-04-01

A newly transient mesoscopic model with a randomly packed powder-bed has been proposed to investigate the heat and mass transfer and laser process quality between neighboring tracks during selective laser melting (SLM) AlSi12 alloy by finite volume method (FVM), considering the solid/liquid phase transition, variable temperature-dependent properties and interfacial force. The results apparently revealed that both the operating temperature and resultant cooling rate were obviously elevated by increasing the laser power. Accordingly, the resultant viscosity of liquid significantly reduced under a large laser power and was characterized with a large velocity, which was prone to result in a more intensive convection within pool. In this case, the sufficient heat and mass transfer occurred at the interface between the previously fabricated tracks and currently building track, revealing a strongly sufficient spreading between the neighboring tracks and a resultant high-quality surface without obvious porosity. By contrast, the surface quality of SLM-processed components with a relatively low laser power notably weakened due to the limited and insufficient heat and mass transfer at the interface of neighboring tracks. Furthermore, the experimental surface morphologies of the top surface were correspondingly acquired and were in full accordance to the calculated results via simulation.

Prediction of melt geometry in laser cutting

Energy Technology Data Exchange (ETDEWEB)

Tani, Giovanni; Tomesani, Luca; Campana, Giampaolo

2003-03-15

In this paper, an analytical model for the evaluation of the melt film geometry in laser cutting of steels is developed. Using as basis, a previous model for kerf geometry estimation developed by the authors, with both reactive and non-reactive process gases, the film thickness and velocity were determined as a function of the kerf depth in the cutting plate. Two criteria were then adopted to predict the quality of the laser cutting operation: the first is based on a minimum acceptable value of the ejection speed of the melt from the bottom of the kerf, the second on the occlusion of the kerf itself due to an excess of molten material in the boundary layer at the kerf width. These criteria determined a feasibility region in the domain of the process and material variables, such as cutting speed, assistant gas pressure, laser beam power and material characteristics. These factors may be successfully used to build a process-planning tool for parameters optimisation and setting, in order to achieve a satisfactory process quality. The model response is in excellent agreement with the feasibility regions reported from experimental data by various authors and demonstrates a relationship between the occurrence of dross adhesion and the two different mechanisms predicted for such a phenomenon were: unsatisfactory ejection speed of the melt film from the bottom of the kerf and occlusion of the kerf.

Structural properties of H13 tool steel parts produced with use of selective laser melting technology

International Nuclear Information System (INIS)

Šafka, J; Ackermann, M; Voleský, L

2016-01-01

This paper deals with establishing of building parameters for 1.2344 (H13) tool steel processed using Selective Laser Melting (SLM) technology with layer thickness of 50 µm. In the first part of the work, testing matrix of models in the form of a cube with chamfered edge were built under various building parameters such as laser scanning speed and laser power. Resulting models were subjected to set of tests including measurement of surface roughness, inspection of inner structure with aid of Light Optical Microscopy and Scanning Electron Microscopy and evaluation of micro-hardness. These tests helped us to evaluate an influence of changes in building strategy to the properties of the resulting model. In the second part of the work, mechanical properties of the H13 steel were examined. For this purpose, the set of samples in the form of “dog bone” were printed under three different alignments towards the building plate and tested on universal testing machine. Mechanical testing of the samples should then reveal if the different orientation and thus different layering of the material somehow influence its mechanical properties. For this type of material, the producer provides the parameters for layer thickness of 30 µm only. Thus, our 50 µm building strategy brings shortening of the building time which is valuable especially for large models. Results of mechanical tests show slight variation in mechanical properties for various alignment of the sample. (paper)

Structural properties of H13 tool steel parts produced with use of selective laser melting technology

Science.gov (United States)

Šafka, J.; Ackermann, M.; Voleský, L.

2016-04-01

This paper deals with establishing of building parameters for 1.2344 (H13) tool steel processed using Selective Laser Melting (SLM) technology with layer thickness of 50 µm. In the first part of the work, testing matrix of models in the form of a cube with chamfered edge were built under various building parameters such as laser scanning speed and laser power. Resulting models were subjected to set of tests including measurement of surface roughness, inspection of inner structure with aid of Light Optical Microscopy and Scanning Electron Microscopy and evaluation of micro-hardness. These tests helped us to evaluate an influence of changes in building strategy to the properties of the resulting model. In the second part of the work, mechanical properties of the H13 steel were examined. For this purpose, the set of samples in the form of “dog bone” were printed under three different alignments towards the building plate and tested on universal testing machine. Mechanical testing of the samples should then reveal if the different orientation and thus different layering of the material somehow influence its mechanical properties. For this type of material, the producer provides the parameters for layer thickness of 30 µm only. Thus, our 50 µm building strategy brings shortening of the building time which is valuable especially for large models. Results of mechanical tests show slight variation in mechanical properties for various alignment of the sample.

Transformation of austenite to duplex austenite-ferrite assembly in annealed stainless steel 316L consolidated by laser melting

Energy Technology Data Exchange (ETDEWEB)

Saeidi, K.; Gao, X. [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, S-106 91 Stockholm (Sweden); Lofaj, F. [Institute of Materials Research of the Slovak Academy of Sciences, Watsonova 47, Košice (Slovakia); Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 916 24 Trnava (Slovakia); Kvetková, L. [Institute of Materials Research of the Slovak Academy of Sciences, Watsonova 47, Košice (Slovakia); Shen, Z.J. [Department of Materials and Environmental Chemistry, Arrhenius Laboratory, Stockholm University, S-106 91 Stockholm (Sweden)

2015-06-05

Highlights: • Mechanical properties, phase and microstructure stability of laser melted steel was studied. • Duplex austenite-ferrite assembly with improved mechanical properties was formed. • Dissolution of Mo in the steel matrix resulted in ferrite stabilization and stress relief. • Enhanced mechanical properties were achieved compared to conventionally casted and annealed steel. - Abstract: Laser melting (LM), with a focused Nd:YAG laser beam, was used to form solid bodies from 316L austenite stainless steel powder and the laser melted samples were heat treated at various temperatures. The phase changes in heat treated samples were characterized using X-ray diffraction (XRD). Samples heat treated at 800 °C and 900 °C remained single austenite while in samples heat treated at 1100 °C and 1400 °C a dual austenite-ferrite phase assembly was formed. The ferrite formation was further verified by electron back scattering diffraction (EBSD) and selective area diffraction (SAD). Microstructural changes were studied by scanning and transmission electron microscopy (SEM, TEM). In samples heat treated up to 900 °C, coalescence of the cellular-sub grains was noticed, whereas in sample heat treated at and above 1100 °C the formation of ferrite phase was observed. The correlation between the microstructure/phase assembly and the measured strength/microhardness were investigated, which indicated that the tensile strength of the laser melted material was significantly higher than that of the conventional 316L steel even after heat treatment whereas caution has to be taken when laser melted material will be exposed to an application temperature above 900 °C.

Infrared laser-induced chaos and conformational disorder in a model polymer crystal: Melting vs ablation

International Nuclear Information System (INIS)

Sumpter, B.G.; Noid, D.W.; Voth, G.A.; Wunderlich, B.

1990-01-01

Molecular dynamics-based computer simulations are presented for the interaction of one and two infrared (IR) laser beams with a model polymer surface. When a single laser beam system is studied over a wide range of intensities, only melting of the polymer, or melting followed by bond dissociation, is observed for up to 100 picoseconds. In contrast, the two-laser simulation results exhibit a marked difference in the energy absorption behavior of the irradiated polymer which, in turn, results in multiple bond dissociations. The results for the one- and two-laser cases studied can be divided into four different classes of physical behavior: (a) the polymer remains in the solid state; (b) the polymer crystal melts; (c) the polymer ablates, but with significant melting (charring); or (d) the polymer ablates with minimal melting. Damage to the model polymer crystal from absorption of energy from either one or two lasers occurs through a mechanism that involves the competition between the absorption of energy and internal energy redistribution. The rate of energy loss from the absorption site(s) relative to the rate of absorption of energy from the radiation field determines rather the polymer melts or ablates (low absorption rates lead to melting or no change and high rates lead to ablation). A sufficiently large rate of energy absorption is only obtainable through the use of two lasers. Two lasers also significantly decrease the total laser intensity required to cause polymer crystal melting. The differences between the one- and two-laser cases are studied by adapting novel signal/subspace techniques to analyze the dynamical changes in the mode spectrum of the polymer as it melts

Fabrication and Thermoelectric Properties of n-Type CoSb2.85Te0.15 Using Selective Laser Melting.

Science.gov (United States)

Yan, Yonggao; Ke, Hongquan; Yang, Jihui; Uher, Ctirad; Tang, Xinfeng

2018-04-25

We report a nonequilibrium fabrication method of n-type CoSb 2.85 Te 0.15 skutterudites using selective laser melting (SLM) technology. A powder of CoSb 2.85 Te 0.15 was prepared by self-propagating high-temperature synthesis (SHS) and served as the raw material for the SLM process. The effect of SLM processing parameters such as the laser power and scanning speed on the quality of the forming CoSb 2.85 Te 0.15 thin layers was systematically analyzed, and the optimal processing window for SLM was determined. A brief postannealing at 450 °C for 4 h, following the SLM process, has resulted in a phase-pure CoSb 2.85 Te 0.15 bulk material deposited on a Ti substrate. The Seebeck coefficient of the annealed SLM prepared bulk material is close to that of the sample prepared by the traditional sintering method, and its maximum ZT value reached 0.56 at 823 K. Moreover, a Ti-Co-Sb ternary compound transition layer of about 70 μm in thickness was found at a dense interface between CoSb 2.85 Te 0.15 and the Ti substrate. The contact resistivity was measured as 37.1 μΩcm 2 . The results demonstrate that SLM, coupled with postannealing, can be used for fabrication of incongruently melting skutterudite compounds on heterogeneous substrates. This lays an important foundation for the follow-up research utilizing energy efficient SHS and SLM processes in rapid printing of thermoelectric modules.

Effect of layer thickness in selective laser melting on microstructure of Al/5 wt.%Fe2O3 powder consolidated parts.

Science.gov (United States)

Dadbakhsh, Sasan; Hao, Liang

2014-01-01

In situ reaction was activated in the powder mixture of Al/5 wt.%Fe2O3 by using selective laser melting (SLM) to directly fabricate aluminium metal matrix composite parts. The microstructural characteristics of these in situ consolidated parts through SLM were investigated under the influence of thick powder bed, 75  μm layer thickness, and 50  μm layer thickness in various laser powers and scanning speeds. It was found that the layer thickness has a strong influence on microstructural outcome, mainly attributed to its impact on oxygen content of the matrix. Various microstructural features (such as granular, coralline-like, and particulate appearance) were observed depending on the layer thickness, laser power, and scanning speed. This was associated with various material combinations such as pure Al, Al-Fe intermetallics, and Al(-Fe) oxide phases formed after in situ reaction and laser rapid solidification. Uniformly distributed very fine particles could be consolidated in net-shape Al composite parts by using lower layer thickness, higher laser power, and lower scanning speed. The findings contribute to the new development of advanced net-shape manufacture of Al composites by combining SLM and in situ reaction process.

Meso-scale defect evaluation of selective laser melting using spatially resolved acoustic spectroscopy.

Science.gov (United States)

Hirsch, M; Catchpole-Smith, S; Patel, R; Marrow, P; Li, Wenqi; Tuck, C; Sharples, S D; Clare, A T

2017-09-01

Developments in additive manufacturing technology are serving to expand the potential applications. Critical developments are required in the supporting areas of measurement and in process inspection to achieve this. CM247LC is a nickel superalloy that is of interest for use in aerospace and civil power plants. However, it is difficult to process via selective laser melting (SLM) as it suffers from cracking during rapid cooling and solidification. This limits the viability of CM247LC parts created using SLM. To quantify part integrity, spatially resolved acoustic spectroscopy (SRAS) has been identified as a viable non-destructive evaluation technique. In this study, a combination of optical microscopy and SRAS was used to identify and classify the surface defects present in SLM-produced parts. By analysing the datasets and scan trajectories, it is possible to correlate morphological information with process parameters. Image processing was used to quantify porosity and cracking for bulk density measurement. Analysis of surface acoustic wave data showed that an error in manufacture in the form of an overscan occurred. Comparing areas affected by overscan with a bulk material, a change in defect density from 1.17% in the bulk material to 5.32% in the overscan regions was observed, highlighting the need to reduce overscan areas in manufacture.

Meso-scale defect evaluation of selective laser melting using spatially resolved acoustic spectroscopy

Science.gov (United States)

Hirsch, M.; Catchpole-Smith, S.; Patel, R.; Marrow, P.; Li, Wenqi; Tuck, C.; Sharples, S. D.; Clare, A. T.

2017-09-01

Developments in additive manufacturing technology are serving to expand the potential applications. Critical developments are required in the supporting areas of measurement and in process inspection to achieve this. CM247LC is a nickel superalloy that is of interest for use in aerospace and civil power plants. However, it is difficult to process via selective laser melting (SLM) as it suffers from cracking during rapid cooling and solidification. This limits the viability of CM247LC parts created using SLM. To quantify part integrity, spatially resolved acoustic spectroscopy (SRAS) has been identified as a viable non-destructive evaluation technique. In this study, a combination of optical microscopy and SRAS was used to identify and classify the surface defects present in SLM-produced parts. By analysing the datasets and scan trajectories, it is possible to correlate morphological information with process parameters. Image processing was used to quantify porosity and cracking for bulk density measurement. Analysis of surface acoustic wave data showed that an error in manufacture in the form of an overscan occurred. Comparing areas affected by overscan with a bulk material, a change in defect density from 1.17% in the bulk material to 5.32% in the overscan regions was observed, highlighting the need to reduce overscan areas in manufacture.

Evaluation of single tracks of 17-4PH steel manufactured at different power densities and scanning speeds by selective laser melting

Directory of Open Access Journals (Sweden)

Makoana, N. W.

2016-11-01

Full Text Available In Selective Laser Melting, the initial units produced are single tracks that overlap to create a single layer; from the sequence of layers, a 3D object is manufactured. The properties of the parts produced by SLM depend heavily on the properties of each single track and each layer formed by these tracks. This study evaluates the effect of processing parameters on the geometrical characteristics of single tracks manufactured from 17-4PH stainless steel powder. A single-mode continuous-wave ytterbium fibre laser was used to manufacture single tracks at laser powers in the range of 100-300 W with a constant spot size of ∼80μm. The single tracks produced were subjected to standard metallographic preparation techniques for further analysis with an optical microscope. Deep molten pool shapes were observed at low scan speeds, while shallow molten pool shapes were observed at high scan speeds. At higher laser power densities, under-cutting and humping effects were also observed. The dimensions of single tracks processed without powder generally decrease with increasing scan speed at constant laser power. However, the geometrical features of the single tracks processed with powder revealed pronounced irregularities believed to be caused by non-homogeneity in the deposited powder layer.

Bioactive Ti metal analogous to human cancellous bone: Fabrication by selective laser melting and chemical treatments.

Science.gov (United States)

Pattanayak, Deepak K; Fukuda, A; Matsushita, T; Takemoto, M; Fujibayashi, S; Sasaki, K; Nishida, N; Nakamura, T; Kokubo, T

2011-03-01

Selective laser melting (SLM) is a useful technique for preparing three-dimensional porous bodies with complicated internal structures directly from titanium (Ti) powders without any intermediate processing steps, with the products being expected to be useful as a bone substitute. In this study the necessary SLM processing conditions to obtain a dense product, such as the laser power, scanning speed, and hatching pattern, were investigated using a Ti powder of less than 45 μm particle size. The results show that a fully dense plate thinner than 1.8 mm was obtained when the laser power to scanning speed ratio was greater than 0.5 and the hatch spacing was less than the laser diameter, with a 30 μm thick powder layer. Porous Ti metals with structures analogous to human cancellous bone were fabricated and the compressive strength measured. The compressive strength was in the range 35-120 MPa when the porosity was in the range 75-55%. Porous Ti metals fabricated by SLM were heat-treated at 1300 °C for 1h in an argon gas atmosphere to smooth the surface. Such prepared specimens were subjected to NaOH, HCl, and heat treatment to provide bioactivity. Field emission scanning electron micrographs showed that fine networks of titanium oxide were formed over the whole surface of the porous body. These treated porous bodies formed bone-like apatite on their surfaces in a simulated body fluid within 3 days. In vivo studies showed that new bone penetrated into the pores and directly bonded to the walls within 12 weeks after implantation into the femur of Japanese white rabbits. The percentage bone affinity indices of the chemical- and heat-treated porous bodies were significantly higher than that of untreated implants. Copyright © 2010 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Study of Internal Channel Surface Roughnesses Manufactured by Selective Laser Melting in Aluminum and Titanium Alloys

Science.gov (United States)

Pakkanen, Jukka; Calignano, Flaviana; Trevisan, Francesco; Lorusso, Massimo; Ambrosio, Elisa Paola; Manfredi, Diego; Fino, Paolo

2016-08-01

Interest in additive manufacturing (AM) has gained considerable impetus over the past decade. One of the driving factors for AM success is the ability to create unique designs with intrinsic characteristics as, e.g., internal channels used for hydraulic components, cooling channels, and heat exchangers. However, a couple of the main problems in internal channels manufactured by AM technologies are the high surface roughness obtained and the distortion of the channel shape. There is still much to understand in these design aspects. In this study, a cylindrical geometry for internal channels to be built with different angles with respect to the building plane in AlSi10Mg and Ti6Al4V alloys by selective laser melting was considered. The internal surfaces of the channels produced in both materials were analyzed by means of a surface roughness tester and by optical and electron microscopy to evaluate the effects of the material and design choices.

An integrated approach of topology optimized design and selective laser melting process for titanium implants materials.

Science.gov (United States)

Xiao, Dongming; Yang, Yongqiang; Su, Xubin; Wang, Di; Sun, Jianfeng

2013-01-01

The load-bearing bone implants materials should have sufficient stiffness and large porosity, which are interacted since larger porosity causes lower mechanical properties. This paper is to seek the maximum stiffness architecture with the constraint of specific volume fraction by topology optimization approach, that is, maximum porosity can be achieved with predefine stiffness properties. The effective elastic modulus of conventional cubic and topology optimized scaffolds were calculated using finite element analysis (FEA) method; also, some specimens with different porosities of 41.1%, 50.3%, 60.2% and 70.7% respectively were fabricated by Selective Laser Melting (SLM) process and were tested by compression test. Results showed that the computational effective elastic modulus of optimized scaffolds was approximately 13% higher than cubic scaffolds, the experimental stiffness values were reduced by 76% than the computational ones. The combination of topology optimization approach and SLM process would be available for development of titanium implants materials in consideration of both porosity and mechanical stiffness.

The Effect of Aging on the Microstructure of Selective Laser Melted Cu-Ni-Si

Science.gov (United States)

Ventura, Anthony P.; Marvel, Christopher J.; Pawlikowski, Gregory; Bayes, Martin; Watanabe, Masashi; Vinci, Richard P.; Misiolek, Wojciech Z.

2017-12-01

Precipitation hardening copper alloy C70250 was selectively laser melted to successfully produce components around 98 pct dense with high mechanical strength and electrical conductivity. Aging heat treatments were carried out at 723 K (450 °C) directly on as-printed samples up to 128 hours. Mechanical testing found that peak yield strength of around 590 MPa could be attained with an electrical conductivity of 34.2 pct IACS after 8 hours of aging. Conductivity continues to increase with further aging while the peak strength appears to be less sensitive to aging time exhibiting a broad range of time where near-peak properties exist. After aging for 128 hours, there is a drop in yield strength to 546 MPa with an increase in conductivity to 43.2 pct IACS. Electron microscopy analysis revealed nanometer-scale silicon-rich oxide particles throughout the material that persist during aging. Deformation twinning is observed in the peak-age condition after tensile testing and several strengthening mechanisms appear to be active to varying degrees throughout aging which account for the broad range of aging time where nearly the peak mechanical properties exist.

Sliding Wear Characteristics and Corrosion Behaviour of Selective Laser Melted 316L Stainless Steel

Science.gov (United States)

Sun, Y.; Moroz, A.; Alrbaey, K.

2014-02-01

Stainless steel is one of the most popular materials used for selective laser melting (SLM) processing to produce nearly fully dense components from 3D CAD models. The tribological and corrosion properties of stainless steel components are important in many engineering applications. In this work, the wear behaviour of SLM 316L stainless steel was investigated under dry sliding conditions, and the corrosion properties were measured electrochemically in a chloride containing solution. The results show that as compared to the standard bulk 316L steel, the SLM 316L steel exhibits deteriorated dry sliding wear resistance. The wear rate of SLM steel is dependent on the vol.% porosity in the steel and by obtaining full density it is possible achieve wear resistance similar to that of the standard bulk 316L steel. In the tested chloride containing solution, the general corrosion behaviour of the SLM steel is similar to that of the standard bulk 316L steel, but the SLM steel suffers from a reduced breakdown potential and is more susceptible to pitting corrosion. Efforts have been made to correlate the obtained results with porosity in the SLM steel.

Effect of adding support structures for overhanging part on fatigue strength in selective laser melting.

Science.gov (United States)

Kajima, Yuka; Takaichi, Atsushi; Nakamoto, Takayuki; Kimura, Takahiro; Kittikundecha, Nuttaphon; Tsutsumi, Yusuke; Nomura, Naoyuki; Kawasaki, Akira; Takahashi, Hidekazu; Hanawa, Takao; Wakabayashi, Noriyuki

2018-02-01

Selective laser melting (SLM) technology was recently introduced to fabricate dental prostheses. However, the fatigue strength of clasps in removable partial dentures prepared by SLM still requires improvement. In this study, we attempted to improve the fatigue strength of clasps by adding support structures for overhanging parts, which can generally be manufactured at an angle to be self-supporting. The results show that the fatigue strength of the supported specimens was more than twice that of unsupported specimens. Electron back-scattered diffraction analysis revealed that the supported specimens exhibited lower kernel average misorientation values than the unsupported specimens, which suggested that the support structure reduced the residual strain during the SLM process and helped to prevent micro-cracks led by thermal distortion. In addition, the supported specimens cooled more rapidly, thereby forming a finer grain size compared to that of the unsupported specimens, which contributed to improving the fatigue strength. The results of this study suggest that the fatigue strength of overhanging parts can be improved by intentionally adding support structures. Copyright © 2017 Elsevier Ltd. All rights reserved.

Surface properties and corrosion behavior of Co-Cr alloy fabricated with selective laser melting technique.

Science.gov (United States)

Xin, Xian-zhen; Chen, Jie; Xiang, Nan; Wei, Bin

2013-01-01

We sought to study the corrosion behavior and surface properties of a commercial cobalt-chromium (Co-Cr) alloy which was fabricated with selective laser melting (SLM) technique. For this purpose, specimens were fabricated using different techniques, such as SLM system and casting methods. Surface hardness testing, microstructure observation, surface analysis using X-ray photoelectron spectroscopy (XPS) and electrochemical corrosion test were carried out to evaluate the corrosion properties and surface properties of the specimens. We found that microstructure of SLM specimens was more homogeneous than that of cast specimens. The mean surface hardness values of SLM and cast specimens were 458.3 and 384.8, respectively; SLM specimens showed higher values than cast ones in hardness. Both specimens exhibited no differences in their electrochemical corrosion properties in the artificial saliva through potentiodynamic curves and EIS, and no significant difference via XPS. Therefore, we concluded that within the scope of this study, SLM-fabricated restorations revealed good surface properties, such as proper hardness, homogeneous microstructure, and also showed sufficient corrosion resistance which could meet the needs of dental clinics.

The biocompatibility of dense and porous Nickel-Titanium produced by selective laser melting.

Science.gov (United States)

Habijan, T; Haberland, C; Meier, H; Frenzel, J; Wittsiepe, J; Wuwer, C; Greulich, C; Schildhauer, T A; Köller, M

2013-01-01

Nickel-Titanium shape memory alloys (NiTi-SMA) are of biomedical interest due to their unusual range of pure elastic deformability and their elastic modulus, which is closer to that of bone than any other metallic or ceramic material. Newly developed porous NiTi, produced by Selective Laser Melting (SLM), is currently under investigation as a potential carrier material for human mesenchymal stem cells (hMSC). SLM enables the production of highly complex and tailor-made implants for patients on the basis of CT data. Such implants could be used for the reconstruction of the skull, face, or pelvis. hMSC are a promising cell type for regenerative medicine and tissue engineering due to their ability to support the regeneration of critical size bone defects. Loading porous SLM-NiTi implants with autologous hMSC may enhance bone growth and healing for critical bone defects. The purpose of this study was to assess whether porous SLM-NiTi is a suitable carrier for hMSC. Specimens of varying porosity and surface structure were fabricated via SLM. hMSC were cultured for 8 days on NiTi specimens, and cell viability was analyzed using two-color fluorescence staining. Viable cells were detected on all specimens after 8 days of cell culture. Cell morphology and surface topography were analyzed by scanning electron microscopy (SEM). Cell morphology and surface topology were dependent on the orientation of the specimens during SLM production. The Nickel ion release can be reduced significantly by aligned laser processing conditions. The presented results clearly attest that both dense SLM-NiTi and porous SLM-NiTi are suitable carriers for hMSC. Nevertheless, before carrying out in vivo studies, some work on optimization of the manufacturing process and post-processing is required. Copyright © 2012 Elsevier B.V. All rights reserved.

Fabrication and characterization of selective laser melting printed Ti–6Al–4V alloys subjected to heat treatment for customized implants design

Directory of Open Access Journals (Sweden)

Mengke Wang

2016-12-01

Full Text Available Selective laser melting (SLM is a promising technique capable of rapidly fabricating customized implants having desired macro- and micro-structures by using computer-aided design models. However, the SLM-based products often have non-equilibrium microstructures and partial surface defects because of the steep thermal gradients and high solidification rates that occur during the laser melting. To meet clinical requirements, a heat treatment was used to tailor the physiochemical properties, homogenize the metallic microstructures, and eliminate surface defects, expecting to improve the cytocompatibility in vitro. Compared with the as-printed Ti–6Al–4V substrate, the heat-treated substrate had a more hydrophilic, rougher and more homogeneous surface, which should promote the early cell attachment, proliferation and osseointegration. More importantly, a crystalline rutile TiO2 layer formed during the heat treatment, which should greatly promote the biocompatibility and corrosion resistance of the implant. Compared to the untreated surfaces, the adhesion and proliferation of human bone mesenchymal stem cells (hBMSCs on heat-treated substrates were significantly enhanced, implying an excellent cytocompatibility after annealing. Therefore, these findings provide an alternative to biofunctionalized SLM-based Ti–6Al–4V implants with optimized physiochemical properties and biocompatibility for orthopedic and dental applications.

Stress assisted selective ablation of ITO thin film by picosecond laser

Science.gov (United States)

Farid, Nazar; Chan, Helios; Milne, David; Brunton, Adam; M. O'Connor, Gerard

2018-01-01

Fast selective pattering with high precession on 175 nm ITO thin film with IR ps lasers is investigated. Ablation parameters are optimized with detailed studies on the scribed depth, topography, and particle generation using AFM and SEM. A comparison of 10 and 150 ps laser revealed that the shorter pulse (10 ps) laser is more appropriate in selective and partial ablation; up to 20 nm resolution for controlled depth with multipulses having energy below the damage threshold is demonstrated. The experimental results are interpreted to involve stress assisted ablation mechanism for the 10 ps laser while thermal ablation along with intense melting occurs for 150 ps laser. The transition between these regimes is estimated to occur at approximately 30 ps.

Ductility improvement due to martensite α' decomposition in porous Ti-6Al-4V parts produced by selective laser melting for orthopedic implants.

Science.gov (United States)

Sallica-Leva, E; Caram, R; Jardini, A L; Fogagnolo, J B

2016-02-01

Ti-6Al-4V parts obtained by selective laser melting typically have an acicular α' martensitic microstructure whose ductility is low. Thus, post-heat treatments are useful for increasing ductility. In this work, the effects of sub-β-transus heat treatments on the mechanical properties of Ti-6Al-4V parts with porous structures are correlated with martensite α' phase decomposition. The precipitation of β phase and the gradual transformation of α' into α phase by the diffusion of excess vanadium from α' to β phase are proposed to be the main events of martensite α' phase decomposition in parts fabricated by selective laser melting. The heat treatment performed at 650°C for 1h produced no microstructural changes, but the samples treated for at the same temperature 2h showed a fine precipitation of β phase along the α' needle boundaries. The heat treatment performed at 800°C for 1 or 2h produced a fine α+β microstructure, in which β phase are present as particles fewer in number and larger in size, when compared with the ones present in the sample heat-treated at 650°C for 2h. Heat-treatment of the parts at 800°C for 2h proved to be the best condition, which improved the ductility of the samples while only slightly reducing their strength. Copyright © 2015 Elsevier Ltd. All rights reserved.

The AlSi10Mg samples produced by selective laser melting: single track, densification, microstructure and mechanical behavior

International Nuclear Information System (INIS)

Wei, Pei; Wei, Zhengying; Chen, Zhen; Du, Jun; He, Yuyang; Li, Junfeng; Zhou, Yatong

2017-01-01

Highlights: • The thermal behavior of AlSi10Mg molten pool was analyzed. • The SLM-processed sample with a relatively low surface roughness was obtained. • Effects of parameters on surface topography of scan track were investigated. • Effects of parameters on microstructure of parts were investigated. • Optimum processing parameters for AlSi10Mg SLM was obtained. - Abstract: This densification behavior and attendant microstructural characteristics of the selective laser melting (SLM) processed AlSi10Mg alloy affected by the processing parameters were systematically investigated. The samples with a single track were produced by SLM to study the influences of laser power and scanning speed on the surface morphologies of scan tracks. Additionally, the bulk samples were produced to investigate the influence of the laser power, scanning speed, and hatch spacing on the densification level and the resultant microstructure. The experimental results showed that the level of porosity of the SLM-processed samples was significantly governed by energy density of laser beam and the hatch spacing. The tensile properties of SLM-processed samples and the attendant fracture surface can be enhanced by decreasing the level of porosity. The microstructure of SLM-processed samples consists of supersaturated Al-rich cellular structure along with eutectic Al/Si situated at the cellular boundaries. The Si content in the cellular boundaries increases with increasing the laser power and decreasing the scanning speed. The hardness of SLM-processed samples was significantly improved by this fine microstructure compared with the cast samples. Moreover, the hardness of SLM-processed samples at overlaps was lower than the hardness observed at track cores.

The AlSi10Mg samples produced by selective laser melting: single track, densification, microstructure and mechanical behavior

Energy Technology Data Exchange (ETDEWEB)

Wei, Pei; Wei, Zhengying, E-mail: zywei@mail.xjtu.edu.cn; Chen, Zhen; Du, Jun; He, Yuyang; Li, Junfeng; Zhou, Yatong

2017-06-30

Highlights: • The thermal behavior of AlSi10Mg molten pool was analyzed. • The SLM-processed sample with a relatively low surface roughness was obtained. • Effects of parameters on surface topography of scan track were investigated. • Effects of parameters on microstructure of parts were investigated. • Optimum processing parameters for AlSi10Mg SLM was obtained. - Abstract: This densification behavior and attendant microstructural characteristics of the selective laser melting (SLM) processed AlSi10Mg alloy affected by the processing parameters were systematically investigated. The samples with a single track were produced by SLM to study the influences of laser power and scanning speed on the surface morphologies of scan tracks. Additionally, the bulk samples were produced to investigate the influence of the laser power, scanning speed, and hatch spacing on the densification level and the resultant microstructure. The experimental results showed that the level of porosity of the SLM-processed samples was significantly governed by energy density of laser beam and the hatch spacing. The tensile properties of SLM-processed samples and the attendant fracture surface can be enhanced by decreasing the level of porosity. The microstructure of SLM-processed samples consists of supersaturated Al-rich cellular structure along with eutectic Al/Si situated at the cellular boundaries. The Si content in the cellular boundaries increases with increasing the laser power and decreasing the scanning speed. The hardness of SLM-processed samples was significantly improved by this fine microstructure compared with the cast samples. Moreover, the hardness of SLM-processed samples at overlaps was lower than the hardness observed at track cores.

Crystal structure and nanotopographical features on the surface of heat-treated and anodized porous titanium biomaterials produced using selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Amin Yavari, S., E-mail: s.aminyavari@tudelft.nl [Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft (Netherlands); FT Innovations BV, Braamsluiper 1, 5831 PW Boxmeer (Netherlands); Wauthle, R. [KU Leuven, Department of Mechanical Engineering, Section Production Engineering, Machine Design and Automation (PMA), Celestijnenlaan 300B, 3001 Leuven (Belgium); LayerWise NV, Kapeldreef 60, Leuven (Belgium); Böttger, A.J. [Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft (Netherlands); Schrooten, J. [Department of Metallurgy and Materials Engineering, KU Leuven, Kasteelpark Arenberg 44 PB 2450, 3001 Heverlee (Belgium); Weinans, H. [Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft (Netherlands); Department of Orthopedics and Department of Rheumatology, UMC Utrecht, Heidelberglaan 100, 3584 CX Utrecht (Netherlands); Zadpoor, A.A. [Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft (Netherlands)

2014-01-30

Porous titanium biomaterials manufactured using additive manufacturing techniques such as selective laser melting are considered promising materials for orthopedic applications where the biomaterial needs to mimic the properties of bone. Despite their appropriate mechanical properties and the ample pore space they provide for bone ingrowth and osseointegration, porous titanium structures have an intrinsically bioinert surface and need to be subjected to surface bio-functionalizing procedures to enhance their in vivo performance. In this study, we used a specific anodizing process to build a hierarchical oxide layer on the surface of porous titanium structures made by selective laser melting of Ti6Al4V ELI powder. The hierarchical structure included both nanotopographical features (nanotubes) and micro-features (micropits). After anodizing, the biomaterial was heat treated in Argon at different temperatures ranging between 400 and 600 °C for either 1 or 2 h to improve its bioactivity. The effects of applied heat treatment on the crystal structure of TiO{sub 2} nanotubes and the nanotopographical features of the surface were studied using scanning electron microscopy and X-ray diffraction. It was shown that the transition from the initial crystal structure, i.e. anatase, to rutile occurs between 500 and 600 °C and that after 2 h of heat treatment at 600 °C the crystal structure is predominantly rutile. The nanotopographical features of the surface were found to be largely unchanged for heat treatments carried out at 500 °C or below, whereas they were partially or largely disrupted after heat treatment at 600 °C. The possible implications of these findings for the bioactivity of porous titanium structures are discussed.

Data demonstrating the effects of build orientation and heat treatment on fatigue behavior of selective laser melted 17–4 PH stainless steel

Directory of Open Access Journals (Sweden)

Aref Yadollahi

2016-06-01

Full Text Available Axial fully-reversed strain-controlled (R=−1 fatigue experiments were performed to obtain data demonstrating the effects of building orientation (i.e. vertical versus horizontal and heat treatment on the fatigue behavior of 17–4 PH stainless steel (SS fabricated via Selective Laser Melting (SLM (Yadollahi et al., submitted for publication [1]. This data article provides detailed experimental data including cyclic stress-strain responses, variations of peak stresses during cyclic deformation, and fractography of post-mortem specimens for SLM 17–4 PH SS.

Phase selection during pulsed laser annealing of manganese

International Nuclear Information System (INIS)

Follstaedt, D.M.; Peercy, P.S.; Perepezko, J.H.

1986-01-01

Pulsed (25 ns) laser-induced heating of the α phase of Mn is found to be sufficiently rapid to bypass solid-state transformation to the high-temperature β, γ, and delta allotropes and thus produce melts that are calculated to be undercooled by approx. 120 K with respect to the equilibrium melting temperature of the delta phase. Nucleation of the γ phase in this highly undercooled melt is observed for sufficiently long melt durations. The experiments thus demonstrate that pulsed laser-induced melting of metals with allotropes permits the study of nucleation and growth in highly undercooled melts with calculable temperatures

Additive Manufacturing of High-Performance 316L Stainless Steel Nanocomposites via Selective Laser Melting

Science.gov (United States)

AlMangour, Bandar Abdulaziz

Austenitic 316L stainless steel alloy is an attractive industrial material combining outstanding corrosion resistance, ductility, and biocompatibility, with promising structural applications and biomedical uses. However, 316L has low strength and wear resistance, limiting its high-performance applicability. Adding secondary hard nanoscale reinforcements to steel matrices, thereby forming steel-matrix nanocomposites (SMCs), can overcome these problems, improving the performance and thereby the applicability of 316L. However, SMC parts with complex-geometry cannot be easily achieved limiting its application. This can be avoided through additive manufacturing (AM) by generating layer-by-layer deposition using computer-aided design data. Expanding the range of AM-applicable materials is necessary to fulfill industrial demand. This dissertation presents the characteristics of new AM-processed high-performance 316L-matrix nanocomposites with nanoscale TiC or TiB2 reinforcements, addressing specific aspects of material design, process control and optimization, and physical metallurgy theory. The nanocomposites were prepared by high-energy ball-milling and consolidated by AM selective laser melting (SLM). Continuous and refined ring-like network structures were obtained with homogenously distributed reinforcements. Additional grain refinement occurred with reinforcement addition, attributed to nanoparticles acting as nuclei for heterogeneous nucleation. The influence of reinforcement content was first investigated; mechanical and tribological behaviors improved with increased reinforcement contents. The compressive yield strengths of composites with TiB2 or TiC reinforcements were approximately five or two times those of 316L respectively. Hot isostatic pressing post-treatment effectively eliminated major cracks and pores in SLM-fabricated components. The effects of the SLM processing parameters on the microstructure and mechanical performance were also investigated. Laser

STUDIES ON WETTABILITY OF STAINLESS STEEL 316L POWDER IN LASER MELTING PROCESS

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KURIAN ANTONY

2014-10-01

Full Text Available Laser sintering is one of the techniques used in additive manufacturing processes. The main objective of the work is to study the effects of process parameters on wetting phenomenon and interfacial energy during laser melting of stainless steel powder. This paper reports wetting of laser melted powder particles and its use for the determination of surface energy of stainless steel powder under laser beam exposure. Process parameters such as laser power, scan speed and beam diameter are considered for study. This study also identifies the process parameters for better wettability which produces smooth surfaces.

Effect of Layer Thickness in Selective Laser Melting on Microstructure of Al/5 wt.%Fe2O3 Powder Consolidated Parts

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Sasan Dadbakhsh

2014-01-01

Full Text Available In situ reaction was activated in the powder mixture of Al/5 wt.%Fe2O3 by using selective laser melting (SLM to directly fabricate aluminium metal matrix composite parts. The microstructural characteristics of these in situ consolidated parts through SLM were investigated under the influence of thick powder bed, 75 μm layer thickness, and 50 μm layer thickness in various laser powers and scanning speeds. It was found that the layer thickness has a strong influence on microstructural outcome, mainly attributed to its impact on oxygen content of the matrix. Various microstructural features (such as granular, coralline-like, and particulate appearance were observed depending on the layer thickness, laser power, and scanning speed. This was associated with various material combinations such as pure Al, Al-Fe intermetallics, and Al(-Fe oxide phases formed after in situ reaction and laser rapid solidification. Uniformly distributed very fine particles could be consolidated in net-shape Al composite parts by using lower layer thickness, higher laser power, and lower scanning speed. The findings contribute to the new development of advanced net-shape manufacture of Al composites by combining SLM and in situ reaction process.

Metal-ceramic bond strength of Co-Cr alloy fabricated by selective laser melting.

Science.gov (United States)

Xiang, Nan; Xin, Xian-Zhen; Chen, Jie; Wei, Bin

2012-06-01

This study was to evaluated the metal-ceramic bond strength of a Co-Cr dental alloy prepared using a selective laser melting (SLM) technique. Two groups comprised of twenty Co-Cr metal bars each were prepared using either a SLM or traditional lost-wax casting method. Ten bars from each group were moulded into standard ISO 9693:1999 dimensions of 25 mm × 3 mm × 0.5 mm with 1.1 mm of porcelain fused onto an 8 mm × 3 mm rectangular area in the centre of each bar. Metal-ceramic bonding was assessed using a three-point bending test. Fracture mode analysis and area fraction of adherence porcelain (AFAP) were determined by measuring Si content of specimens by SEM/EDS. Student's t-test within the groups demonstrated no significant difference for the mean bond strength between the SLM and traditional cast sample groups. While SEM/EDS analysis indicated a mixed fracture mode on the debonding interface of both the SLM and the cast groups, the SLM group showed significantly more porcelain adherence than the control group (p<0.05). The SLM metal-ceramic system exhibited a bonding strength that exceeds the requirement of ISO 9691:1999(E) and it even showed a better behaviour in porcelain adherence test comparable to traditional cast methods. Copyright © 2012 Elsevier Ltd. All rights reserved.

Effects of Laser Re-melting on the Corrosion Properties of HVOF Coatings

Science.gov (United States)

Yilbas, B. S.; Toor, I. H.; Patel, F.; Baig, M. A.

2013-05-01

HVOF coating of Inconel 625 powder on carbon steel is carried out. Laser melting of the resulting coating is realized to improve coating structural integrity. Morphological and microstructural changes are examined in the coating prior and after laser treatment process using scanning electron microscopy, energy dispersive spectroscopy, and x-ray diffraction (XRD). The residual stress developed is measured on the surface vicinity of the laser-treated coating using the XRD technique. The corrosion resistance of the laser-treated and untreated coating surfaces is measured, incorporating the potentiodynamic tests in 0.5 M NaCl aqueous solution. It is found that laser treatment reduces the pores and produces cellular structures with different sizes and orientations in the coating. Laser-controlled melting improves the corrosion resistance of the coating surface.

Corrosion behaviour of laser surface melted magnesium alloy AZ91D

International Nuclear Information System (INIS)

Taltavull, C.; Torres, B.; Lopez, A.J.; Rodrigo, P.; Otero, E.; Atrens, A.; Rams, J.

2014-01-01

A high power diode laser (HPDL) was used to produce laser surface melting (LSM) treatments on the surface of the Mg alloy AZ91D. Different treatments with different microstructures were produced by varying the laser-beam power and laser-scanning speed. Corrosion evaluation, using hydrogen evolution and electrochemical measurements, led to a relationship between microstructure and corrosion. Most corrosion rates for LSM treated specimens were within the scatter of the as-received AZ91D, whereas some treatments gave higher corrosion rates and some of the samples had corrosion rates lower than the average of the corrosion rate for AZ91D. There were differences in corroded surface morphology. Nevertheless laser treatments introduced surface discontinuities, which masked the effect of the microstructure. Removing these surface defects decreased the corrosion rate for the laser-treated samples. - Highlights: • Corrosion behavior of AZ91D Mg alloys is intimately related with its microstructure. • Laser surface melting treatments allows surface modification of the microstructure. • Different laser parameters can achieve different microstructures. • Controlling laser parameters can produce different corrosion rates and morphologies. • Increase of surface roughness due to laser treatment is relevant to the corrosion rate

LASER INDUCED SELECTIVE ACTIVATION UTILIZING AUTO-CATALYTIC ELECTROLESS PLATING ON POLYMER SURFACE

DEFF Research Database (Denmark)

Zhang, Yang; Nielsen, Jakob Skov; Tang, Peter Torben

2009-01-01

. Characterization of the deposited copper layer was used to select and improve laser parameters. Several types of polymers with different melting points were used as substrate. Using the above mentioned laser treatment, standard grades of thermoplastic materials such as ABS, SAN, PE, PC and others have been......This paper presents a new method for selective micro metallization of polymers induced by laser. An Nd: YAG laser was employed to draw patterns on polymer surfaces using a special set-up. After subsequent activation and auto-catalytic electroless plating, copper only deposited on the laser tracks....... Induced by the laser, porous and rough structures are formed on the surface, which favours the palladium attachment during the activation step prior to the metallization. Laser focus detection, scanning electron microscopy (SEM) and other instruments were used to analyze the topography of the laser track...

Mechanical and shape memory properties of porous Ni50.1Ti49.9 alloys manufactured by selective laser melting.

Science.gov (United States)

Taheri Andani, Mohsen; Saedi, Soheil; Turabi, Ali Sadi; Karamooz, M R; Haberland, Christoph; Karaca, Haluk Ersin; Elahinia, Mohammad

2017-04-01

Near equiatomic NiTi shape memory alloys were fabricated in dense and designed porous forms by Selective Laser Melting (SLM) and their mechanical and shape memory properties were systematically characterized. Particularly, the effects of pore morphology on their mechanical responses were investigated. Dense and porous NiTi alloys exhibited good shape memory effect with a recoverable strain of about 5% and functional stability after eight cycles of compression. The stiffness and residual plastic strain of porous NiTi were found to depend highly on the pore shape and the level of porosity. Since porous NiTi structures have lower elastic modulus and density than dense NiTi with still good shape memory properties, they are promising materials for lightweight structures, energy absorbers, and biomedical implants. Copyright © 2017 Elsevier Ltd. All rights reserved.

Influence of Inherent Surface and Internal Defects on Mechanical Properties of Additively Manufactured Ti6Al4V Alloy: Comparison between Selective Laser Melting and Electron Beam Melting.

Science.gov (United States)

Fousová, Michaela; Vojtěch, Dalibor; Doubrava, Karel; Daniel, Matěj; Lin, Chiu-Feng

2018-03-31

Additive manufacture (AM) appears to be the most suitable technology to produce sophisticated, high quality, lightweight parts from Ti6Al4V alloy. However, the fatigue life of AM parts is of concern. In our study, we focused on a comparison of two techniques of additive manufacture-selective laser melting (SLM) and electron beam melting (EBM)-in terms of the mechanical properties during both static and dynamic loading. All of the samples were untreated to focus on the influence of surface condition inherent to SLM and EBM. The EBM samples were studied in the as-built state, while SLM was followed by heat treatment. The resulting similarity of microstructures led to comparable mechanical properties in tension, but, due to differences in surface roughness and specific internal defects, the fatigue strength of the EBM samples reached only half the value of the SLM samples. Higher surface roughness that is inherent to EBM contributed to multiple initiations of fatigue cracks, while only one crack initiated on the SLM surface. Also, facets that were formed by an intergranular cleavage fracture were observed in the EBM samples.

Influence of Inherent Surface and Internal Defects on Mechanical Properties of Additively Manufactured Ti6Al4V Alloy: Comparison between Selective Laser Melting and Electron Beam Melting

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Michaela Fousová

2018-03-01

Full Text Available Additive manufacture (AM appears to be the most suitable technology to produce sophisticated, high quality, lightweight parts from Ti6Al4V alloy. However, the fatigue life of AM parts is of concern. In our study, we focused on a comparison of two techniques of additive manufacture—selective laser melting (SLM and electron beam melting (EBM—in terms of the mechanical properties during both static and dynamic loading. All of the samples were untreated to focus on the influence of surface condition inherent to SLM and EBM. The EBM samples were studied in the as-built state, while SLM was followed by heat treatment. The resulting similarity of microstructures led to comparable mechanical properties in tension, but, due to differences in surface roughness and specific internal defects, the fatigue strength of the EBM samples reached only half the value of the SLM samples. Higher surface roughness that is inherent to EBM contributed to multiple initiations of fatigue cracks, while only one crack initiated on the SLM surface. Also, facets that were formed by an intergranular cleavage fracture were observed in the EBM samples.

Solidified Structure and Corrosion Behavior of Laser-melt Magnesium Alloy

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FANG Zhi-hao

2017-12-01

Full Text Available The AZ91D magnesium alloy samples were scanned by millisecond pulse Nd:YAG laser under high pure argon protection. The surface morphology, microstructure and composition of the treated magnesium alloy were studied by X-ray diffraction, optical microscopy, scanning electron microscopy, atomic force microscopy. In addition, the corrosion surface which was corroded using simulated body fluid and the mass fraction of 3.5%NaCl solution was observed and material corrosion rate was calculated. The results show that, at the same corrosion time, compared with the untreated samples, the surface corrosion resistance is improved by the enrichment of Al at the irradiated surface by the joint effect of the combination of refined homogeneous microstructure of α-Mg phase and β-Mg17Al12 phase and the selective vaporization and the chemical composition of base metal in the laser-treated AZ91D alloy; the solidification equation is obtained by calculating the relation between the size of the dendrite cell and the cooling rate in laser melting zone.

Mechanical Properties of Ti-6Al-4V Octahedral Porous Material Unit Formed by Selective Laser Melting

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Jianfeng Sun

2012-01-01

Full Text Available The Ti-6Al-4V octahedral porous material unit is designed to calculate its load. In this paper, ANSYS is adopted for the load simulation of the unit. And a simplified model of dimensional theoretical calculation is established, by which the analytical equation of the fracture load is obtained and the calculation of the load of Ti-6Al-4V is completed. Moreover, selective laser melting is adopted in processing the Ti-6Al-4V porous material unit. The experimental value of fracture load of this material is obtained through compression experiment. The results show that the simulation curves approximate the variation tendency of the elastic deformation of the compression curves; the curves of theoretical calculation approximate the general variation tendency; and the experimental value of fracture load is very close to the theoretical value. Therefore, the theoretical prediction accuracy of fracture load is high, which lays the foundation for the mechanical properties of the octahedral porous material.

Structure and Mechanical Properties of the AlSi10Mg Alloy Samples Manufactured by Selective Laser Melting

Science.gov (United States)

Li, Xiaodan; Ni, Jiaqiang; Zhu, Qingfeng; Su, Hang; Cui, Jianzhong; Zhang, Yifei; Li, Jianzhong

2017-11-01

The AlSi10Mg alloy samples with the size of 14×14×91mm were produced by the selective laser melting (SLM) method in different building direction. The structures and the properties at -70°C of the sample in different direction were investigated. The results show that the structure in different building direction shows different morphology. The fish scale structures distribute on the side along the building direction, and the oval structures distribute on the side vertical to the building direction. Some pores in with the maximum size of 100 μm exist of the structure. And there is no major influence for the build orientation on the tensile properties. The tensile strength and the elongation of the sample in the building direction are 340 Mpa and 11.2 % respectively. And the tensile strength and the elongation of the sample vertical to building direction are 350 Mpa and 13.4 % respectively

Defects-tolerant Co-Cr-Mo dental alloys prepared by selective laser melting.

Science.gov (United States)

Qian, B; Saeidi, K; Kvetková, L; Lofaj, F; Xiao, C; Shen, Z

2015-12-01

CrCoMo alloy specimens were successfully fabricated using selective laser melting (SLM). The aim of this study was to carefully investigate microstructure of the SLM specimens in order to understand the influence of their structural features inter-grown on different length scales ranging from nano- to macro-levels on their mechanical properties. Two different sets of processing parameters developed for building the inner part (core) and the surface (skin) of dental prostheses were tested. Microstructures were characterized by SEM, EBSD and XRD analysis. The elemental distribution was assessed by EDS line profile analysis under TEM. The mechanical properties of the specimens were measured. The microstructures of both specimens were characterized showing formation of grains comprised of columnar sub-grains with Mo-enrichment at the sub-grain boundaries. Clusters of columnar sub-grains grew coherently along one common crystallographic direction forming much larger single crystal grains which are intercrossing in different directions forming an overall dendrite-like microstructure. Three types of microstructural defects were occasionally observed; small voids (10 μm). Despite the presence of these defects, the yield and the ultimate tensile strength (UTS) were 870 and 430MPa and 1300MPa and 1160MPa, respectively, for the skin and core specimens which are higher than casted dental alloy. Although the formation of microstructural defects is hard to be avoided during the SLM process, the SLM CoCrMo alloys can achieve improved mechanical properties than their casted counterparts, implying they are "defect-tolerant". Copyright © 2015 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Tribological behavior of Ti6Al4V cellular structures produced by Selective Laser Melting.

Science.gov (United States)

Bartolomeu, F; Sampaio, M; Carvalho, O; Pinto, E; Alves, N; Gomes, J R; Silva, F S; Miranda, G

2017-05-01

Additive manufacturing (AM) technologies enable the fabrication of innovative structures with complex geometries not easily manufactured by traditional processes. Regarding metallic cellular structures with tailored/customized mechanical and wear performance aiming to biomedical applications, Selective Laser Melting (SLM) is a remarkable solution for their production. Focusing on prosthesis and implants, in addition to a suitable Young's modulus it is important to assess the friction response and wear resistance of these cellular structures in a natural environment. In this sense, five cellular Ti6Al4V structures with different open-cell sizes (100-500µm) were designed and produced by SLM. These structures were tribologicaly tested against alumina using a reciprocating sliding ball-on-plate tribometer. Samples were submerged in Phosphate Buffered Saline (PBS) fluid at 37°C, in order to mimic in some extent the human body environment. The results showed that friction and wear performance of Ti6Al4V cellular structures is influenced by the structure open-cell size. The higher wear resistance was obtained for structures with 100µm designed open-cell size due to the higher apparent area of contact to support tribological loading. Copyright © 2017 Elsevier Ltd. All rights reserved.

Exploiting Process-Related Advantages of Selective Laser Melting for the Production of High-Manganese Steel.

Science.gov (United States)

Haase, Christian; Bültmann, Jan; Hof, Jan; Ziegler, Stephan; Bremen, Sebastian; Hinke, Christian; Schwedt, Alexander; Prahl, Ulrich; Bleck, Wolfgang

2017-01-11

Metal additive manufacturing has strongly gained scientific and industrial importance during the last decades due to the geometrical flexibility and increased reliability of parts, as well as reduced equipment costs. Within the field of metal additive manufacturing methods, selective laser melting (SLM) is an eligible technique for the production of fully dense bulk material with complex geometry. In the current study, we addressed the application of SLM for processing a high-manganese TRansformation-/TWinning-Induced Plasticity (TRIP/TWIP) steel. The solidification behavior was analyzed by careful characterization of the as-built microstructure and element distribution using optical and scanning electron microscopy (SEM). In addition, the deformation behavior was studied using uniaxial tensile testing and SEM. Comparison with conventionally produced TRIP/TWIP steel revealed that elemental segregation, which is normally very pronounced in high-manganese steels and requires energy-intensive post processing, is reduced due to the high cooling rates during SLM. Also, the very fast cooling promoted ε- and α'-martensite formation prior to deformation. The superior strength and pronounced anisotropy of the SLM-produced material was correlated with the microstructure based on the process-specific characteristics.

Exploiting Process-Related Advantages of Selective Laser Melting for the Production of High-Manganese Steel

Directory of Open Access Journals (Sweden)

Christian Haase

2017-01-01

Full Text Available Metal additive manufacturing has strongly gained scientific and industrial importance during the last decades due to the geometrical flexibility and increased reliability of parts, as well as reduced equipment costs. Within the field of metal additive manufacturing methods, selective laser melting (SLM is an eligible technique for the production of fully dense bulk material with complex geometry. In the current study, we addressed the application of SLM for processing a high-manganese TRansformation-/TWinning-Induced Plasticity (TRIP/TWIP steel. The solidification behavior was analyzed by careful characterization of the as-built microstructure and element distribution using optical and scanning electron microscopy (SEM. In addition, the deformation behavior was studied using uniaxial tensile testing and SEM. Comparison with conventionally produced TRIP/TWIP steel revealed that elemental segregation, which is normally very pronounced in high-manganese steels and requires energy-intensive post processing, is reduced due to the high cooling rates during SLM. Also, the very fast cooling promoted ε- and α’-martensite formation prior to deformation. The superior strength and pronounced anisotropy of the SLM-produced material was correlated with the microstructure based on the process-specific characteristics.

A custom-made temporomandibular joint prosthesis for fabrication by selective laser melting: Finite element analysis.

Science.gov (United States)

Xu, Xiangliang; Luo, Danmei; Guo, Chuanbin; Rong, Qiguo

2017-08-01

A novel and custom-made selective laser melting (SLM) 3D-printed alloplastic temporomandibular joint (TMJ) prosthesis is proposed. The titanium-6aluminium-4vanadium (Ti-6Al-4V) condyle component and ultra-high molecular weight polyethylene (UHMWPE) fossa component comprised the total alloplastic TMJ replacement prosthesis. For the condyle component, an optimized tetrahedral open-porous scaffold with combined connection structures, i.e. an inlay rod and an onlay plate, between the prosthesis and remaining mandible was designed. The trajectory of movement of the intact condyle was assessed via kinematic analysis to facilitate the design of the fossa component. The behaviours of the intact mandible and mandible with the prosthesis were compared. The biomechanical behaviour was analysed by assessing the stress distribution on the prosthesis and strain distribution on the mandible. After muscle force was applied, the magnitude of the compressive strain on the condyle neck of the mandible with the prosthesis was lower than that on the condyle neck of the intact mandible, with the exception of the area about the screws; additionally, the magnitude of the strain at the scaffold-bone interface was relatively high. Copyright © 2017. Published by Elsevier Ltd.

Fatigue Strength Prediction for Titanium Alloy TiAl6V4 Manufactured by Selective Laser Melting

Science.gov (United States)

Leuders, Stefan; Vollmer, Malte; Brenne, Florian; Tröster, Thomas; Niendorf, Thomas

2015-09-01

Selective laser melting (SLM), as a metalworking additive manufacturing technique, received considerable attention from industry and academia due to unprecedented design freedom and overall balanced material properties. However, the fatigue behavior of SLM-processed materials often suffers from local imperfections such as micron-sized pores. In order to enable robust designs of SLM components used in an industrial environment, further research regarding process-induced porosity and its impact on the fatigue behavior is required. Hence, this study aims at a transfer of fatigue prediction models, established for conventional process-routes, to the field of SLM materials. By using high-resolution computed tomography, load increase tests, and electron microscopy, it is shown that pore-based fatigue strength predictions for a titanium alloy TiAl6V4 have become feasible. However, the obtained accuracies are subjected to scatter, which is probably caused by the high defect density even present in SLM materials manufactured following optimized processing routes. Based on thorough examination of crack surfaces and crack initiation sites, respectively, implications for optimization of prediction accuracy of the models in focus are deduced.

Microhardness and microstructure evolution of TiB2 reinforced Inconel 625/TiB2 composite produced by selective laser melting

Science.gov (United States)

Zhang, Baicheng; Bi, Guijun; Nai, Sharon; Sun, Chen-nan; Wei, Jun

2016-06-01

In this study, micron-size TiB2 particles were utilized to reinforce Inconel 625 produced by selective laser melting. Exceptional microhardness 600-700 HV0.3 of the composite was obtained. In further investigation, the microstructure and mechanical properties of Inconel 625/TiB2 composite can be significantly influenced by addition of TiB2 particles during SLM. It was found that the long directional columnar grains observed from SLM-processed Inconel 625 were totally changed to fine dendritic matrix due to the addition of TiB2 particles. Moreover, with laser energy density (LED) of 1200 J/m, a Ti, Mo rich interface around TiB2 particles with fine thickness can be observed by FESEM and EDS. The microstructure evolution can be determined by different laser energy density (LED): under 1200 J/m, γ phase in dendrite grains; under 600 J/m, γ phase in combination of dendritic and acicular grains; under 400 J/m, γ phase acicular grains. Under optimized LED 1200 J/m, the dynamic nanohardness (8.62 GPa) and elastic modulus (167 GPa) of SLM-processed Inconel 625/TiB2 composite are higher compared with those of SLM-processed Inconel 625 (3.97 GPa and 135 GPa, respectively).

Laser melting of groove defect repair on high thermal conductivity steel (HTCS-150)

Science.gov (United States)

Norhafzan, B.; Aqida, S. N.; Fazliana, F.; Reza, M. S.; Ismail, I.; Khairil, C. M.

2018-02-01

This paper presents laser melting repair of groove defect on HTCS-150 surface using Nd:YAG laser system. Laser melting process was conducted using JK300HPS Nd:YAG twin lamp laser source with 1064 nm wavelength and pulsed mode. The parameters are pulse repetition frequency (PRF) that is set from 70 to 100 Hz, average power ( P A) of 50-70 W, and laser spot size of 0.7 mm. HTCS-150 samples were prepared with groove dimension of 0.3 mm width and depths of 0.5 mm using EDM wire cut. Groove defect repaired using laser melting process on groove surface area with various parameters' process. The melted surface within the groove was characterized for subsurface hardness profile, roughness, phase identification, chemical composition, and metallographic study. The roughness analysis indicates high PRF at large spot size caused high surface roughness and low surface hardness. Grain refinement of repaired layer was analyzed within the groove as a result of rapid heating and cooling. The hardness properties of modified HTCS inside the groove and the bulk surface increased two times from as received HTCS due to grain refinement which is in agreement with Hall-Petch equation. These findings are significant to parameter design of die repair for optimum surface integrity and potential for repairing crack depth and width of less than 0.5 and 0.3 mm, respectively.

Influence of Scanning Strategies on Processing of Aluminum Alloy EN AW 2618 Using Selective Laser Melting

Science.gov (United States)

Palousek, David; Pantelejev, Libor; Hoeller, Christian; Pichler, Rudolf; Tesicky, Lukas; Kaiser, Jozef

2018-01-01

This paper deals with various selective laser melting (SLM) processing strategies for aluminum 2618 powder in order to get material densities and properties close to conventionally-produced, high-strength 2618 alloy. To evaluate the influence of laser scanning strategies on the resulting porosity and mechanical properties a row of experiments was done. Three types of samples were used: single-track welds, bulk samples and samples for tensile testing. Single-track welds were used to find the appropriate processing parameters for achieving continuous and well-shaped welds. The bulk samples were built with different scanning strategies with the aim of reaching a low relative porosity of the material. The combination of the chessboard strategy with a 2 × 2 mm field size fabricated with an out-in spiral order was found to eliminate a major lack of fusion defects. However, small cracks in the material structure were found over the complete range of tested parameters. The decisive criteria was the elimination of small cracks that drastically reduced mechanical properties. Reduction of the thermal gradient using support structures or fabrication under elevated temperatures shows a promising approach to eliminating the cracks. Mechanical properties of samples produced by SLM were compared with the properties of extruded material. The results showed that the SLM-processed 2618 alloy could only reach one half of the yield strength and tensile strength of extruded material. This is mainly due to the occurrence of small cracks in the structure of the built material. PMID:29443912

Influence of Scanning Strategies on Processing of Aluminum Alloy EN AW 2618 Using Selective Laser Melting.

Science.gov (United States)

Koutny, Daniel; Palousek, David; Pantelejev, Libor; Hoeller, Christian; Pichler, Rudolf; Tesicky, Lukas; Kaiser, Jozef

2018-02-14

This paper deals with various selective laser melting (SLM) processing strategies for aluminum 2618 powder in order to get material densities and properties close to conventionally-produced, high-strength 2618 alloy. To evaluate the influence of laser scanning strategies on the resulting porosity and mechanical properties a row of experiments was done. Three types of samples were used: single-track welds, bulk samples and samples for tensile testing. Single-track welds were used to find the appropriate processing parameters for achieving continuous and well-shaped welds. The bulk samples were built with different scanning strategies with the aim of reaching a low relative porosity of the material. The combination of the chessboard strategy with a 2 × 2 mm field size fabricated with an out-in spiral order was found to eliminate a major lack of fusion defects. However, small cracks in the material structure were found over the complete range of tested parameters. The decisive criteria was the elimination of small cracks that drastically reduced mechanical properties. Reduction of the thermal gradient using support structures or fabrication under elevated temperatures shows a promising approach to eliminating the cracks. Mechanical properties of samples produced by SLM were compared with the properties of extruded material. The results showed that the SLM-processed 2618 alloy could only reach one half of the yield strength and tensile strength of extruded material. This is mainly due to the occurrence of small cracks in the structure of the built material.

Numerical analysis of the heating phase and densification mechanism in polymers selective laser melting process

Science.gov (United States)

Mokrane, Aoulaiche; Boutaous, M'hamed; Xin, Shihe

2018-05-01

The aim of this work is to address a modeling of the SLS process at the scale of the part in PA12 polymer powder bed. The powder bed is considered as a continuous medium with homogenized properties, meanwhile understanding multiple physical phenomena occurring during the process and studying the influence of process parameters on the quality of final product. A thermal model, based on enthalpy approach, will be presented with details on the multiphysical couplings that allow the thermal history: laser absorption, melting, coalescence, densification, volume shrinkage and on numerical implementation using FV method. The simulations were carried out in 3D with an in-house developed FORTRAN code. After validation of the model with comparison to results from literature, a parametric analysis will be proposed. Some original results as densification process and the thermal history with the evolution of the material, from the granular solid state to homogeneous melted state will be discussed with regards to the involved physical phenomena.

Investigation into Effects of Scanning Speed on in Vitro Biocompatibility of Selective Laser Melted 316L Stainless Steel Parts

Directory of Open Access Journals (Sweden)

Shang Yitong

2017-01-01

Full Text Available In recent years, selective laser melting (SLM has gained an important place in fabrication due to their strong individualization which cannot be manufactured using conventional processes such as casting or forging. By proper control of the SLM processing parameters, characteristics of the alloy can be optimized. In the present work, 316L stainless steel (SS, as a widely used biomedical material, is investigated in terms of the effects of scanning speed on in vitro biocompatibility during SLM process. Cytotoxicity assay is adopted to assess the in vitro biocompatibility. The results show the scanning speed strongly affects the in vitro biocompatibility of 316L SS parts and with prolongs of incubation time, the cytotoxicity increase and the in vitro biocompatibility gets worse. The optimal parameters are determined as follows: scanning speed of 900 mm/s, laser power of 195 W, hatch spacing of 0.09 mm and layer thickness of 0.02 mm. The processing parameters lead to the change of surface morphology and microstructures of samples, which can affect the amount of toxic ions release, such as Cr, Mo and Co, that can increase risks to patient health and reduce the biocompatibility.

Surface characterization and wear behaviour of laser surface melted AISI 316L stainless steel

CSIR Research Space (South Africa)

Kumar, A

2010-01-01

Full Text Available The present study concerns an in depth investigation of the influence of laser surface melting of AISI 316L stainless steel using Ar and N2 as shrouding atmosphere. Laser surface melting has been carried out using a 5 kW continuous wave (CW) fibre...

Selective laser melting of Ti6Al4V alloy for biomedical applications: Temperature monitoring and microstructural evolution

Energy Technology Data Exchange (ETDEWEB)

Yadroitsev, I., E-mail: ihar.yadroitsau@enise.fr [Université de Lyon, Ecole Nationale d’Ingénieurs de Saint-Etienne, 58 rue Jean Parot, 42023 Saint-Etienne (France); Krakhmalev, P. [Karlstad University, Department of Mechanical and Materials Engineering, SE-651 88 Karlstad (Sweden); Yadroitsava, I. [Université de Lyon, Ecole Nationale d’Ingénieurs de Saint-Etienne, 58 rue Jean Parot, 42023 Saint-Etienne (France)

2014-01-15

Highlights: • Temperature measurements of molten pool were done using CCD camera. • Temperature of molten pool versus scanning speed and laser power was determined. • Microstructures and microhardness of SLM samples were analyzed. • Influence of heat treatment on microstructure were discussed and presented. -- Abstract: Selective laser melting (SLM) is a kind of additive manufacturing where parts are made directly from 3D CAD data layer-by-layer from powder material. SLM products are used in various industries including aerospace, automotive, electronic, chemical, biomedical and other high-tech areas. The properties of the parts produced by SLM depend strongly on the material nature, characteristics of each single track and each single layer, as well as the strength of the connections between them. Studying the temperature distribution during SLM is important because temperature gradient and heat transfer determine the microstructure and finally mechanical properties of the SLM part. In this study a CCD camera was applied for determination of the surface temperature distribution and the molten pool size of Ti6Al4V alloy. The investigation of the microstructure evolution after different heat treatments was carried out to determine the microstructure in terms of applicability for the biomedical industry.

Influence of scan strategy and molten pool configuration on microstructures and tensile properties of selective laser melting additive manufactured aluminum based parts

Science.gov (United States)

Dai, Donghua; Gu, Dongdong; Zhang, Han; Xiong, Jiapeng; Ma, Chenglong; Hong, Chen; Poprawe, Reinhart

2018-02-01

Selective laser melting additive manufacturing of the AlSi12 material parts through the re-melting of the previously solidified layer using the continuous two layers 90° rotate scan strategy was conducted. The influence of the re-melting behavior and scan strategy on the formation of the ;track-track; and ;layer-layer; molten pool boundaries (MPBs), dimensional accuracy, microstructure feature, tensile properties, microscopic sliding behavior and the fracture mechanism as loaded a tensile force has been studied. It showed that the defects, such as the part distortion, delamination and cracks, were significantly eliminated with the deformation rate less than 1%. The microstructure of a homogeneous distribution of the Si phase, no apparent grain orientation on both sides of the MPBs, was produced in the as-fabricated part, promoting the efficient transition of the load stress. Cracks preferentially initiate at the ;track-track; MPBs when the tensile stress increases to a certain value, resulting in the formation of the cleavage steps along the tensile loading direction. The cracks propagate along the ;layer-layer; MPBs, generating the fine dimples. The mechanical behavior of the SLM-processed AlSi12 parts can be significantly enhanced with the ultimate tensile strength, yield strength and elongation of 476.3 MPa, 315.5 MPa and 6.7%, respectively.

Melting phenomenon and laser annealing in semiconductors

International Nuclear Information System (INIS)

Narayan, J.

1981-03-01

The work on annealing of displacement damage, dissolution of boron precipitates, and the broadening of dopant profiles in semiconductors after treating with ruby and dye laser pulses is reviewed in order to provide convincing evidence for the melting phenomenon and illustrate the mechanism associated with laser annealing. The nature of the solid-liquid interface and the interface instability during rapid solidification is considered in detail. It is shown that solute concentrations after pulsed laser annealing can far exceed retrograde maxima values. However, there is a critical solute concentration above which a planar solid-liquid interface becomes unstable and breaks into a cellular structure. The solute concentrations and cell sizes associated with this instability are calculated using a perturbation theory, and compared with experimental results

Microstructure and Mechanical Properties of Ti-6Al-4V Fabricated by Selective Laser Melting of Powder Produced by Granulation-Sintering-Deoxygenation Method

Science.gov (United States)

Sun, Pei; Fang, Z. Zak; Zhang, Ying; Xia, Yang

2017-12-01

Commercial spherical Ti powders for additive manufacturing applications are produced today by melt-atomization methods at relatively high costs. A meltless production method, called granulation-sintering-deoxygenation (GSD), was developed recently to produce spherical Ti alloy powder at a significantly reduced cost. In this new process, fine hydrogenated Ti particles are agglomerated to form spherical granules, which are then sintered to dense spherical particles. After sintering, the solid fully dense spherical Ti alloy particles are deoxygenated using novel low-temperature deoxygenation processes with either Mg or Ca. This technical communication presents results of 3D printing using GSD powder and the selective laser melting (SLM) technique. The results showed that tensile properties of parts fabricated from spherical GSD Ti-6Al-4V powder by SLM are comparable with typical mill-annealed Ti-6Al-4V. The characteristics of 3D printed Ti-6Al-4V from GSD powder are also compared with that of commercial materials.

[Comparison of adaptation and microstructure of titanium upper complete denture base fabricated by selecting laser melting and electron beam melting].

Science.gov (United States)

Ye, Y; Xiong, Y Y; Zhu, J R; Sun, J

2017-06-09

Objective: To fabricate Ti alloy frameworks for a maxillary complete denture with three-dimensional printing (3DP) technique, such as selective laser melting (SLM) and electron beam melting (EBM), and to evaluate the microstructure of these frameworks and their adaptation to the die stone models. Methods: Thirty pairs of edentulous casts were divided into 3 groups randomly and equally. In each group, one of the three techniques (SLM, EBM, conventional technique) was used to fabricate Ti alloy frameworks. The base-cast sets were transversally sectioned into 3 sections at the distal of canines, mesial of first molars, and the posterior palatal zone. The gap between the metal base and cast was measured in the 3 sections. Stereoscopic microscope was used to measure the gap. Three pieces of specimens of 5 mm diameter were fabricated with Ti alloy by SLM, EBM and the traditional casting technology (as mentioned above). Scanning electron microscope (SEM) was used to evaluate the differences of microstructure among these specimens. Results: The gaps between the metal base and cast were (99.4±17.0), (98.2±26.1), and (99.6± 16.1) μm in conventional method; (99.4 ± 22.8), (83.1 ± 19.3), and (103.3 ± 13.8) μm in SLM technique; (248.3±70.3), (279.1±71.9), and (189.1±31.6) μm in EBM technique. There was no statistical difference in the value of gaps between SLM Ti alloy and conventional method Ti alloy group ( P> 0.05). There was statistical difference among EBM Ti alloy, conventional method Ti alloy and SLM Ti alloy group ( Palloy showed more uniform and compact microstructure than the cast Ti alloy and EBM Ti alloy did. Conclusions: SLM technique showed initial feasibility to manufacture the dental base of complete denture. The mechanical properties and microstructure of the denture frameworks prepared by SLM indicate that these dentures are appropriate for clinical use. EBM technique is inadequate to make a complete denture now.

Kinetic approach in numerical modeling of melting and crystallization at laser cladding with powder injection

Energy Technology Data Exchange (ETDEWEB)

Mirzade, F. Kh., E-mail: fmirzade@rambler.ru [Institute on Laser and Information Technology, Russian Academy of Sciences, 1 Svyatoozerskaya Street, Shatura, Moscow Region 140700 (Russian Federation); Niziev, V.G.; Panchenko, V. Ya.; Khomenko, M.D.; Grishaev, R.V. [Institute on Laser and Information Technology, Russian Academy of Sciences, 1 Svyatoozerskaya Street, Shatura, Moscow Region 140700 (Russian Federation); Pityana, S.; Rooyen, Corney van [CSIR-National Laser Centre, Building 46A, Meiring Nauder Road, Brummeria, Pretoria (South Africa)

2013-08-15

The numerical model of laser cladding with coaxial powder injection includes the equations for heat transfer, melting and crystallization kinetics. It has been shown that the main parameters influencing the melt pool dynamics and medium maximum temperature are mass feed rate, laser power and scanning velocity. It has been observed that, due to the phase change occurring with superheating/undercooling, the melt zone has the boundary distinguished from melting isotherm. The calculated melt pool dimensions and dilution are in a good agreement with the experimental results for cladding of 431 martensitic stainless steel onto carbon steel substrate.

Selective Laser Sintering And Melting Of Pristine Titanium And Titanium Ti6Al4V Alloy Powders And Selection Of Chemical Environment For Etching Of Such Materials

Directory of Open Access Journals (Sweden)

Dobrzański L.A.

2015-09-01

Full Text Available The aim of the investigations described in this article is to present a selective laser sintering and melting technology to fabricate metallic scaffolds made of pristine titanium and titanium Ti6Al4V alloy powders. Titanium scaffolds with different properties and structure were manufactured with this technique using appropriate conditions, notably laser power and laser beam size. The purpose of such elements is to replace the missing pieces of bones, mainly cranial and facial bones in the implantation treatment process. All the samples for the investigations were designed in CAD/CAM (3D MARCARM ENGINEERING AutoFab (Software for Manufacturing Applications software suitably integrated with an SLS/SLM system. Cube-shaped test samples dimensioned 10×10×10 mm were designed for the investigations using a hexagon-shaped base cell. The so designed 3D models were transferred to the machine software and the actual rapid manufacturing process was commenced. The samples produced according to the laser sintering technology were subjected to chemical processing consisting of etching the scaffolds’ surface in different chemical mediums. Etching was carried out to remove the loosely bound powder from the surface of scaffolds, which might detach from their surface during implantation treatment and travel elsewhere in an organism. The scaffolds created were subjected to micro- and spectroscopic examinations

Physics-based simulation modeling and optimization of microstructural changes induced by machining and selective laser melting processes in titanium and nickel based alloys

Science.gov (United States)

Arisoy, Yigit Muzaffer

Manufacturing processes may significantly affect the quality of resultant surfaces and structural integrity of the metal end products. Controlling manufacturing process induced changes to the product's surface integrity may improve the fatigue life and overall reliability of the end product. The goal of this study is to model the phenomena that result in microstructural alterations and improve the surface integrity of the manufactured parts by utilizing physics-based process simulations and other computational methods. Two different (both conventional and advanced) manufacturing processes; i.e. machining of Titanium and Nickel-based alloys and selective laser melting of Nickel-based powder alloys are studied. 3D Finite Element (FE) process simulations are developed and experimental data that validates these process simulation models are generated to compare against predictions. Computational process modeling and optimization have been performed for machining induced microstructure that includes; i) predicting recrystallization and grain size using FE simulations and the Johnson-Mehl-Avrami-Kolmogorov (JMAK) model, ii) predicting microhardness using non-linear regression models and the Random Forests method, and iii) multi-objective machining optimization for minimizing microstructural changes. Experimental analysis and computational process modeling of selective laser melting have been also conducted including; i) microstructural analysis of grain sizes and growth directions using SEM imaging and machine learning algorithms, ii) analysis of thermal imaging for spattering, heating/cooling rates and meltpool size, iii) predicting thermal field, meltpool size, and growth directions via thermal gradients using 3D FE simulations, iv) predicting localized solidification using the Phase Field method. These computational process models and predictive models, once utilized by industry to optimize process parameters, have the ultimate potential to improve performance of

Comparative melting and healing of B-DNA and Z-DNA by an infrared laser pulse

International Nuclear Information System (INIS)

Man, Viet Hoang; Pan, Feng; Sagui, Celeste; Roland, Christopher

2016-01-01

We explore the use of a fast laser melting simulation approach combined with atomistic molecular dynamics simulations in order to determine the melting and healing responses of B-DNA and Z-DNA dodecamers with the same d(5′-CGCGCGCGCGCG-3′) 2 sequence. The frequency of the laser pulse is specifically tuned to disrupt Watson-Crick hydrogen bonds, thus inducing melting of the DNA duplexes. Subsequently, the structures relax and partially refold, depending on the field strength. In addition to the inherent interest of the nonequilibrium melting process, we propose that fast melting by an infrared laser pulse could be used as a technique for a fast comparison of relative stabilities of same-sequence oligonucleotides with different secondary structures with full atomistic detail of the structures and solvent. This could be particularly useful for nonstandard secondary structures involving non-canonical base pairs, mismatches, etc.

Comparative melting and healing of B-DNA and Z-DNA by an infrared laser pulse

Energy Technology Data Exchange (ETDEWEB)

Man, Viet Hoang; Pan, Feng; Sagui, Celeste, E-mail: sagui@ncsu.edu; Roland, Christopher, E-mail: cmroland@ncsu.edu [Department of Physics, North Carolina State University, Raleigh, North Carolina 27695-8202 (United States)

2016-04-14

We explore the use of a fast laser melting simulation approach combined with atomistic molecular dynamics simulations in order to determine the melting and healing responses of B-DNA and Z-DNA dodecamers with the same d(5′-CGCGCGCGCGCG-3′){sub 2} sequence. The frequency of the laser pulse is specifically tuned to disrupt Watson-Crick hydrogen bonds, thus inducing melting of the DNA duplexes. Subsequently, the structures relax and partially refold, depending on the field strength. In addition to the inherent interest of the nonequilibrium melting process, we propose that fast melting by an infrared laser pulse could be used as a technique for a fast comparison of relative stabilities of same-sequence oligonucleotides with different secondary structures with full atomistic detail of the structures and solvent. This could be particularly useful for nonstandard secondary structures involving non-canonical base pairs, mismatches, etc.

Determination of Strain Rate Sensitivity of Micro-struts Manufactured Using the Selective Laser Melting Method

Science.gov (United States)

Gümrük, Recep; Mines, R. A. W.; Karadeniz, Sami

2018-03-01

Micro-lattice structures manufactured using the selective laser melting (SLM) process provides the opportunity to realize optimal cellular materials for impact energy absorption. In this paper, strain rate-dependent material properties are measured for stainless steel 316L SLM micro-lattice struts in the strain rate range of 10-3 to 6000 s-1. At high strain rates, a novel version of the split Hopkinson Bar has been developed. Strain rate-dependent materials data have been used in Cowper-Symonds material model, and the scope and limit of this model in the context of SLM struts have been discussed. Strain rate material data and the Cowper-Symonds model have been applied to the finite element analysis of a micro-lattice block subjected to drop weight impact loading. The model output has been compared to experimental results, and it has been shown that the increase in crush stress due to impact loading is mainly the result of strain rate material behavior. Hence, a systematic methodology has been developed to investigate the impact energy absorption of a micro-lattice structure manufactured using additive layer manufacture (SLM). This methodology can be extended to other micro-lattice materials and configurations, and to other impact conditions.

How does the surface treatment change the cytocompatibility of implants made by selective laser melting?

Science.gov (United States)

Matouskova, Lucie; Ackermann, Michal; Horakova, Jana; Capek, Lukas; Henys, Petr; Safka, Jiri

2018-04-01

The study investigates the potential for producing medical components via Selective Laser Melting technology (SLM). The material tested consisted of the biocompatible titanium alloy Ti6Al4V. The research involved the testing of laboratory specimens produced using SLM technology both in vitro and for surface roughness. The aim of the research was to clarify whether SLM technology affects the cytocompatibility of implants and, thus, whether SLM implants provide suitable candidates for medical use following zero or minimum post-fabrication treatment. Areas covered: The specimens were tested with an osteoblast cell line and, subsequently, two post-treatment processes were compared: non-treated (as-fabricated) and glass-blasted. Interactions with MG-63 cells were evaluated by means of metabolic MTT assay and microscope techniques (scanning electron microscopy, fluorescence microscopy). Surface roughness was observed on both the non-treated and glass-blasted SLM specimens. Expert Commentary: The research concluded that the glass-blasting of SLM Ti6Al4V significantly reduces surface roughness. The arithmetic mean roughness Ra was calculated at 3.4 µm for the glass-blasted and 13.3 µm for the non-treated surfaces. However, the results of in vitro testing revealed that the non-treated surface was better suited to cell growth.

GEOMETRIC COMPLEXITY ANALYSIS IN AN INTEGRATIVE TECHNOLOGY EVALUATION MODEL (ITEM FOR SELECTIVE LASER MELTING (SLM#

Directory of Open Access Journals (Sweden)

S. Merkt

2012-01-01

Full Text Available

ENGLISH ABSTRACT: Selective laser melting (SLM is becoming an economically viable choice for manufacturing complex serial parts. This paper focuses on a geometric complexity analysis as part of the integrative technology evaluation model (ITEM presented here. In contrast to conventional evaluation methodologies, the ITEM considers interactions between product and process innovations generated by SLM. The evaluation of manufacturing processes that compete with SLM is the main goal of ITEM. The paper includes a complexity analysis of a test part from Festo AG. The paper closes with a discussion of how the expanded design freedom of SLM can be used to improve company operations, and how the complexity analysis presented here can be seen as a starting point for feature-based complexity analysis..

AFRIKAANSE OPSOMMING: Selektiewe lasersmelting word geleidelik ’n gangbare ekonomiese keuse vir die vervaar-diging van opeenvolgende komplekse onderdele. Die navorsing is toegespits op die ontleding van meetkundige kompleksiteit as ’n gedeelte van ’n integrerende tegnologiese evalueringsmodel. Gemeet teen konvensionele evalueringsmodelle behandel die genoemde metode interaksies tussen produkte- en prosesinnovasies wat gegenereer word. Die navorsing behandel ’n kompleksiteitsontleding van ’n toetsonderdeel van die firma FESTO AG. Die resultaat toon hoe kompleksiteits-analise gebruik kan word as die vertrekpunt vir eienskapsgebaseerde analise.

Development and characterization of a coronary polylactic acid stent prototype generated by selective laser melting.

Science.gov (United States)

Flege, Christian; Vogt, Felix; Höges, Simon; Jauer, Lucas; Borinski, Mauricio; Schulte, Vera A; Hoffmann, Rainer; Poprawe, Reinhart; Meiners, Wilhelm; Jobmann, Monika; Wissenbach, Konrad; Blindt, Rüdiger

2013-01-01

In-stent restenosis is still an important issue and stent thrombosis is an unresolved risk after coronary intervention. Biodegradable stents would provide initial scaffolding of the stenosed segment and disappear subsequently. The additive manufacturing technology Selective Laser Melting (SLM) enables rapid, parallel, and raw material saving generation of complex 3- dimensional structures with extensive geometric freedom and is currently in use in orthopedic or dental applications. Here, SLM process parameters were adapted for poly-L-lactid acid (PLLA) and PLLA-co-poly-ε-caprolactone (PCL) powders to generate degradable coronary stent prototypes. Biocompatibility of both polymers was evidenced by assessment of cell morphology and of metabolic and adhesive activity at direct and indirect contact with human coronary artery smooth muscle cells, umbilical vein endothelial cells, and endothelial progenitor cells. γ-sterilization was demonstrated to guarantee safety of SLM-processed parts. From PLLA and PCL, stent prototypes were successfully generated and post-processing by spray- and dip-coating proved to thoroughly smoothen stent surfaces. In conclusion, for the first time, biodegradable polymers and the SLM technique were combined for the manufacturing of customized biodegradable coronary artery stent prototypes. SLM is advocated for the development of biodegradable coronary PLLA and PCL stents, potentially optimized for future bifurcation applications.

Numerical analysis of radiation propagation in innovative volumetric receivers based on selective laser melting techniques

Science.gov (United States)

Alberti, Fabrizio; Santiago, Sergio; Roccabruna, Mattia; Luque, Salvador; Gonzalez-Aguilar, Jose; Crema, Luigi; Romero, Manuel

2016-05-01

Volumetric absorbers constitute one of the key elements in order to achieve high thermal conversion efficiencies in concentrating solar power plants. Regardless of the working fluid or thermodynamic cycle employed, design trends towards higher absorber output temperatures are widespread, which lead to the general need of components of high solar absorptance, high conduction within the receiver material, high internal convection, low radiative and convective heat losses and high mechanical durability. In this context, the use of advanced manufacturing techniques, such as selective laser melting, has allowed for the fabrication of intricate geometries that are capable of fulfilling the previous requirements. This paper presents a parametric design and analysis of the optical performance of volumetric absorbers of variable porosity conducted by means of detailed numerical ray tracing simulations. Sections of variable macroscopic porosity along the absorber depth were constructed by the fractal growth of single-cell structures. Measures of performance analyzed include optical reflection losses from the absorber front and rear faces, penetration of radiation inside the absorber volume, and radiation absorption as a function of absorber depth. The effects of engineering design parameters such as absorber length and wall thickness, material reflectance and porosity distribution on the optical performance of absorbers are discussed, and general design guidelines are given.

Process optimisation in selective laser melting

NARCIS (Netherlands)

van Vaerenbergh, J.

2008-01-01

The work presented here summarises part of the work I have done for the past six years. After a few interesting months of research on laser cutting of thick steel plates, I was lucky to land up in the emerging domain of Rapid Prototyping (RP): producing complex products layer by layer, directly from

Functionalisation of Ti6Al4V components fabricated using selective laser melting with a bioactive compound.

Science.gov (United States)

Vaithilingam, Jayasheelan; Kilsby, Samuel; Goodridge, Ruth D; Christie, Steven D R; Edmondson, Steve; Hague, Richard J M

2015-01-01

Surface modification of an implant with a biomolecule is used to improve its biocompatibility and to reduce post-implant complications. In this study, a novel approach has been used to functionalise phosphonic acid monolayers with a drug. Ti6Al4V components fabricated using selective laser melting (SLM) were functionalised with Paracetamol (a pharmaceutically relevant biomolecule) using phosphonic acid based self-assembled monolayers (SAMs). The attachment, stability of the monolayers on the SLM fabricated surface and functionalisation of SAMs with Paracetamol were studied using X-ray photoelectron spectroscopy (XPS) and surface wettability measurements. The obtained results confirmed that SAMs were stable on the Ti6Al4V surface for over four weeks and then began to desorb from the surface. The reaction used to functionalise the phosphonic acid monolayers with Paracetamol was noted to be successful. Thus, the proposed method has the potential to immobilise drugs/proteins to SAM coated surfaces and improve their biocompatibility and reduce post-implant complications. Copyright © 2014. Published by Elsevier B.V.

Effect of heat treatment on mechanical properties and microstructure of selective laser melting 316L stainless steel

Science.gov (United States)

Kamariah, M. S. I. N.; Harun, W. S. W.; Khalil, N. Z.; Ahmad, F.; Ismail, M. H.; Sharif, S.

2017-10-01

Selective Laser Melting (SLM) has been one of the preferred Additive Manufacturing process to fabricate parts due to its merits in terms of design freedom, lower material waste and faster production when compare to the conventional manufacturing processes. However, due to the thermal gradient experienced during the process, the parts are exposed to the residual stress that leads to parts distortion. This work presents the effect of heat treatments on the micro-hardness of 316L stainless steel parts. In current study, SLM has been employed to fabricate 316L stainless steel compacts. Different heat treatments of 650°C, 950°C, and 1100°C for 2 hours were applied on the compacts. Hardness test were performed on the as-built and heat-treated compacts. The relationship between the microstructures and micro-hardness were discussed in this paper. The results revealed that the micro-hardness of the as-built compacts is between 209.0 and 212.2 HV, which is much higher than the heattreated compacts.

Effect of Different Connection Modes on Bolt Structural Properties of TC4 Alloy in Selective Laser Melting

Science.gov (United States)

Li, Xiaodan; Huang, Shuangjun; Xu, Liang; Hui, Li; Zhou, Song

2017-12-01

The bolt structural properties of selective laser melted (SLM) samples produced from TC4 powder metal has been investigated. Two different connection molds relative to single lap joint and bilateral lap joint as well as two different state of surface quality were considered. Samples and test procedures were designed in accordance with HB 5143 and HB 5287 standard. The results show that there is a strong influence of connection molds on the dynamic behavior of SLM produced TC4. The mechanical properties of bilateral lap joint are better than those of the single lap joint. Meanwhile the fatigue performance of the bilateral lap joint is much stronger than that of the single lap joint which it is a symmetrical structure of the two-shear test on both sides of the force evenly, while the single lap joint is a single shear sample of the uneven force. There are two kinds of fracture form most of which are broken in the first row of screw and a small part in the middle of the connecting plate.

Theoretical description of laser melt pool dynamics, Task order number B239634, Quarter 3 report

Energy Technology Data Exchange (ETDEWEB)

Dykhne, A.

1995-05-10

Melting of solid matter under laser radiation is realized in almost every process of laser technology. The present paper addresses melted material flows in cases when melt zones are shallow, i.e., the zone width is appreciably greater than or of the same order as its depth. Such conditions are usually realized when hardening, doping or perforating thin plates or when using none-deep penetration. Melted material flowing under conditions of deep penetration, drilling of deep openings and cutting depends on a number of additional factors (as compared to the shallow-pool case), namely, formation of a vapor and gas cavern in the sample and propagation of the laser beam through the cavern. These extra circumstances complicate hydrodynamic consideration of the liquid bath and will be addressed is the paper to follow.

Full melting of a two-dimensional complex plasma crystal triggered by localized pulsed laser heating

Science.gov (United States)

Couëdel, L.; Nosenko, V.; Rubin-Zuzic, M.; Zhdanov, S.; Elskens, Y.; Hall, T.; Ivlev, A. V.

2018-04-01

The full melting of a two-dimensional plasma crystal was induced in a principally stable monolayer by localized laser stimulation. Two distinct behaviors of the crystal after laser stimulation were observed depending on the amount of injected energy: (i) below a well-defined threshold, the laser melted area recrystallized; (ii) above the threshold, it expanded outwards in a similar fashion to mode-coupling instability-induced melting, rapidly destroying the crystalline order of the whole complex plasma monolayer. The reported experimental observations are due to the fluid mode-coupling instability, which can pump energy into the particle monolayer at a rate surpassing the heat transport and damping rates in the energetic localized melted spot, resulting in its further growth. This behavior exhibits remarkable similarities with impulsive spot heating in ordinary reactive matter.

Numerical and experimental investigation into the subsequent thermal cycling during selective laser melting of multi-layer 316L stainless steel

Science.gov (United States)

Liu, Yang; Zhang, Jian; Pang, Zhicong

2018-01-01

Subsequent thermal cycling (STC), as the unique thermal behavior during the multi-layer manufacturing process of selective laser melting (SLM), brings about unique microstructure of the as-produced parts. A multi-layer finite element (FE) model was proposed to study the STC along with a contrast experiment. The FE simulational results show that as layer increases, the maximum temperature, dimensions and liquid lifetime of the molten pool increase, while the heating and cooling rates decrease. The maximum temperature point shifts into the molten pool, and central of molten pool shifts backward. The neighborly underlying layer can be remelted thoroughly when laser irradiates a powder layer, thus forming an excellent bonding between neighbor layers. The contrast experimental results between the single-layer and triple-layer samples show that grains in of latter become coarsen and tabular along the height direction compared with those of the former. Moreover, this effect become more serious in 2nd and 1st layers in the triple-layer sample. All the above illustrate that the STC has an significant influence on the thermal behavior during SLM process, and thus affects the microstructure of SLMed parts.

Effects of surface shape on the geometry and surface topography of the melt pool in low-power density laser melting

KAUST Repository

Kim, Youngdeuk

2011-04-15

The quantitative correlations between workpiece volume and melt pool geometry, as well as the flow and thermal features of the melt pool are established. Thermocapillary convections in melt pool with a deformable free surface are investigated with respect to surface shape and laser intensity. When the contact angle between the tangent to the top surface and the vertical wall at the hot center is acute, the free surface flattens, compared with that of the initial free surface. Otherwise, the free surface forms a bowl-like shape with a deep crater and a low peripheral rim when the contact angle at the hot center is obtuse. Increasing the workpiece volume at a fixed laser intensity and a negative radial height gradient cause linear decreases in the geometric size and magnitude of flow and temperature of the melt pool. Conversely, linear increases are observed with a positive radial height gradient. © 2011 American Institute of Chemical Engineers (AIChE).

A novel coping metal material CoCrCu alloy fabricated by selective laser melting with antimicrobial and antibiofilm properties.

Science.gov (United States)

Ren, Ling; Memarzadeh, Kaveh; Zhang, Shuyuan; Sun, Ziqing; Yang, Chunguang; Ren, Guogang; Allaker, Robert P; Yang, Ke

2016-10-01

The aim of this study was to fabricate a novel coping metal CoCrCu alloy using a selective laser melting (SLM) technique with antimicrobial and antibiofilm activities and to investigate its microstructure, mechanical properties, corrosion resistance and biocompatibility. Novel CoCrCu alloy was fabricated using SLM from a mixture of commercial CoCr based alloy and elemental Cu powders. SLM CoCr without Cu served as control. Antibacterial activity was analyzed using standard antimicrobial tests, and antibiofilm properties were investigated using confocal laser scanning microscope. Cu distribution and microstructure were determined using scanning electron microscope, optical microscopy and X-ray diffraction. Corrosion resistance was evaluated by potential dynamic polarization and biocompatibility measured using an MTT assay. SLM CoCrCu alloys were found to be bactericidal and able to inhibit biofilm formation. Other factors such as microstructure, mechanical properties, corrosion resistance and biocompatibility were similar to those of SLM CoCr alloys. The addition of appropriate amounts of Cu not only maintains normal beneficial properties of CoCr based alloys, but also provides SLM CoCrCu alloys with excellent antibacterial and antibiofilm capabilities. This material has the potential to be used as a coping metal for dental applications. Copyright © 2016 Elsevier B.V. All rights reserved.

Dimensional accuracy of internal cooling channel made by selective laser melting (SLM And direct metal laser sintering (DMLS processes in fabrication of internally cooled cutting tools

Directory of Open Access Journals (Sweden)

Ghani S. A. C.

2017-01-01

Full Text Available Selective laser melting(SLM and direct metal laser sintering(DMLS are preferred additive manufacturing processes in producing complex physical products directly from CAD computer data, nowadays. The advancement of additive manufacturing promotes the design of internally cooled cutting tool for effectively used in removing generated heat in metal machining. Despite the utilisation of SLM and DMLS in a fabrication of internally cooled cutting tool, the level of accuracy of the parts produced remains uncertain. This paper aims at comparing the dimensional accuracy of SLM and DMLS in machining internally cooled cutting tool with a special focus on geometrical dimensions such as hole diameter. The surface roughness produced by the two processes are measured with contact perthometer. To achieve the objectives, geometrical dimensions of identical tool holders for internally cooled cutting tools fabricated by SLM and DMLS have been determined by using digital vernier calliper and various magnification of a portable microscope. In the current study, comparing internally cooled cutting tools made of SLM and DMLS showed that generally the higher degree of accuracy could be obtained with DMLS process. However, the observed differences in surface roughness between SLM and DMLS in this study were not significant. The most obvious finding to emerge from this study is that the additive manufacturing processes selected for fabricating the tool holders for internally cooled cutting tool in this research are capable of producing the desired internal channel shape of internally cooled cutting tool.

Effects of ZrB{sub 2} on substructure and wear properties of laser melted in situ ZrB{sub 2p}/6061Al composites

Energy Technology Data Exchange (ETDEWEB)

Zeng, Yida [School of Material Science and Engineering, Tianjin University, Tianjin 300072 (China); State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China); Chao, Yuhjin [School of Material Science and Engineering, Tianjin University, Tianjin 300072 (China); Department of Mechanical Engineering, University of South Carolina, Columbia, SC 29208 (United States); Luo, Zhen, E-mail: lz@tju.edu.cn [School of Material Science and Engineering, Tianjin University, Tianjin 300072 (China); State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China); Cai, Yangchuan [School of Material Science and Engineering, Tianjin University, Tianjin 300072 (China); State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China); Huang, Yongxian [State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China)

2016-03-01

Graphical abstract: - Highlights: • Laser beam partly disperses ZrB{sub 2} particle clusters and showing dispersed particles state after matrix solidification. • Laser melting process narrower cellular spacing in composites than AA6061 matrix. • Compared with matrix alloy, crystal orientation near melted layer edge of the composites is almost random duo to heterogeneous nucleation in melt and pinning effect of laser dispersed ZrB{sub 2} nanoparticles at solidification front. • Laser melted layer shows better wear properties than matrix and composite without laser melting. - Abstract: Aluminum matrix composites reinforced by in situ ZrB{sub 2} particles were successfully fabricated from an Al-KBF{sub 4}-K{sub 2}ZrF{sub 6} system via a direct melt reaction. A laser surface melting strategy is used to improve the surface strength of the in situ ZrB{sub 2p}/6061Al composite, which includes a series of laser-melted composites with different laser power processed by a 2 kW YAG laser generator. XRD and EDS results demonstrated the existence of ZrB{sub 2} nanoparticles in the composite. After laser melting, the penetration depth of the molten pool increases with increasing power density. OM and SEM analysis indicate that the laser melting process yields narrower cellular spacing of the matrix and partly disperses the ZrB{sub 2} particle clusters. Compared with laser-melted matrix alloys, the crystal orientations near the melted layers edge of the composite are almost random due to heterogeneous nucleation in the melt and the pinning effect of laser-dispersed ZrB{sub 2} nanoparticles at the solidification front. Wear test results show that the laser melted layer performs better at wear resistance than both the substrate and the matrix AA6061 by measuring wear mass loss. Compared with composite samples prepared without laser melting, the wear mass loss of the laser melted composites decreased from 61 to 56 mg under a load of 98 N for 60 min.

Neutron Imaging for Selective Laser Melting Inconel Hardware with Internal Passages

Science.gov (United States)

Tramel, Terri L.; Norwood, Joseph K.; Bilheux, Hassina

2014-01-01

Additive Manufacturing is showing great promise for the development of new innovative designs and large potential life cycle cost reduction for the Aerospace Industry. However, more development work is required to move this technology into space flight hardware production. With selective laser melting (SLM), hardware that once consisted of multiple, carefully machined and inspected pieces, joined together can be made in one part. However standard inspection techniques cannot be used to verify that the internal passages are within dimensional tolerances or surface finish requirements. NASA/MSFC traveled to Oak Ridge National Lab's (ORNL) Spallation Neutron Source to perform some non-destructive, proof of concept imaging measurements to assess the capabilities to understand internal dimensional tolerances and internal passages surface roughness. This presentation will describe 1) the goals of this proof of concept testing, 2) the lessons learned when designing and building these Inconel 718 test specimens to minimize beam time, 3) the neutron imaging test setup and test procedure to get the images, 4) the initial results in images, volume and a video, 4) the assessment of using this imaging technique to gather real data for designing internal flow passages in SLM manufacturing aerospace hardware, and lastly 5) how proper cleaning of the internal passages is critically important. In summary, the initial results are very promising and continued development of a technique to assist in SLM development for aerospace components is desired by both NASA and ORNL. A plan forward that benefits both ORNL and NASA will also be presented, based on the promising initial results. The initial images and volume reconstruction showed that clean, clear images of the internal passages geometry are obtainable. These clear images of the internal passages of simple geometries will be compared to the build model to determine any differences. One surprising result was that a new cleaning

Microstructure and mechanical behavior of pulsed laser surface melted AISI D2 cold work tool steel

International Nuclear Information System (INIS)

Yasavol, N.; Abdollah-zadeh, A.; Ganjali, M.; Alidokht, S.A.

2013-01-01

Highlights: ► Melted zone contained fine dendrites in the bottom and equiaxed grains on the top. ► Microstructural refinements of PLSM led to microhardness enhancement. ► Higher scanning rate and lower laser energy were more effective to refine the microstructure. - Abstract: D2 cold work tool steel (CWTS) was subjected to pulse laser surface melting (PLSM) at constant frequency of 20 Hz Nd: YAG laser with different energies, scanning rate and pulse durations radiated to the surface. Characterizing the PLSM, with optical and field emission scanning electron microscopy, electron backscattered diffraction and surface hardness mapping technique was used to evaluate the microhardness and mechanical behavior of different regions of melting pool. Increasing laser energy and reducing the laser scanning rate results in deeper melt pool formation. Moreover, PLSM has led to entirely dissolution of the carbides and re-solidification of cellular/dendritic structure of a fine scale surrounded by a continuous interdendritic network. This caused an increase in surface microhardness, 2–4 times over that of the base metal.

Microstructure and mechanical behavior of pulsed laser surface melted AISI D2 cold work tool steel

Energy Technology Data Exchange (ETDEWEB)

Yasavol, N. [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Abdollah-zadeh, A., E-mail: zadeh@modares.ac.ir [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Ganjali, M. [Materials and Energy Research Center, P.O. Box 14155-4777, Karaj (Iran, Islamic Republic of); Alidokht, S.A. [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of)

2013-01-15

Highlights: Black-Right-Pointing-Pointer Melted zone contained fine dendrites in the bottom and equiaxed grains on the top. Black-Right-Pointing-Pointer Microstructural refinements of PLSM led to microhardness enhancement. Black-Right-Pointing-Pointer Higher scanning rate and lower laser energy were more effective to refine the microstructure. - Abstract: D2 cold work tool steel (CWTS) was subjected to pulse laser surface melting (PLSM) at constant frequency of 20 Hz Nd: YAG laser with different energies, scanning rate and pulse durations radiated to the surface. Characterizing the PLSM, with optical and field emission scanning electron microscopy, electron backscattered diffraction and surface hardness mapping technique was used to evaluate the microhardness and mechanical behavior of different regions of melting pool. Increasing laser energy and reducing the laser scanning rate results in deeper melt pool formation. Moreover, PLSM has led to entirely dissolution of the carbides and re-solidification of cellular/dendritic structure of a fine scale surrounded by a continuous interdendritic network. This caused an increase in surface microhardness, 2-4 times over that of the base metal.

Rapid additive manufacturing of MR compatible multipinhole collimators with selective laser melting of tungsten powder.

Science.gov (United States)

Deprez, Karel; Vandenberghe, Stefaan; Van Audenhaege, Karen; Van Vaerenbergh, Jonas; Van Holen, Roel

2013-01-01

The construction of complex collimators with a high number of oblique pinholes is very labor intensive, expensive or is sometimes impossible with the current available techniques (drilling, milling or electric discharge machining). All these techniques are subtractive: one starts from solid plates and the material at the position of the pinholes is removed. The authors used a novel technique for collimator construction, called metal additive manufacturing. This process starts with a solid piece of tungsten on which a first layer of tungsten powder is melted. Each subsequent layer is then melted on the previous layer. This melting is done by selective laser melting at the locations where the CAD design file defines solid material. A complex collimator with 20 loftholes with 500 μm diameter pinhole opening was designed and produced (16 mm thick and 70 × 52 mm(2) transverse size). The density was determined, the production accuracy was measured (GOM ATOS II Triple Scan, Nikon AZ100M microscope, Olympus IMT200 microscope). Point source measurements were done by mounting the collimator on a SPECT detector. Because there is increasing interest in dual-modality SPECT-MR imaging, the collimator was also positioned in a 7T MRI scanner (Bruker Pharmascan). A uniform phantom was acquired using T1, T2, and T2* sequences to check for artifacts or distortion of the phantom images due to the collimator presence. Additionally, three tungsten sample pieces (250, 500, and 750 μm thick) were produced. The density, attenuation (140 keV beam), and uniformity (GE eXplore Locus SP micro-CT) of these samples were measured. The density of the collimator was equal to 17.31 ± 0.10 g∕cm(3) (89.92% of pure tungsten). The production accuracy ranges from -260 to +650 μm. The aperture positions have a mean deviation of 5 μm, the maximum deviation was 174 μm and the minimum deviation was -122 μm. The mean aperture diameter is 464 ± 19 μm. The calculated and measured sensitivity and

The biocompatibility of dense and porous Nickel-Titanium produced by selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Habijan, T., E-mail: Tim.Habijan@rub.de [Surgical Research, Department of Surgery, BG Kliniken Bergmannsheil, Ruhr-University Bochum, Buerkle-de-la-Camp-Platz 1, 44789 Bochum (Germany); Haberland, C.; Meier, H. [Institute Product and Service Engineering, Ruhr-University Bochum (Germany); Frenzel, J. [Institute for Materials, Ruhr-University Bochum (Germany); Wittsiepe, J. [Department of Hygiene, Social and Environmental Medicine, Ruhr-University Bochum (Germany); Wuwer, C.; Greulich, C.; Schildhauer, T.A.; Koeller, M. [Surgical Research, Department of Surgery, BG Kliniken Bergmannsheil, Ruhr-University Bochum, Buerkle-de-la-Camp-Platz 1, 44789 Bochum (Germany)

2013-01-01

Nickel-Titanium shape memory alloys (NiTi-SMA) are of biomedical interest due to their unusual range of pure elastic deformability and their elastic modulus, which is closer to that of bone than any other metallic or ceramic material. Newly developed porous NiTi, produced by Selective Laser Melting (SLM), is currently under investigation as a potential carrier material for human mesenchymal stem cells (hMSC). SLM enables the production of highly complex and tailor-made implants for patients on the basis of CT data. Such implants could be used for the reconstruction of the skull, face, or pelvis. hMSC are a promising cell type for regenerative medicine and tissue engineering due to their ability to support the regeneration of critical size bone defects. Loading porous SLM-NiTi implants with autologous hMSC may enhance bone growth and healing for critical bone defects. The purpose of this study was to assess whether porous SLM-NiTi is a suitable carrier for hMSC. Specimens of varying porosity and surface structure were fabricated via SLM. hMSC were cultured for 8 days on NiTi specimens, and cell viability was analyzed using two-color fluorescence staining. Viable cells were detected on all specimens after 8 days of cell culture. Cell morphology and surface topography were analyzed by scanning electron microscopy (SEM). Cell morphology and surface topology were dependent on the orientation of the specimens during SLM production. The Nickel ion release can be reduced significantly by aligned laser processing conditions. The presented results clearly attest that both dense SLM-NiTi and porous SLM-NiTi are suitable carriers for hMSC. Nevertheless, before carrying out in vivo studies, some work on optimization of the manufacturing process and post-processing is required. - Highlights: Black-Right-Pointing-Pointer Specimens, varying in porosity and surface structure were produced via SLM. Black-Right-Pointing-Pointer Biocompatibility of these specimens was analyzed. Black

The biocompatibility of dense and porous Nickel–Titanium produced by selective laser melting

International Nuclear Information System (INIS)

Habijan, T.; Haberland, C.; Meier, H.; Frenzel, J.; Wittsiepe, J.; Wuwer, C.; Greulich, C.; Schildhauer, T.A.; Köller, M.

2013-01-01

Nickel–Titanium shape memory alloys (NiTi-SMA) are of biomedical interest due to their unusual range of pure elastic deformability and their elastic modulus, which is closer to that of bone than any other metallic or ceramic material. Newly developed porous NiTi, produced by Selective Laser Melting (SLM), is currently under investigation as a potential carrier material for human mesenchymal stem cells (hMSC). SLM enables the production of highly complex and tailor-made implants for patients on the basis of CT data. Such implants could be used for the reconstruction of the skull, face, or pelvis. hMSC are a promising cell type for regenerative medicine and tissue engineering due to their ability to support the regeneration of critical size bone defects. Loading porous SLM-NiTi implants with autologous hMSC may enhance bone growth and healing for critical bone defects. The purpose of this study was to assess whether porous SLM-NiTi is a suitable carrier for hMSC. Specimens of varying porosity and surface structure were fabricated via SLM. hMSC were cultured for 8 days on NiTi specimens, and cell viability was analyzed using two-color fluorescence staining. Viable cells were detected on all specimens after 8 days of cell culture. Cell morphology and surface topography were analyzed by scanning electron microscopy (SEM). Cell morphology and surface topology were dependent on the orientation of the specimens during SLM production. The Nickel ion release can be reduced significantly by aligned laser processing conditions. The presented results clearly attest that both dense SLM-NiTi and porous SLM-NiTi are suitable carriers for hMSC. Nevertheless, before carrying out in vivo studies, some work on optimization of the manufacturing process and post-processing is required. - Highlights: ► Specimens, varying in porosity and surface structure were produced via SLM. ► Biocompatibility of these specimens was analyzed. ► All specimens were completely coated with a layer

Investigation of the High-Cycle Fatigue Life of Selective Laser Melted and Hot Isostatically Pressed Ti-6Al-4v

Science.gov (United States)

2015-03-26

marketed for production of parts with metal alloys: electron-beam melting and laser sintering (LS) [3, 10, 36]. The primary distinction between EBM and LS...staircase method described in ASTM STP 588 [68]. The first specimen in a staircase test is tested at a maximum stress level corresponding to the

Exploration of the fragmentation of laser shock-melted aluminum using x-ray backlighting

Directory of Open Access Journals (Sweden)

Lin Zhang

2016-05-01

Full Text Available The fragmentation of shock-melted metal material is an important scientific problem in shock physics and is suitable for experimentally investigating by the laser-driven x-ray backlighting technique. This letter reports on the exploration of laser shock-melted aluminum fragmentation by means of x-ray backlighting at the SGII high energy facility in China. High-quality and high-resolution radiographs with negligible motion blur were obtained and these images enabled analysis of the mass distribution of the fragmentation product.

Laser melt injection of hard ceramic particles into Al and Ti alloys - processing, microstructure and mechanical behavior

NARCIS (Netherlands)

Ocelik, V; Nijman, S.; van Ingen, R; Oliveira, U; De Hosson, J Th M

2003-01-01

The conditions for a successful Laser Melt Injection (LMI) of SiC and WC particles into the melt pool of Al8Si and Ti6Al4V alloys were studied exptl. and theor. by FEM calcns. The laser employed is a high power Nd:YAG. The formation of a relatively thick aluminum oxide layer on the Al melt surface

Study of Material Consolidation at Higher Throughput Parameters in Selective Laser Melting of Inconel 718

Science.gov (United States)

Prater, Tracie

2016-01-01

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid

Effect of complex alloying of powder materials on properties of laser melted surface layers

International Nuclear Information System (INIS)

Tesker, E.I.; Gur'ev, V.A.; Elistratov, V.S.; Savchenko, A.N.

2001-01-01

Quality and properties of laser melted surface layers produced using self-fluxing powder mixture of Ni-Cr-B-Si system and the same powders with enhanced Fe content alloyed with Co, Ti, Nb, Mo have been investigated. Composition of powder material is determined which does not cause of defect formation under laser melting and makes possible to produce a good mechanical and tribological properties of treated surface [ru

Image analysis as an improved melting criterion in laser-heated diamond anvil cell

OpenAIRE

Salem, Ran; Matityahu, Shlomi; Melchior, Aviva; Nikolaevsky, Mark; Noked, Ori; Sterer, Eran

2015-01-01

The precision of melting curve measurements using laser-heated diamond anvil cell (LHDAC) is largely limited by the correct and reliable determination of the onset of melting. We present a novel image analysis of speckle interference patterns in the LHDAC as a way to define quantitative measures which enable an objective determination of the melting transition. Combined with our low-temperature customized IR pyrometer, designed for measurements down to 500K, our setup allows studying the melt...

Selective removal of CuIn1−xGaxSe2 absorber layer with no edge melting using a nanosecond Nd : YAG laser

International Nuclear Information System (INIS)

Lee, S H; Kim, C K; In, J H; Jeong, S H; Shim, H S

2013-01-01

This paper reports that selective removal of a CuIn 1−x Ga x Se 2 (CIGS) thin film on a Mo-coated glass substrate can be achieved with no edge melting or damage of the Mo layer using a nanosecond Nd : YAG laser with a wavelength of 1064 nm. It is shown that the two crucial parameters that determine the possibility of clean removal of only the CIGS layer are Ga concentration of the CIGS film and laser fluence. For CIGS films with Ga/(Ga+In) ratio greater than about 0.2 for which the band gap energy is close to or over the photon energy (1.17 eV), laser-induced thermal expansion proved to be the mechanism of film removal that drives an initial bulging of the film and then fracture into tens of micrometre sized fragments as observed in in situ shadowgraph images. The fracture-type removal of CIGS films was further verified by scanning electron micrographs of the craters showing that the original shapes of the CIGS polycrystals remain intact along the crater rim. A numerical simulation of film temperature under the irradiation conditions of selective removal was carried out to show that the magnitude of induced thermal stress within the film closely agreed to the yield strength of the CIGS thin film. The results confirmed that a nanosecond laser could be a better choice for P2 and P3 scribing of CIGS thin films if process conditions are properly determined. (paper)

In situ elaboration of a binary Ti-26Nb alloy by selective laser melting of elemental titanium and niobium mixed powders.

Science.gov (United States)

Fischer, M; Joguet, D; Robin, G; Peltier, L; Laheurte, P

2016-05-01

Ti-Nb alloys are excellent candidates for biomedical applications such as implantology and joint replacement because of their very low elastic modulus, their excellent biocompatibility and their high strength. A low elastic modulus, close to that of the cortical bone minimizes the stress shielding effect that appears subsequent to the insertion of an implant. The objective of this study is to investigate the microstructural and mechanical properties of a Ti-Nb alloy elaborated by selective laser melting on powder bed of a mixture of Ti and Nb elemental powders (26 at.%). The influence of operating parameters on porosity of manufactured samples and on efficacy of dissolving Nb particles in Ti was studied. The results obtained by optical microscopy, SEM analysis and X-ray microtomography show that the laser energy has a significant effect on the compactness and homogeneity of the manufactured parts. Homogeneous and compact samples were obtained for high energy levels. Microstructure of these samples has been further characterized. Their mechanical properties were assessed by ultrasonic measures and the Young's modulus found is close to that of classically elaborated Ti-26 Nbingot. Copyright © 2016 Elsevier B.V. All rights reserved.

Intragranular cellular segregation network structure strengthening 316L stainless steel prepared by selective laser melting

Science.gov (United States)

Zhong, Yuan; Liu, Leifeng; Wikman, Stefan; Cui, Daqing; Shen, Zhijian

2016-03-01

A feasibility study was performed to fabricate ITER In-Vessel components by Selective Laser Melting (SLM) supported by Fusion for Energy (F4E). Almost fully dense 316L stainless steel (SS316L) components were prepared from gas-atomized powder and with optimized SLM processing parameters. Tensile tests and Charpy-V tests were carried out at 22 °C and 250 °C and the results showed that SLM SS316L fulfill the RCC-MR code. Microstructure characterization reveals the presence of hierarchical macro-, micro- and nano-structures in as-built samples that were very different from SS316L microstructures prepared by other established methods. The formation of a characteristic intragranular cellular segregation network microstructure appears to contribute to the increase of yield strength without losing ductility. Silicon oxide nano-inclusions were formed during the SLM process that generated a micro-hardness fluctuation in the building direction. The combined influence of a cellular microstructure and the nano-inclusions constraints the size of ductile dimples to nano-scale. The crack propagation is hindered by a pinning effect that improves the defect-tolerance of the SLM SS316L. This work proves that it was possible to manufacture SS316L with properties suitable for ITER First Wall panels. Further studies on irradiation properties of SLM SS316L and manufacturing of larger real-size components are needed.

Microstructure and mechanical properties of stainless steel/calcium silicate composites manufactured by selective laser melting.

Science.gov (United States)

Zheng, Zeng; Wang, Lianfeng; Jia, Min; Cheng, Lingyu; Yan, Biao

2017-02-01

Selective laser melting (SLM) is raised as one kind of additive manufacturing (AM) which is based on the discrete-stacking concept. This technique can fabricate advanced composites with desirable properties directly from 3D CAD data. In this research, 316L stainless steel (316L SS) and different fractions of calcium silicate (CaSiO 3 ) composites (weight fractions of calcium silicate are 0%, 5%,10% and 15%, respectively) were prepared by SLM technique with a purpose to develop biomedical metallic materials. The relative density, tensile, microhardness and elastic modulus of the composites were tested, their microstructures and fracture morphologies were observed using optical microscope (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). It was found that the addition of CaSiO 3 particles influenced the microstructure and mechanical properties of specimens significantly. The CaSiO 3 precipitates from the overlap of adjacent tracks and became the origin of the defects. The tensile strength of specimens range 320-722MPa. The microhardness and elastic modulus are around 250HV and 215GPa respectively. These composites were ductile materials and the fracture mode of the composites was mixed mode of ductile and brittle fracture. The 316L SS/CaSiO 3 composites can be a potential biomedical metallic materials in the medical field. Copyright © 2016. Published by Elsevier B.V.

Mechanical Properties of Optimized Diamond Lattice Structure for Bone Scaffolds Fabricated via Selective Laser Melting

Science.gov (United States)

Zhang, David Z.; Zhang, Peng; Zhao, Miao; Jafar, Salman

2018-01-01

Developments in selective laser melting (SLM) have enabled the fabrication of periodic cellular lattice structures characterized by suitable properties matching the bone tissue well and by fluid permeability from interconnected structures. These multifunctional performances are significantly affected by cell topology and constitutive properties of applied materials. In this respect, a diamond unit cell was designed in particular volume fractions corresponding to the host bone tissue and optimized with a smooth surface at nodes leading to fewer stress concentrations. There were 33 porous titanium samples with different volume fractions, from 1.28 to 18.6%, manufactured using SLM. All of them were performed under compressive load to determine the deformation and failure mechanisms, accompanied by an in-situ approach using digital image correlation (DIC) to reveal stress–strain evolution. The results showed that lattice structures manufactured by SLM exhibited comparable properties to those of trabecular bone, avoiding the effects of stress-shielding and increasing longevity of implants. The curvature of optimized surface can play a role in regulating the relationship between density and mechanical properties. Owing to the release of stress concentration from optimized surface, the failure mechanism of porous titanium has been changed from the pattern of bottom-up collapse by layer (or cell row) to that of the diagonal (45°) shear band, resulting in the significant enhancement of the structural strength. PMID:29510492

Mechanical Properties of Optimized Diamond Lattice Structure for Bone Scaffolds Fabricated via Selective Laser Melting.

Science.gov (United States)

Liu, Fei; Zhang, David Z; Zhang, Peng; Zhao, Miao; Jafar, Salman

2018-03-03

Developments in selective laser melting (SLM) have enabled the fabrication of periodic cellular lattice structures characterized by suitable properties matching the bone tissue well and by fluid permeability from interconnected structures. These multifunctional performances are significantly affected by cell topology and constitutive properties of applied materials. In this respect, a diamond unit cell was designed in particular volume fractions corresponding to the host bone tissue and optimized with a smooth surface at nodes leading to fewer stress concentrations. There were 33 porous titanium samples with different volume fractions, from 1.28 to 18.6%, manufactured using SLM. All of them were performed under compressive load to determine the deformation and failure mechanisms, accompanied by an in-situ approach using digital image correlation (DIC) to reveal stress-strain evolution. The results showed that lattice structures manufactured by SLM exhibited comparable properties to those of trabecular bone, avoiding the effects of stress-shielding and increasing longevity of implants. The curvature of optimized surface can play a role in regulating the relationship between density and mechanical properties. Owing to the release of stress concentration from optimized surface, the failure mechanism of porous titanium has been changed from the pattern of bottom-up collapse by layer (or cell row) to that of the diagonal (45°) shear band, resulting in the significant enhancement of the structural strength.

Metallurgical and interfacial characterization of PFM Co-Cr dental alloys fabricated via casting, milling or selective laser melting.

Science.gov (United States)

Al Jabbari, Y S; Koutsoukis, T; Barmpagadaki, X; Zinelis, S

2014-04-01

Bulk and interfacial characterization of porcelain fused to metal (PFM) Co-Cr dental alloys fabricated via conventional casting, milling and selective laser melting. Three groups of metallic specimens made of PFM Co-Cr dental alloys were prepared using casting (CST), milling (MIL) and selective laser sintering (SLM). The porosity of the groups was evaluated using X-ray scans. The microstructures of the specimens were evaluated via SEM examination, EDX and XRD analysis. Vickers hardness testing was utilized to measure the hardness of the specimens. Interfacial characterization was conducted on the porcelain-covered specimens from each group to test the elemental distribution with and without the application of INmetalbond. The elemental distribution of the probed elements was assessed using EDX line profile analysis. Hardness results were statistically analyzed using one-way ANOVA and Holm-Sidak's method (α=0.05). X-ray radiography revealed the presence of porosity only in the CST group. Different microstructures were identified among the groups. Together with the γ phase matrix, a second phase, believed to be the Co3Mo phase, was also observed by SEM and subsequent XRD analysis. Cr7C3 and Cr23C6 carbides were also identified via XRD analysis in the CST and MIL groups. The hardness values were 320±12 HV, 297±5 HV and 371±10 HV, and statistically significant differences were evident among the groups. The microstructure and hardness of PFM Co-Cr dental alloys are dependent on the manufacturing technique employed. Given the differences in microstructural and hardness properties among the tested groups, further differences in their clinical behavior are anticipated. Copyright © 2014 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Supplementary Microstructural Features Induced During Laser Surface Melting of Thermally Sprayed Inconel 625 Coatings

Science.gov (United States)

Ahmed, Nauman; Voisey, K. T.; McCartney, D. G.

2014-02-01

Laser surface melting of thermally sprayed coatings has the potential to enhance their corrosion properties by incorporating favorable microstructural changes. Besides homogenizing the as-sprayed structure, laser melting may induce certain microstructural modifications (i.e., supplementary features) in addition to those that directly improve the corrosion performance. Such features, being a direct result of the laser treatment process, are described in this paper which is part of a broader study in which high velocity oxy-fuel sprayed Inconel 625 coatings on mild-steel substrates were treated with a diode laser and the modified microstructure characterized using optical and scanning electron microscopy and x-ray diffraction. The laser treated coating features several different zones, including a region with a microstructure in which there is a continuous columnar dendritic structure through a network of retained oxide stringers.

Microstructure and mechanical behavior of pulsed laser surface melted AISI D2 cold work tool steel

Science.gov (United States)

Yasavol, N.; Abdollah-zadeh, A.; Ganjali, M.; Alidokht, S. A.

2013-01-01

D2 cold work tool steel (CWTS) was subjected to pulse laser surface melting (PLSM) at constant frequency of 20 Hz Nd: YAG laser with different energies, scanning rate and pulse durations radiated to the surface. Characterizing the PLSM, with optical and field emission scanning electron microscopy, electron backscattered diffraction and surface hardness mapping technique was used to evaluate the microhardness and mechanical behavior of different regions of melting pool. Increasing laser energy and reducing the laser scanning rate results in deeper melt pool formation. Moreover, PLSM has led to entirely dissolution of the carbides and re-solidification of cellular/dendritic structure of a fine scale surrounded by a continuous interdendritic network. This caused an increase in surface microhardness, 2-4 times over that of the base metal.

Influence of Ultrasonic Surface Rolling on Microstructure and Wear Behavior of Selective Laser Melted Ti-6Al-4V Alloy

Directory of Open Access Journals (Sweden)

Zhen Wang

2017-10-01

Full Text Available The present article studied the effect of ultrasonic surface rolling process (USRP on the microstructure and wear behavior of a selective laser melted Ti-6Al-4V alloy. Surface characteristics were investigated using optical microscope, nano-indentation, scanning electron microscope, transmission electron microscope and laser scanning confocal microscope. Results indicated that the thickness of pore-free surfaces increased to 100~200 μm with the increasing ultrasonic surface rolling numbers. Severe work hardening occurred in the densified layer, resulting in the formation of refined grains, dislocation walls and deformation twins. After 1000 N 6 passes, about 15.5% and 14.1% increment in surficial Nano-hardness and Vickers-hardness was obtained, respectively. The hardness decreased gradually from the top surface to the substrate. Wear tests revealed that the friction coefficient declined from 0.74 (polished surface to 0.64 (USRP treated surface and the wear volume reduced from 0.205 mm−3 to 0.195 mm−3. The difference in wear volume between USRP treated and polished samples increased with sliding time. The enhanced wear resistance was concluded to be associated with the improvement of hardness and shear resistance and also the inhibition of delamination initiation.

Simulation Analysis and Performance Study of CoCrMo Porous Structure Manufactured by Selective Laser Melting

Science.gov (United States)

Guoqing, Zhang; Junxin, Li; Jin, Li; Chengguang, Zhang; Zefeng, Xiao

2018-04-01

To fabricate porous implants with improved biocompatibility and mechanical properties that are matched to their application using selective laser melting (SLM), flow within the mold and compressive properties and performance of the porous structures must be comprehensively studied. Parametric modeling was used to build 3D models of octahedron and hexahedron structures. Finite element analysis was used to evaluate the mold flow and compressive properties of the parametric porous structures. A DiMetal-100 SLM molding apparatus was used to manufacture the porous structures and the results evaluated by light microscopy. The results showed that parametric modeling can produce robust models. Square structures caused higher blood cell adhesion than cylindrical structures. "Vortex" flow in square structures resulted in chaotic distribution of blood elements, whereas they were mostly distributed around the connecting parts in the cylindrical structures. No significant difference in elastic moduli or compressive strength was observed in square and cylindrical porous structures of identical characteristics. Hexahedron, square and cylindrical porous structures had the same stress-strain properties. For octahedron porous structures, cylindrical structures had higher stress-strain properties. Using these modeling and molding results, an important basis for designing and the direct manufacture of fixed biological implants is provided.

Simulation Analysis and Performance Study of CoCrMo Porous Structure Manufactured by Selective Laser Melting

Science.gov (United States)

Guoqing, Zhang; Junxin, Li; Jin, Li; Chengguang, Zhang; Zefeng, Xiao

2018-05-01

To fabricate porous implants with improved biocompatibility and mechanical properties that are matched to their application using selective laser melting (SLM), flow within the mold and compressive properties and performance of the porous structures must be comprehensively studied. Parametric modeling was used to build 3D models of octahedron and hexahedron structures. Finite element analysis was used to evaluate the mold flow and compressive properties of the parametric porous structures. A DiMetal-100 SLM molding apparatus was used to manufacture the porous structures and the results evaluated by light microscopy. The results showed that parametric modeling can produce robust models. Square structures caused higher blood cell adhesion than cylindrical structures. "Vortex" flow in square structures resulted in chaotic distribution of blood elements, whereas they were mostly distributed around the connecting parts in the cylindrical structures. No significant difference in elastic moduli or compressive strength was observed in square and cylindrical porous structures of identical characteristics. Hexahedron, square and cylindrical porous structures had the same stress-strain properties. For octahedron porous structures, cylindrical structures had higher stress-strain properties. Using these modeling and molding results, an important basis for designing and the direct manufacture of fixed biological implants is provided.

Finite element modeling of melting and fluid flow in the laser-heated diamond-anvil cell

Science.gov (United States)

Gomez-Perez, N.; Rodriguez, J. F.; McWilliams, R. S.

2017-04-01

The laser-heated diamond anvil cell is widely used in the laboratory study of materials behavior at high-pressure and high-temperature, including melting curves and liquid properties at extreme conditions. Laser heating in the diamond cell has long been associated with fluid-like motion in samples, which is routinely used to determine melting points and is often described as convective in appearance. However, the flow behavior of this system is poorly understood. A quantitative treatment of melting and flow in the laser-heated diamond anvil cell is developed here to physically relate experimental motion to properties of interest, including melting points and viscosity. Numerical finite-element models are used to characterize the temperature distribution, melting, buoyancy, and resulting natural convection in samples. We find that continuous fluid motion in experiments can be explained most readily by natural convection. Fluid velocities, peaking near values of microns per second for plausible viscosities, are sufficiently fast to be detected experimentally, lending support to the use of convective motion as a criterion for melting. Convection depends on the physical properties of the melt and the sample geometry and is too sluggish to detect for viscosities significantly above that of water at ambient conditions, implying an upper bound on the melt viscosity of about 1 mPa s when convective motion is detected. A simple analytical relationship between melt viscosity and velocity suggests that direct viscosity measurements can be made from flow speeds, given the basic thermodynamic and geometric parameters of samples are known.

Dynamic fragmentation of laser shock-melted tin: experiment and modelling

Energy Technology Data Exchange (ETDEWEB)

De Resseguier, T. [CNRS ENSMA, Lab Combust and Deton, F-86961 Futuroscope (France); Signor, L.; Dragon, A. [CNRS ENSMA, Mecan and Phys Mat Lab, F-86961 Futuroscope (France); Signor, L.; Roy, G. [CEA Valduc, 21 - Is-sur-Tille (France)

2010-07-01

Dynamic fragmentation of shock-loaded metals is an issue of considerable importance for both basic science and a variety of technological applications, such as pyrotechnics or inertial confinement fusion, the latter involving high energy laser irradiation of thin metallic shells. Whereas spall fracture in solid materials has been extensively studied for many years, little data can be found yet about the evolution of this phenomenon after partial or full melting on compression or on release. Here, we present an investigation of dynamic fragmentation in laser shock-melted tin, from the 'micro-spall' process (ejection of a cloud of fine droplets) occurring upon reflection of the compressive pulse from the target free surface, to the late rupture observed in the un-spalled melted layer (leading to the formation of larger spherical fragments). Experimental results consist of time-resolved velocity measurements and post-shock observations of recovered targets and fragments. They provide original information regarding the loss of tensile strength associated with melting, the cavitation mechanism likely to occur in the melted metal, the sizes of the subsequent fragments and their ejection velocities. A theoretical description based on an energetic approach adapted to the case of a liquid metal is implemented as a failure criterion in a one-dimensional hydro-code including a multi-phase equation of state for tin. The resulting predictions of the micro-spall process are compared with experimental data. In particular, the use of a new experimental technique to quantify the fragment size distributions leads to a much better agreement with theory than previously reported. Finally, a complementary approach focused on cavitation is proposed to evaluate the role of this phenomenon in the fragmentation of the melted metal. (authors)

Microstructures induced by excimer laser surface melting of the SiC{sub p}/Al metal matrix composite

Energy Technology Data Exchange (ETDEWEB)

Qian, D.S., E-mail: Daishu.qian@postgrad.manchester.ac.uk; Zhong, X.L.; Yan, Y.Z.; Hashimoto, T.; Liu, Z.

2017-08-01

Highlights: • Microstructural analysis of the excimer laser-melted SiC{sub p}/AA2124;. • Analytical, FEM, and SPH simulation of the laser-material interaction;. • Mechanism of the formation of the laser-induced microstructure. - Abstract: Laser surface melting (LSM) was carried out on the SiC{sub p}/Al metal matrix composite (MMC) using a KrF excimer laser with a fluence of 7 J/cm{sup 2}. The re-solidification microstructure was characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM) equipped with energy dispersive X-ray detector, and X-ray diffraction (XRD) analysis. It was found that a 2.5 μm thick melted layer was formed in the near-surface region, in which dissolution of the intermetallics and removal of the SiC particles occurred. The thermal and material response upon laser irradiation was simulated using three models, i.e. analytical model, finite element model (FEM) and smoothed-particle hydrodynamics (SPH) model. The effect of SiC particles on the LSM process, the mechanism of the SiC removal and the re-solidification microstructures in the melted layer were discussed. The simulation results were in good agreement with the experimental results and contributed to the generic understanding of the re-solidification microstructures induced by ns-pulsed lasers.

Chip bonding of low-melting eutectic alloys by transmitted laser radiation

Science.gov (United States)

Hoff, Christian; Venkatesh, Arjun; Schneider, Friedrich; Hermsdorf, Jörg; Bengsch, Sebastian; Wurz, Marc C.; Kaierle, Stefan; Overmeyer, Ludger

2017-06-01

Present-day thermode bond systems for the assembly of radio-frequency identification (RFID) chips are mechanically inflexible, difficult to control, and will not meet future manufacturing challenges sufficiently. Chip bonding, one of the key processes in the production of integrated circuits (ICs), has a high potential for optimization with respect to process duration and process flexibility. For this purpose, the technologies used, so far, are supposed to be replaced by a transmission laser-bonding process using low-melting eutectic alloys. In this study, successful bonding investigations of mock silicon chips and of RFID chips on flexible polymer substrates are presented using the low-melting eutectic alloy, 52In48Sn, and a laser with a wavelength of 2 μm.

Experimental investigation of hydrodynamics of melt layer during laser cutting of steel

Energy Technology Data Exchange (ETDEWEB)

Hirano, Koji; Fabbro, Remy, E-mail: hirano.koji@nsc.co.jp [PIMM Laboratory (Arts et Metiers ParisTech-CNRS), 151 Boulevard de l' Hopital 75013 Paris (France)

2011-03-16

In a laser cutting process, understanding of the hydrodynamics of melt layer is significant, because it is an important factor which controls the final quality. In this work, we observed the hydrodynamics of melt layer on a kerf front in the case of laser cutting of steel with an inert gas. The observation shows that the melt flow on the kerf front exhibits strong instability, depending on cutting velocity. In the intermediate range of velocities, the flow on the central part of the kerf front is continuous, whereas the flow along the sides is discontinuous. It is first confirmed that the instability in the side flow is the cause of striation initiation from the top part of the kerf. The origin of the instability is discussed in terms of instabilities in thermal dynamics and hydrodynamics. The proposed model shows reasonable agreement with experimental results.

The effect of laser surface melting on microstructure and corrosion behavior of friction stir welded aluminum alloy 2219

Science.gov (United States)

Ma, Shengchong; Zhao, Yong; Zou, Jiasheng; Yan, Keng; Liu, Chuan

2017-11-01

This study aimed to explore the electrochemical properties and microstructure of friction stir welds to understand the correlation between their properties and processing. Friction stir welding is a promising solid-state joining process for high-strength aluminum alloys (AA). Although friction stir welding (FSW) eliminates the problems of fusion welding due to the fact that it is performed below Tm, it causes severe plastic deformation in the material. Some AA welded by FSW exhibit relatively poor corrosion resistance. In this research, the corrosion resistance of such welds was enhanced through laser surface melting. A friction stir weld of AA 2219 was laser melted. The melt depth and microstructure were observed using optical and scanning electron microscopy. The melt zone exhibited epitaxially grown columnar grains. The redistribution of elemental composition was analyzed using energy-dispersive spectroscopy. The anticorrosion properties of both laser-melted and original welds were studied in aqueous 3.5% NaCl solution using cyclic potentiodynamic polarization. The results indicated a noticeable increase in the pitting corrosion resistance after the laser treatment on the surface. The repassivation potential was nobler than the corrosion potential after the laser treatment, confirming that the resistance to pitting growth improved.

Laser-induced selective metallization of polypropylene doped with multiwall carbon nanotubes

Science.gov (United States)

Ratautas, Karolis; Gedvilas, Mindaugas; Stankevičiene, Ina; Jagminienė, Aldona; Norkus, Eugenijus; Pira, Nello Li; Sinopoli, Stefano; Račiukaitis, Gediminas

2017-08-01

Moulded interconnect devices (MID) offer the material, weight and cost saving by integration electronic circuits directly into polymeric components used in automotive and other consumer products. Lasers are used to write circuits directly by modifying the surface of polymers followed by an electroless metal plating. A new composite material - the polypropylene doped with multiwall carbon nanotubes was developed for the laser-induced selective metallization. Mechanism of surface activation by laser irradiation was investigated in details utilising pico- and nanoseconds lasers. Deposition of copper was performed in the autocatalytic electroless plating bath. The laser-activated polymer surfaces have been studied using the Raman spectroscopy and scanning electron microscope (SEM). Microscopic images revealed that surface becomes active only after its melting by a laser. Alterations in the Raman spectra of the D and G bands indicated the clustering of carbon additives in the composite material. Optimal laser parameters for the surface activation were found by measuring a sheet resistance of the finally metal-plated samples. A spatially selective copper plating was achieved with the smallest conductor line width of 22 μm at the laser scanning speed of 3 m/s and the pulse repetition rate of 100 kHz. Finally, the technique was validated by making functional electronic circuits by this MID approach.

[Design and fabrication of the custom-made titanium condyle by selective laser melting technology].

Science.gov (United States)

Chen, Jianyu; Luo, Chongdai; Zhang, Chunyu; Zhang, Gong; Qiu, Weiqian; Zhang, Zhiguang

2014-10-01

To design and fabricate the custom-made titanium mandibular condyle by the reverse engineering technology combined with selective laser melting (SLM) technology and to explore the mechanical properties of the SLM-processed samples and the application of the custom-made condyle in the temporomandibular joint (TMJ) reconstruction. The three-dimensional model of the mandibular condyle was obtained from a series of CT databases. The custom-made condyle model was designed by the reverse engineering software. The mandibular condyle was made of titanium powder with a particle size of 20-65 µm as the basic material and the processing was carried out in an argon atmosphere by the SLM machine. The yield strength, ultimate strength, bending strength, hardness, surface morphology and roughness were tested and analyzed. The finite element analysis (FEA) was used to analyze the stress distribution. The complex geometry and the surface of the custom-made condyle can be reproduced precisely by the SLM. The mechanical results showed that the yield strength, ultimate strength, bending strength and hardness were (559±14) MPa, (659±32) MPa, (1 067±42) MPa, and (212±4)HV, respectively. The surface roughness was reduced by sandblast treatment. The custom-made titanium condyle can be fabricated by SLM technology which is time-saving and highly digitized. The mechanical properties of the SLM sample can meet the requirements of surgical implant material in the clinic. The possibility of fabricating custom-made titanium mandibular condyle combined with the FEA opens new interesting perspectives for TMJ reconstruction.

Laser Beam Melting of Alumina: Effect of Absorber Additions

Science.gov (United States)

Moniz, Liliana; Colin, Christophe; Bartout, Jean-Dominique; Terki, Karim; Berger, Marie-Hélène

2018-03-01

Ceramic laser beam melting offers new manufacturing possibilities for complex refractory structures. Poor absorptivity in near infra-red wavelengths of oxide ceramics is overcome with absorber addition to ceramic powders. Absorbers affect powder bed densities and geometrical stability of melted tracks. Optimum absorber content is defined for Al2O3 by minimizing powder bed porosity, maximizing melting pool geometrical stability and limiting shrinkage. Widest stability fields are obtained with addition of 0.1 wt.% C and 0.5 wt.% β-SiC. Absorption coefficient values of Beer-Lambert law follow stability trends: they increase with C additions, whereas with β-SiC, a maximum is reached for 0.5 wt.%. Powder particle ejections are also identified. Compared to metallic materials, this ejection phenomenon can no longer be neglected when establishing a three-dimensional manufacturing strategy.

Enthalpy model for heating, melting, and vaporization in laser ablation

OpenAIRE

Vasilios Alexiades; David Autrique

2010-01-01

Laser ablation is used in a growing number of applications in various areas including medicine, archaeology, chemistry, environmental and materials sciences. In this work the heat transfer and phase change phenomena during nanosecond laser ablation of a copper (Cu) target in a helium (He) background gas at atmospheric pressure are presented. An enthalpy model is outlined, which accounts for heating, melting, and vaporization of the target. As far as we know, this is the first model th...

XCT analysis of the influence of melt strategies on defect population in Ti–6Al–4V components manufactured by Selective Electron Beam Melting

International Nuclear Information System (INIS)

Tammas-Williams, S.; Zhao, H.; Léonard, F.; Derguti, F.; Todd, I.; Prangnell, P.B.

2015-01-01

Selective Electron Beam Melting (SEBM) is a promising powder bed Additive Manufacturing technique for near-net-shape manufacture of high-value titanium components. However without post-manufacture HIPing the fatigue life of SEBM parts is currently dominated by the presence of porosity. In this study, the size, volume fraction, and spatial distribution of the pores in model samples have been characterised in 3D, using X-ray Computed Tomography, and correlated to the process variables. The average volume fraction of the pores (< 0.2%) was measured to be lower than that usually observed in competing processes, such as selective laser melting, but a strong relationship was found with the different beam strategies used to contour, and infill by hatching, a part section. The majority of pores were found to be small spherical gas pores, concentrated in the infill hatched region; this was attributed to the lower energy density and less focused beam used in the infill strategy allowing less opportunity for gas bubbles to escape the melt pool. Overall, increasing the energy density or focus of the beam was found to correlate strongly to a reduction in the level of gas porosity. Rarer irregular shaped pores were mostly located in the contour region and have been attributed to a lack of fusion between powder particles. - Graphical abstract: Display Omitted - Highlights: • Vast majority of defects detected were small spherical gas pores. • Gas bubbles trapped in the powder granules expand and coalesce in the melt pool. • Pores have been shown not to be randomly distributed. • Larger and deeper melt pools give more opportunity for gas to escape. • Minor changes to melt strategy result in significant reductions in pore population

XCT analysis of the influence of melt strategies on defect population in Ti–6Al–4V components manufactured by Selective Electron Beam Melting

Energy Technology Data Exchange (ETDEWEB)

Tammas-Williams, S., E-mail: Samuel.tammas-wiliams@manchester.ac.uk [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom); Department of Materials Science and Engineering, University of Sheffield, Sheffield S1 3JD (United Kingdom); Zhao, H. [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom); Department of Materials Science and Engineering, University of Sheffield, Sheffield S1 3JD (United Kingdom); Léonard, F. [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom); Derguti, F.; Todd, I. [Department of Materials Science and Engineering, University of Sheffield, Sheffield S1 3JD (United Kingdom); Prangnell, P.B. [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom)

2015-04-15

Selective Electron Beam Melting (SEBM) is a promising powder bed Additive Manufacturing technique for near-net-shape manufacture of high-value titanium components. However without post-manufacture HIPing the fatigue life of SEBM parts is currently dominated by the presence of porosity. In this study, the size, volume fraction, and spatial distribution of the pores in model samples have been characterised in 3D, using X-ray Computed Tomography, and correlated to the process variables. The average volume fraction of the pores (< 0.2%) was measured to be lower than that usually observed in competing processes, such as selective laser melting, but a strong relationship was found with the different beam strategies used to contour, and infill by hatching, a part section. The majority of pores were found to be small spherical gas pores, concentrated in the infill hatched region; this was attributed to the lower energy density and less focused beam used in the infill strategy allowing less opportunity for gas bubbles to escape the melt pool. Overall, increasing the energy density or focus of the beam was found to correlate strongly to a reduction in the level of gas porosity. Rarer irregular shaped pores were mostly located in the contour region and have been attributed to a lack of fusion between powder particles. - Graphical abstract: Display Omitted - Highlights: • Vast majority of defects detected were small spherical gas pores. • Gas bubbles trapped in the powder granules expand and coalesce in the melt pool. • Pores have been shown not to be randomly distributed. • Larger and deeper melt pools give more opportunity for gas to escape. • Minor changes to melt strategy result in significant reductions in pore population.

Fatigue strength of Co-Cr-Mo alloy clasps prepared by selective laser melting.

Science.gov (United States)

Kajima, Yuka; Takaichi, Atsushi; Nakamoto, Takayuki; Kimura, Takahiro; Yogo, Yoshiaki; Ashida, Maki; Doi, Hisashi; Nomura, Naoyuki; Takahashi, Hidekazu; Hanawa, Takao; Wakabayashi, Noriyuki

2016-06-01

We aimed to investigate the fatigue strength of Co-Cr-Mo clasps for removable partial dentures prepared by selective laser melting (SLM). The Co-Cr-Mo alloy specimens for tensile tests (dumbbell specimens) and fatigue tests (clasp specimens) were prepared by SLM with varying angles between the building and longitudinal directions (i.e., 0° (TL0, FL0), 45° (TL45, FL45), and 90° (TL90, FL90)). The clasp specimens were subjected to cyclic deformations of 0.25mm and 0.50mm for 10(6) cycles. The SLM specimens showed no obvious mechanical anisotropy in tensile tests and exhibited significantly higher yield strength and ultimate tensile strength than the cast specimens under all conditions. In contrast, a high degree of anisotropy in fatigue performance associated with the build orientation was found. For specimens under the 0.50mm deflection, FL90 exhibited significantly longer fatigue life (205,418 cycles) than the cast specimens (112,770 cycles). In contrast, the fatigue lives of FL0 (28,484 cycles) and FL45 (43,465 cycles) were significantly shorter. The surface roughnesses of FL0 and FL45 were considerably higher than those of the cast specimens, whereas there were no significant differences between FL90 and the cast specimens. Electron backscatter diffraction (EBSD) analysis indicated the grains of FL0 showed preferential close to orientation of the γ phase along the normal direction to the fracture surface. In contrast, the FL45 and FL90 grains showed no significant preferential orientation. Fatigue strength may therefore be affected by a number of factors, including surface roughness and crystal orientation. The SLM process is a promising candidate for preparing tough removable partial denture frameworks, as long as the appropriate build direction is adopted. Copyright © 2016 Elsevier Ltd. All rights reserved.

Two-dimensional model of laser alloying of binary alloy powder with interval of melting temperature

Science.gov (United States)

Knyzeva, A. G.; Sharkeev, Yu. P.

2017-10-01

The paper contains two-dimensional model of laser beam melting of powders from binary alloy. The model takes into consideration the melting of alloy in some temperature interval between solidus and liquidus temperatures. The external source corresponds to laser beam with energy density distributed by Gauss law. The source moves along the treated surface according to given trajectory. The model allows investigating the temperature distribution and thickness of powder layer depending on technological parameters.

Effect of Heat Treatment on Microstructure and Impact Toughness of Ti-6Al-4V Manufactured by Selective Laser Melting Process

Directory of Open Access Journals (Sweden)

Lee K.-A.

2017-06-01

Full Text Available This study manufactured Ti-6Al-4V alloy using one of the powder bed fusion 3D-printing processes, selective laser melting, and investigated the effect of heat treatment (650°C/3hrs on microstructure and impact toughness of the material. Initial microstructural observation identified prior-β grain along the building direction before and after heat treatment. In addition, the material formed a fully martensite structure before heat treatment, and after heat treatment, α and β phase were formed simultaneously. Charpy impact tests were conducted. The average impact energy measured as 6.0 J before heat treatment, and after heat treatment, the average impact energy increased by approximately 20% to 7.3 J. Fracture surface observation after the impact test showed that both alloys had brittle characteristics on macro levels, but showed ductile fracture characteristics and dimples at micro levels.

Phase selection during pulsed laser annealing of Fe-V alloys

International Nuclear Information System (INIS)

Perepezko, J.H.; Follstaedt, D.M.; Peercy, P.S.

1987-01-01

Pulsed laser melting of the low-temperature σ (tetragonal, D8/sub b/) phase has been used to generate a liquid undercooled with respect to the melting point of the higher-temperature, equilibrium α (bcc) solid solution in equiatomic Fe-V alloys. From calculations based on reported thermodynamic data and equilibrium transformation temperatures, the metastable melting point of the σ phase is about 1720 K for an Fe-50 at.% V alloy, which is 54 K below the melting temperature of the α phase. During rapid heating of well-annealed σ-phase material with a 30 ns laser pulse to above melt threshold, the σ → α reaction is suppressed, so that the melt zone is undercooled by -- 54 K with respect to the equilibrium α phase. The α phase nucleates from the undercooled molten surface layer and is retained during the subsequent rapid cooling (-- 10/sup 10/ K/s) because of the relatively sluggish α → σ transformation. X-ray diffraction (Read camera) and TEM identified the σ phase in the near-surface after melting σ with incident laser energies (1.0-1.41 J/cm/sup 2/) which are well above the melt threshold as determined by changes in reflectivity (-- 0.7 J/cm/sup 2/). The α phase nucleated from the undercooled liquid within -- 20 ns

Compensation strategy to reduce geometry and mechanics mismatches in porous biomaterials built with Selective Laser Melting.

Science.gov (United States)

Bagheri, Zahra S; Melancon, David; Liu, Lu; Johnston, R Burnett; Pasini, Damiano

2017-06-01

The accuracy of Additive Manufacturing processes in fabricating porous biomaterials is currently limited by their capacity to render pore morphology that precisely matches its design. In a porous biomaterial, a geometric mismatch can result in pore occlusion and strut thinning, drawbacks that can inherently compromise bone ingrowth and severely impact mechanical performance. This paper focuses on Selective Laser Melting of porous microarchitecture and proposes a compensation scheme that reduces the morphology mismatch between as-designed and as-manufactured geometry, in particular that of the pore. A spider web analog is introduced, built out of Ti-6Al-4V powder via SLM, and morphologically characterized. Results from error analysis of strut thickness are used to generate thickness compensation relations expressed as a function of the angle each strut formed with the build plane. The scheme is applied to fabricate a set of three-dimensional porous biomaterials, which are morphologically and mechanically characterized via micro Computed Tomography, mechanically tested and numerically analyzed. For strut thickness, the results show the largest mismatch (60% from the design) occurring for horizontal members, reduces to 3.1% upon application of the compensation. Similar improvement is observed also for the mechanical properties, a factor that further corroborates the merit of the design-oriented scheme here introduced. Copyright © 2016 Elsevier Ltd. All rights reserved.

Ab initio molecular dynamics simulation of laser melting of silicon

NARCIS (Netherlands)

Silvestrelli, P.-L.; Alavi, A.; Parrinello, M.; Frenkel, D.

1996-01-01

The method of ab initio molecular dynamics, based on finite temperature density functional theory, is used to simulate laser heating of crystal silicon. We have found that a high concentration of excited electrons dramatically weakens the covalent bond. As a result, the system undergoes a melting

Comparison on mechanical anisotropies of selective laser melted Ti-6Al-4V alloy and 304 stainless steel

Energy Technology Data Exchange (ETDEWEB)

Yu, Hanchen; Yang, Jingjing; Yin, Jie; Wang, Zemin, E-mail: zmwang@hust.edu.cn; Zeng, Xiaoyan

2017-05-17

Near-fully dense Ti-6Al-4V and 304 stainless steel samples have been produced applying selective laser melting (SLM) in the present work. The microstructures, textures and microhardnesses on horizontal and vertical cross sections, as well as the tensile properties of horizontally and vertically SLMed samples are investigated. It is found that the microstructures of the two SLMed alloys are mainly composed of hexagonal close-packed (HCP) martensitic phase or face-centered cubic (FCC) austenitic phase within columnar structures in Ti-6Al-4V alloy and 304 stainless steel, respectively. For both SLMed alloys, the tensile properties and microhardnesses show anisotropic though the textures are weak. Especially, the Ti-6Al-4V samples show even stronger anisotropic mechanical properties compared with 304 stainless steel. The higher length-width ratios of the columnar structures, rather than the weaker textures or the less symmetry of HCP crystal structure in SLMed Ti-6Al-4V are believed to be responsible for the stronger mechanical anisotropies. As expected, heat treatment is an effective method to eliminate columnar structures and leads to nearly isotropic mechanical properties.

Comparison of the bond strength of ceramics to Co-Cr alloys made by casting and selective laser melting.

Science.gov (United States)

Lawaf, Shirin; Nasermostofi, Shahbaz; Afradeh, Mahtasadat; Azizi, Arash

2017-02-01

Considering the importance of metal-ceramic bond, the present study aimed to compare the bond strength of ceramics to cobalt-chrome (Co-Cr) alloys made by casting and selective laser melting (SLM). In this in-vitro experimental study, two sample groups were prepared, with one group comprising of 10 Co-Cr metal frameworks fabricated by SLM method and the other of 10 Co-Cr metal frameworks fabricated by lost wax cast method with the dimensions of 0.5 × 3 × 25 mm (following ISO standard 9693). Porcelain with the thickness of 1.1 mm was applied on a 3 × 8-mm central rectangular area of each sample. Afterwards, bond strengths of the samples were assessed with a Universal Testing Machine. Statistical analysis was performed with Kolmogorov-Smirnov test and T-test. Bond strength in the conventionally cast group equaled 74.94 ± 16.06 MPa, while in SLM group, it equaled 69.02 ± 5.77 MPa. The difference was not statistically significant ( P ≤ .05). The results indicated that the bond strengths between ceramic and Co-Cr alloys made by casting and SLM methods were not statistically different.

Effect of process parameters on formability of laser melting deposited 12CrNi2 alloy steel

Science.gov (United States)

Peng, Qian; Dong, Shiyun; Kang, Xueliang; Yan, Shixing; Men, Ping

2018-03-01

As a new rapid prototyping technology, the laser melting deposition technology not only has the advantages of fast forming, high efficiency, but also free control in the design and production chain. Therefore, it has drawn extensive attention from community.With the continuous improvement of steel performance requirements, high performance low-carbon alloy steel is gradually integrated into high-tech fields such as aerospace, high-speed train and armored equipment.However, it is necessary to further explore and optimize the difficult process of laser melting deposited alloy steel parts to achieve the performance and shape control.This article took the orthogonal experiment on alloy steel powder by laser melting deposition ,and revealed the influence rule of the laser power, scanning speed, powder gas flow on the quality of the sample than the dilution rate, surface morphology and microstructure analysis were carried out.Finally, under the optimum technological parameters, the Excellent surface quality of the alloy steel forming part with high density, no pore and cracks was obtained.

Laser melt injection of hard ceramic particles into Al and Ti alloys - processing, microstructure and mechanical behaviour

NARCIS (Netherlands)

Ocelik, V.; Nijman, S.; van Ingen, R.; Oliveira, U.; de Hosson, J.T.M.; Brebbia, CA; DeHosson, JTM; Nishida, SI

2003-01-01

The conditions for a successful Laser Melt Injection (LMI) of SiC and WC particles into the melt pool of Al8Si and Ti6A14V alloys were studied experimentally and theoretically by FEM calculations. The laser employed is a high power Nd:YAG. The formation of a relatively thick aluminium oxide layer on

Comparison of mechanical properties and microstructural characterization of CoCrMo alloy obtained via selective laser melting (SLM) and casting techniques

Energy Technology Data Exchange (ETDEWEB)

Mergulhao, Marcello Vertamatti; Podesta, Carlos Eduardo; Neves, Mauricio David Martins das, E-mail: marcellovertamatti@usp.br [Instituto de Pesquisas Energeticas e Nucleares (IPEN/CNEN-SP), Sao Paulo, SP (Brazil)

2016-07-01

Full text: Advances in processes using the powder metallurgy techniques are making this technology competitive compared to the other traditional manufacturing processes, especially in medicine area. The additive manufacturing technique - selective laser melting (SLM) was applied in a biomaterial of CoCrMo alloy (ASTM F75), to study the mechanical properties and microstructural characterization in comparison between the conventional technique - lost wax casting. The gas atomized powder was investigated by their physical (as apparent density, bulk density and flow rate) and the chemical properties (SEM-EDS and X-ray fluorescence). Specimens of standard samples were manufactured using these techniques to evaluate the mechanical properties as yield strength, maximum tensile, rupture tensile, elongation, elastic modulus, transverse rupture strength and the Vickers hardness. Before the mechanical tests the microstructure of specimens were examined using optical microscope (OM) and SEM-EDS. The results of mechanical properties showed a higher values in the SLM specimens compared with the obtained in the cast specimens. The micrographs revealed a typical morphology of consolidation process, like as the characterized by selected layer used in the SLM technique and the primary and secondary dendrites arms in the casting technique. (author)

Continuous functionally graded porous titanium scaffolds manufactured by selective laser melting for bone implants.

Science.gov (United States)

Han, Changjun; Li, Yan; Wang, Qian; Wen, Shifeng; Wei, Qingsong; Yan, Chunze; Hao, Liang; Liu, Jie; Shi, Yusheng

2018-04-01

A significant requirement for a bone implant is to replicate the functional gradient across the bone to mimic the localization change in stiffness. In this work, continuous functionally graded porous scaffolds (FGPSs) based on the Schwartz diamond unit cell with a wide range of graded volume fraction were manufactured by selective laser melting (SLM). The micro-topology, strut dimension characterization and effect of graded volume fraction on the mechanical properties of SLM-processed FGPSs were systematically investigated. The micro-topology observations indicate that diamond FGPSs with a wide range of graded volume fraction from 7.97% to 19.99% were fabricated without any defects, showing a good geometric reproduction of the original designs. The dimensional characterization demonstrates the capability of SLM in manufacturing titanium diamond FGPSs with the strut size of 483-905µm. The elastic modulus and yield strength of the titanium diamond FGPSs can be tailored in the range of 0.28-0.59GPa and 3.79-17.75MPa respectively by adjusting the graded volume fraction, which are comparable to those of the cancellous bone. The mathematical relationship between the graded porosity and compression properties of a FGPS was revealed. Furthermore, two equations based on the Gibson and Ashby model have been established to predict the modulus and yield strength of SLM-processed diamond FGPSs. Compared to homogeneous diamond porous scaffolds, FGPSs provide a wide range of mutative pore size and porosity, which are potential to be tailored to optimize the pore space for bone tissue growth. The findings provide a basis of new methodologies to design and manufacture superior graded scaffolds for bone implant applications. Copyright © 2018 Elsevier Ltd. All rights reserved.

Ultrafast direct imprinting of nanostructures in metals by pulsed laser melting

International Nuclear Information System (INIS)

Cui Bo; Keimel, Chris; Chou, Stephen Y

2010-01-01

We report a method of one-step direct patterning of metallic nanostructures. In the method, termed laser assisted direct imprinting (LADI), the surface of a metal film on a substrate is melted by a single excimer laser pulse and subsequently imprinted within ∼100 ns using a transparent quartz mold, while the substrate is kept at a low temperature and in a solid phase. Using LADI, we imprinted gratings with ∼100 nm linewidth, 100 nm depth, and 200 nm pitch, as well as isolated mesas of ∼20 μm size, in Al, Au, Cu and Ni thin films. We found that the quartz mold was able to imprint metals even at temperatures higher than its melting point. The technique could be extended to other metals regardless of their ductility and hardness, and would find applications in photonic and plasmonic device production.

High resolution selective multilayer laser processing by nanosecond laser ablation of metal nanoparticle films

International Nuclear Information System (INIS)

Ko, Seung H.; Pan Heng; Hwang, David J.; Chung, Jaewon; Ryu, Sangil; Grigoropoulos, Costas P.; Poulikakos, Dimos

2007-01-01

Ablation of gold nanoparticle films on polymer was explored using a nanosecond pulsed laser, with the goal to achieve feature size reduction and functionality not amenable with inkjet printing. The ablation threshold fluence for the unsintered nanoparticle deposit was at least ten times lower than the reported threshold for the bulk film. This could be explained by the combined effects of melting temperature depression, lower conductive heat transfer loss, strong absorption of the incident laser beam, and the relatively weak bonding between nanoparticles. The ablation physics were verified by the nanoparticle sintering characterization, ablation threshold measurement, time resolved ablation plume shadowgraphs, analysis of ablation ejecta, and the measurement and calculation of optical properties. High resolution and clean feature fabrication with small energy and selective multilayer processing are demonstrated

Study of melt flow dynamics and influence on quality for CO{sub 2} laser fusion cutting

Energy Technology Data Exchange (ETDEWEB)

Riveiro, A; Quintero, F; Lusquinos, F; Comesana, R; Pou, J [Applied Physics Department, University of Vigo, ETSII, Lagoas-Marcosende, 9, 36310 Vigo (Spain)

2011-04-06

The understanding of melt flow dynamics during fusion laser cutting is still a topic of great importance because this determines the quality characteristics of the processed workpiece. Despite the complexity of the experimental study of the physical processes involved in this technique, fusion laser cutting can be visualized during the processing of glass because this material absorbs the laser radiation provided by a CO{sub 2} laser but shows transparency to visible radiation. Then, we present in this work the results of the study of the melt flow dynamics during laser cutting of glass. Under different experimental conditions, the dynamics of the cutting front and its complete geometry (front wall inclination), and the evolution of the melt along the cut edge were analysed using a high-speed video camera to study the process. A phenomenon concerning the plasma plume formed during the process was observed, which has not been previously reported in the literature. This can displace the normal shock wave (MSD) commonly formed in the inlet kerf and can affect the assist gas flow into the kerf. On the other hand, the analysis of the recorded images allowed the determination of not only the amount of molten material along the cut edge but also the direction and velocity of the melt. Relevant processing parameters affecting the flow of molten material were assessed. These results were used as a basis to explain the different processes involved in the generation of dross, a typical imperfection appearing in laser cutting.

Development of continuous glass melting for production of Nd-doped phosphate glasses for the NIF and LMJ laser system

International Nuclear Information System (INIS)

Campbell, J. H.; Ficini-Dorn, G.; Hawley-Fedder, R.; McLean, M. J.; Suratwala, T.; Trombert, J. H.

1998-01-01

The NIF and LMJ laser systems require about 3380 and 4752 Nd-doped laser glass slabs, respectively. Continuous laser glass melting and forming will be used for the first time to manufacture these slabs. Two vendors have been chosen to produce the glass: Hoya Corporation and Schott Glass Technologies. The laser glass melting systems that each of these two vendors have designed, built and tested are arguably the most advanced in the world. Production of the laser glass will begin on a pilot scale in the fall of 1999

Selective laser melting-produced porous titanium scaffolds regenerate bone in critical size cortical bone defects.

Science.gov (United States)

Van der Stok, Johan; Van der Jagt, Olav P; Amin Yavari, Saber; De Haas, Mirthe F P; Waarsing, Jan H; Jahr, Holger; Van Lieshout, Esther M M; Patka, Peter; Verhaar, Jan A N; Zadpoor, Amir A; Weinans, Harrie

2013-05-01

Porous titanium scaffolds have good mechanical properties that make them an interesting bone substitute material for large bone defects. These scaffolds can be produced with selective laser melting, which has the advantage of tailoring the structure's architecture. Reducing the strut size reduces the stiffness of the structure and may have a positive effect on bone formation. Two scaffolds with struts of 120-µm (titanium-120) or 230-µm (titanium-230) were studied in a load-bearing critical femoral bone defect in rats. The defect was stabilized with an internal plate and treated with titanium-120, titanium-230, or left empty. In vivo micro-CT scans at 4, 8, and 12 weeks showed more bone in the defects treated with scaffolds. Finally, 18.4 ± 7.1 mm(3) (titanium-120, p = 0.015) and 18.7 ± 8.0 mm(3) (titanium-230, p = 0.012) of bone was formed in those defects, significantly more than in the empty defects (5.8 ± 5.1 mm(3) ). Bending tests on the excised femurs after 12 weeks showed that the fusion strength reached 62% (titanium-120) and 45% (titanium-230) of the intact contralateral femurs, but there was no significant difference between the two scaffolds. This study showed that in addition to adequate mechanical support, porous titanium scaffolds facilitate bone formation, which results in high mechanical integrity of the treated large bone defects. Copyright © 2012 Orthopaedic Research Society.

Highly porous, low elastic modulus 316L stainless steel scaffold prepared by selective laser melting.

Science.gov (United States)

Čapek, Jaroslav; Machová, Markéta; Fousová, Michaela; Kubásek, Jiří; Vojtěch, Dalibor; Fojt, Jaroslav; Jablonská, Eva; Lipov, Jan; Ruml, Tomáš

2016-12-01

Recently, porous metallic materials have been extensively studied as candidates for use in the fabrication of scaffolds and augmentations to repair trabecular bone defects, e.g. in surroundings of joint replacements. Fabricating these complex structures by using common approaches (e.g., casting and machining) is very challenging. Therefore, rapid prototyping techniques, such as selective laser melting (SLM), have been investigated for these applications. In this study, we characterized a highly porous (87 vol.%) 316L stainless steel scaffold prepared by SLM. 316L steel was chosen because it presents a biomaterial still widely used for fabrication of joint replacements and, from the practical point of view, use of the same material for fabrication of an augmentation and a joint replacement is beneficial for corrosion prevention. The results are compared to the reported properties of two representative nonporous 316L stainless steels prepared either by SLM or casting and subsequent hot forging. The microstructural and mechanical properties and the surface chemical composition and interaction with the cells were investigated. The studied material exhibited mechanical properties that were similar to those of trabecular bone (compressive modulus of elasticity ~0.15GPa, compressive yield strength ~3MPa) and cytocompatibility after one day that was similar to that of wrought 316L stainless steel, which is a commonly used biomaterial. Based on the obtained results, SLM is a suitable method for the fabrication of porous 316L stainless steel scaffolds with highly porous structures. Copyright © 2016 Elsevier B.V. All rights reserved.

Preparation of n-type Bi{sub 2}Te{sub 3} thermoelectric materials by non-contact dispenser printing combined with selective laser melting

Energy Technology Data Exchange (ETDEWEB)

Wu, Keping; Yan, Yonggao; Zhang, Jian; Mao, Yu; Xie, Hongyao; Zhang, Qingjie; Tang, Xinfeng [State Key Laboratory of Advanced Technology for Materials Synthesis and Processing, Wuhan University of Technology, Wuhan, Hubei (China); Yang, Jihui [Department of Materials Science and Engineering, University of Washington, Seattle, WA (United States); Uher, Ctirad [Department of Physics, University of Michigan, Ann Arbor, MI (United States)

2017-06-15

The manufacturing cost has been a bottle neck for broader applications of thermoelectric (TE) modules. We have developed a rapid, facile, and low cost method that combines non-contact dispenser printing with selective laser melting (SLM) and we demonstrate it on n-type Bi{sub 2}Te{sub 3}-based materials. Using this approach, single phase n-type Bi{sub 2}Te{sub 2.7}Se{sub 0.3} thin layers with the Seebeck coefficient of -152 μV K{sup -1} at 300 K have been prepared. Assembling such thin layers on top of each other, the performance of thus prepared bulk sample is comparable to Bi{sub 2}Te{sub 3}-based materials fabricated by the conventional techniques. Dispenser printing combined with SLM is a promising manufacturing process for TE materials. (copyright 2017 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

The role of a low-energy–density re-scan in fabricating crack-free Al85Ni5Y6Co2Fe2 bulk metallic glass composites via selective laser melting

International Nuclear Information System (INIS)

Li, X.P.; Kang, C.W.; Huang, H.; Sercombe, T.B.

2014-01-01

Highlights: • We proposed a re-scan strategy to prevent crack propagation in SLM. • The re-scan should be carried out at a low laser energy density. • The underlying mechanism is through reduction and relief of residual stresses. • Lowered temperature gradient and superplasticity account for reduction of stress. • For the first time, a crack-free BMGCs gear with a large size was produced. - Abstract: In this paper, we have investigated the use of a re-scanning strategy to prevent propagation of macro-cracks during the selective laser melting of an Al 85 Ni 5 Y 6 Co 2 Fe 2 bulk metallic glass composites (BMGCs). These cracks form as a result of the high residual stress caused by the rapid heating and cooling of the material by the laser beam. Unlike crystalline materials, the BMGCs possess a supercooled liquid region in which the residual stress can be relieved by plastic flow. We show that by using a high power initial scan (designed to melt the material) followed by a lower power re-scan (for stress relief) cracking can be prevented. Using this approach, crack-free Al 85 Ni 5 Y 6 Co 2 Fe 2 BMGCs components have been fabricated, including a gear with a diameter ∼25 mm and height ∼10 mm

Investigation on Selective Laser Melting AlSi10Mg Cellular Lattice Strut: Molten Pool Morphology, Surface Roughness and Dimensional Accuracy

Directory of Open Access Journals (Sweden)

Xuesong Han

2018-03-01

Full Text Available AlSi10Mg inclined struts with angle of 45° were fabricated by selective laser melting (SLM using different scanning speed and hatch spacing to gain insight into the evolution of the molten pool morphology, surface roughness, and dimensional accuracy. The results show that the average width and depth of the molten pool, the lower surface roughness and dimensional deviation decrease with the increase of scanning speed and hatch spacing. The upper surface roughness is found to be almost constant under different processing parameters. The width and depth of the molten pool on powder-supported zone are larger than that of the molten pool on the solid-supported zone, while the width changes more significantly than that of depth. However, if the scanning speed is high enough, the width and depth of the molten pool and the lower surface roughness almost keep constant as the density is still high. Therefore, high dimensional accuracy and density as well as good surface quality can be achieved simultaneously by using high scanning speed during SLMed cellular lattice strut.

Effects of the TiC Nanoparticle on Microstructures and Tensile Properties of Selective Laser Melted IN718/TiC Nanocomposites

Science.gov (United States)

Yao, Xiling; Moon, Seung Ki; Lee, Bing Yang; Bi, Guijun

2018-03-01

The purpose of this paper is to investigate the effects of TiC nanoparticle content on microstructures and tensile properties of the IN718/TiC nanocomposites fabricated by selective laser melting (SLM). 0.5wt%, 1.0wt%, and 2.0wt% of TiC nanoparticles are added to the IN718 powders. The bulk-form IN718/TiC nanocomposites with different TiC contents are fabricated in-situ by SLM using the same process settings. The evolution of microstructures and tensile properties as the effect of changing the TiC content is studied using the optical microscopy, scanning electron microscopy, X-ray diffraction analysis, and tensile testing. The increase of TiC content refines the microstructure, promotes the formation of the cellular morphology, and reduces the size and continuity of Laves precipitates. Increasing the TiC content improves the yield strength and ultimate tensile strength but decreases the ductility. The grain refinement, dislocation bowing, dislocation punching, and the reduction in Laves precipitate contribute to the strengthening effect in the IN718/TiC nanocomposites.

Investigation on Selective Laser Melting AlSi10Mg Cellular Lattice Strut: Molten Pool Morphology, Surface Roughness and Dimensional Accuracy.

Science.gov (United States)

Han, Xuesong; Zhu, Haihong; Nie, Xiaojia; Wang, Guoqing; Zeng, Xiaoyan

2018-03-07

AlSi10Mg inclined struts with angle of 45° were fabricated by selective laser melting (SLM) using different scanning speed and hatch spacing to gain insight into the evolution of the molten pool morphology, surface roughness, and dimensional accuracy. The results show that the average width and depth of the molten pool, the lower surface roughness and dimensional deviation decrease with the increase of scanning speed and hatch spacing. The upper surface roughness is found to be almost constant under different processing parameters. The width and depth of the molten pool on powder-supported zone are larger than that of the molten pool on the solid-supported zone, while the width changes more significantly than that of depth. However, if the scanning speed is high enough, the width and depth of the molten pool and the lower surface roughness almost keep constant as the density is still high. Therefore, high dimensional accuracy and density as well as good surface quality can be achieved simultaneously by using high scanning speed during SLMed cellular lattice strut.

Role of melt behavior in modifying oxidation distribution using an interface incorporated model in selective laser melting of aluminum-based material

Energy Technology Data Exchange (ETDEWEB)

Gu, Dongdong, E-mail: dongdonggu@nuaa.edu.cn; Dai, Donghua [College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Yudao Street 29, Nanjing 210016 (China); Institute of Additive Manufacturing (3D Printing), Nanjing University of Aeronautics and Astronautics, Yudao Street 29, Nanjing 210016 (China)

2016-08-28

A transient three dimensional model for describing the molten pool dynamics and the response of oxidation film evolution in the selective laser melting of aluminum-based material is proposed. The physical difference in both sides of the scan track, powder-solid transformation and temperature dependent physical properties are taken into account. It shows that the heat energy tends to accumulate in the powder material rather than in the as-fabricated part, leading to the formation of the asymmetrical patterns of the temperature contour and the attendant larger dimensions of the molten pool in the powder phase. As a higher volumetric energy density is applied (≥1300 J/mm{sup 3}), a severe evaporation is produced with the upward direction of velocity vector in the irradiated powder region while a restricted operating temperature is obtained in the as-fabricated part. The velocity vector continuously changes from upward direction to the downward one as the scan speed increases from 100 mm/s to 300 mm/s, promoting the generation of the debris of the oxidation films and the resultant homogeneous distribution state in the matrix. For the applied hatch spacing of 50 μm, a restricted remelting phenomenon of the as-fabricated part is produced with the upward direction of the convection flow, significantly reducing the turbulence of the thermal-capillary convection on the breaking of the oxidation films, and therefore, the connected oxidation films through the neighboring layers are typically formed. The morphology and distribution of the oxidation are experimentally acquired, which are in a good agreement with the results predicted by simulation.

Bone ingrowth potential of electron beam and selective laser melting produced trabecular-like implant surfaces with and without a biomimetic coating.

Science.gov (United States)

Biemond, J E; Hannink, G; Verdonschot, N; Buma, P

2013-03-01

The bone ingrowth potential of trabecular-like implant surfaces produced by either selective laser melting (SLM) or electron beam melting (EBM), with or without a biomimetic calciumphosphate coating, was examined in goats. For histological analysis and histomorphometry of bone ingrowth depth and bone implant contact specimens were implanted in the femoral condyle of goats. For mechanical push out tests to analyse mechanical implant fixation specimens were implanted in the iliac crest. The follow up periods were 4 (7 goats) and 15 weeks (7 goats). Both the SLM and EBM produced trabecular-like structures showed a variable bone ingrowth after 4 weeks. After 15 weeks good bone ingrowth was found in both implant types. Irrespective to the follow up period, and the presence of a coating, no histological differences in tissue reaction around SLM and EBM produced specimens was found. Histological no coating was detected at 4 and 15 weeks follow up. At both follow up periods the mechanical push out strength at the bone implant interface was significantly lower for the coated SLM specimens compared to the uncoated SLM specimens. The expected better ingrowth characteristics and mechanical fixation strength induced by the coating were not found. The lower mechanical strength of the coated specimens produced by SLM is a remarkable result, which might be influenced by the gross morphology of the specimens or the coating characteristics, indicating that further research is necessary.

Microstructures and mechanical properties of Co-29Cr-6Mo alloy fabricated by selective laser melting process for dental applications.

Science.gov (United States)

Takaichi, Atsushi; Suyalatu; Nakamoto, Takayuki; Joko, Natsuka; Nomura, Naoyuki; Tsutsumi, Yusuke; Migita, Satoshi; Doi, Hisashi; Kurosu, Shingo; Chiba, Akihiko; Wakabayashi, Noriyuki; Igarashi, Yoshimasa; Hanawa, Takao

2013-05-01

The selective laser melting (SLM) process was applied to a Co-29Cr-6Mo alloy, and its microstructure, mechanical properties, and metal elution were investigated to determine whether the fabrication process is suitable for dental applications. The microstructure was evaluated using scanning electron microscopy with energy-dispersed X-ray spectroscopy (SEM-EDS), X-ray diffractometry (XRD), and electron back-scattered diffraction pattern analysis. The mechanical properties were evaluated using a tensile test. Dense builds were obtained when the input energy of the laser scan was higher than 400 J mm⁻³, whereas porous builds were formed when the input energy was lower than 150 J mm⁻³. The microstructure obtained was unique with fine cellular dendrites in the elongated grains parallel to the building direction. The γ phase was dominant in the build and its preferential orientation was confirmed along the building direction, which was clearly observed for the builds fabricated at lower input energy. Although the mechanical anisotropy was confirmed in the SLM builds due to the unique microstructure, the yield strength, UTS, and elongation were higher than those of the as-cast alloy and satisfied the type 5 criteria in ISO22764. Metal elution from the SLM build was smaller than that of the as-cast alloy, and thus, the SLM process for the Co-29Cr-6Mo alloy is a promising candidate for fabricating dental devices. Copyright © 2013 Elsevier Ltd. All rights reserved.

The Enhancement of Mg Corrosion Resistance by Alloying Mn and Laser-Melting

Directory of Open Access Journals (Sweden)

Youwen Yang

2016-03-01

Full Text Available Mg has been considered a promising biomaterial for bone implants. However, the poor corrosion resistance has become its main undesirable property. In this study, both alloying Mn and laser-melting were applied to enhance the Mg corrosion resistance. The corrosion resistance, mechanical properties, and microstructure of rapid laser-melted Mg-xMn (x = 0–3 wt % alloys were investigated. The alloys were composed of dendrite grains, and the grains size decreased with increasing Mn. Moreover, Mn could dissolve and induce the crystal lattice distortion of the Mg matrix during the solidification process. Mn ranging from 0–2 wt % dissolved completely due to rapid laser solidification. As Mn contents further increased up to 3 wt %, a small amount of Mn was left undissolved. The compressive strength of Mg-Mn alloys increased first (up to 2 wt % and then decreased with increasing Mn, while the hardness increased continuously. The refinement of grains and the increase in corrosion potential both made contributions to the enhancement of Mg corrosion resistance.

Microstructure anisotropy and its effect on mechanical properties of reduced activation ferritic/martensitic steel fabricated by selective laser melting

Science.gov (United States)

Huang, Bo; Zhai, Yutao; Liu, Shaojun; Mao, Xiaodong

2018-03-01

Selective laser melting (SLM) is a promising way for the fabrication of complex reduced activation ferritic/martensitic steel components. The microstructure of the SLM built China low activation martensitic (CLAM) steel plates was observed and analyzed. The hardness, Charpy impact and tensile testing of the specimens in different orientations were performed at room temperature. The results showed that the difference in the mechanical properties was related to the anisotropy in microstructure. The planer unmelted porosity in the interface of the adjacent layers induced opening/tensile mode when the tensile samples parallel to the build direction were tested whereas the samples vertical to the build direction fractured in the shear mode with the grains being sheared in a slant angle. Moreover, the impact absorbed energy (IAE) of all impact specimens was significantly lower than that of the wrought CLAM steel, and the IAE of the samples vertical to the build direction was higher than that of the samples parallel to the build direction. The impact fracture surfaces revealed that the load parallel to the build layers caused laminated tearing among the layers, and the load vertical to the layers induced intergranular fracture across the layers.

Thermophysical Properties of Selected II-VI Semiconducting Melts

Science.gov (United States)

Li, C.; Su, Ching-Hua; Lehoczky, S. L.; Scripa, R. N.; Ban, H.; Lin, B.

2004-01-01

Thermophysical properties are essential for the accurate predication of the crystal growth process by computational modeling. Currently, the temperature dependent thermophysical property data for the II-VI semiconductor melts are scarce. This paper reports the results of the temperature dependence of melt density, viscosity and electrical conductivity of selected II-VI compounds, including HgTe, HgCdTe and HgZnTe. The melt density was measured using a pycnometric method, and the viscosity and electrical conductivity were measured by a transient torque method. The results were compared with and showed good agreement with the existing data in the literature.

Immobilisation of an antibacterial drug to Ti6Al4V components fabricated using selective laser melting

Science.gov (United States)

Vaithilingam, Jayasheelan; Kilsby, Samuel; Goodridge, Ruth D.; Christie, Steven D. R.; Edmondson, Steve; Hague, Richard J. M.

2014-09-01

Bacterial infections from biomedical implants and surgical devices are a major problem in orthopaedic, dental and vascular surgery. Although the sources of contaminations that lead to bacterial infections are known, it is not possible to control or avoid such infections completely. In this study, an approach to immobilise Ciprofloxacin® (an antibacterial drug) to phosphonic acid based self-assembled monolayers (SAMs) adsorbed on a selectively laser melted (SLM) Ti6Al4V structure, has been presented. X-ray photoelectron spectroscopy (XPS) and static water contact angle measurements confirmed the attachment of SAMs and the drug. Results showed that Ciprofloxacin® is highly stable under the oxidative conditions used in this study. In-vitro stability was estimated by immersing the Ciprofloxacin® immobilised substrates in 10 mM of Tris-HCl buffer (pH-7.4) for 42 days. The Tris-HCl buffer was analysed using UV-vis spectrophotometry at 7, 14, 28 and 42 day time intervals to determine the release of the immobilised drug. The drug was observed to release in a sustained manner. 50% of the drug was released after 4 weeks with approximately 40% of the drug remaining after 6 weeks. Antibacterial susceptibility tests revealed that the immobilised drug was therapeutically active upon its release. This study demonstrates the potential to use self-assembled monolayers to modify SLM fabricated surfaces with therapeutics.

Effect of Heat Treatment on the Properties of CoCrMo Alloy Manufactured by Selective Laser Melting

Science.gov (United States)

Guoqing, Zhang; Junxin, Li; Xiaoyu, Zhou; Jin, Li; Anmin, Wang

2018-05-01

To obtain medical implants with better mechanical properties, it is necessary to conduct studies on the heat treatment process of the selective laser melting (SLM) manufacturing parts. The differential scanning calorimetry method was used to study the heat treatment process of the phase transition of SLM CoCrMo alloy parts. The tensile properties were tested with a tensile test machine, the quantity of carbide precipitated after heat treatment was measured by energy-dispersive x-ray spectroscopy, and the tensile fracture morphology of the parts was investigated using SEM. The obtained results were: Mechanical properties in terms of elongation and tensile strength of CoCrMo alloy manufactured by SLM that had been heat-treated at 1200 °C for 2 h followed by cooling with water were not only higher than the national standard but also higher than the experimental results of the same batch of castings. The mechanism of fracture of parts manufactured by SLM without heat treatment was brittle fracture, whereas parts which had been heat-treated at 1200 °C for 2 h combined with water cooling and at 1200 °C for 1 h with furnace cooling suffered ductile fracture. This study provides the basis for defining the applications for which CoCrMo alloys manufactured by SLM are suitable within the field of medical implants.

Enthalpy model for heating, melting, and vaporization in laser ablation

Directory of Open Access Journals (Sweden)

Vasilios Alexiades

2010-09-01

Full Text Available Laser ablation is used in a growing number of applications in various areas including medicine, archaeology, chemistry, environmental and materials sciences. In this work the heat transfer and phase change phenomena during nanosecond laser ablation of a copper (Cu target in a helium (He background gas at atmospheric pressure are presented. An enthalpy model is outlined, which accounts for heating, melting, and vaporization of the target. As far as we know, this is the first model that connects the thermodynamics and underlying kinetics of this challenging phase change problem in a self-consistent way.

Laser-induced selective metallization of polypropylene doped with multiwall carbon nanotubes

Energy Technology Data Exchange (ETDEWEB)

Ratautas, Karolis, E-mail: karolis.ratautas@ftmc.lt [Center for Physical Sciences and Technology, Savanoriu Ave. 231, Vilnius LT-02300 (Lithuania); Gedvilas, Mindaugas; Stankevičiene, Ina; Jagminienė, Aldona; Norkus, Eugenijus [Center for Physical Sciences and Technology, Savanoriu Ave. 231, Vilnius LT-02300 (Lithuania); Pira, Nello Li [Centro Ricerche Fiat, Strada Torino 50, Orbassano 10043 (Italy); Sinopoli, Stefano [BioAge Srl, Via Dei Glicini 25, Lamezia Terme 88046 (Italy); Račiukaitis, Gediminas [Center for Physical Sciences and Technology, Savanoriu Ave. 231, Vilnius LT-02300 (Lithuania)

2017-08-01

Highlights: • PP doped with multiwall CNT can be activated with ns laser for electroless plating. • Developed material is cheap decision for MID applications. • Activation mechanism was preliminary proposed. • Demo for automotive application has been manufactured. - Abstract: Moulded interconnect devices (MID) offer the material, weight and cost saving by integration electronic circuits directly into polymeric components used in automotive and other consumer products. Lasers are used to write circuits directly by modifying the surface of polymers followed by an electroless metal plating. A new composite material – the polypropylene doped with multiwall carbon nanotubes was developed for the laser-induced selective metallization. Mechanism of surface activation by laser irradiation was investigated in details utilising pico- and nanoseconds lasers. Deposition of copper was performed in the autocatalytic electroless plating bath. The laser-activated polymer surfaces have been studied using the Raman spectroscopy and scanning electron microscope (SEM). Microscopic images revealed that surface becomes active only after its melting by a laser. Alterations in the Raman spectra of the D and G bands indicated the clustering of carbon additives in the composite material. Optimal laser parameters for the surface activation were found by measuring a sheet resistance of the finally metal-plated samples. A spatially selective copper plating was achieved with the smallest conductor line width of 22 μm at the laser scanning speed of 3 m/s and the pulse repetition rate of 100 kHz. Finally, the technique was validated by making functional electronic circuits by this MID approach.

Laser-induced selective metallization of polypropylene doped with multiwall carbon nanotubes

International Nuclear Information System (INIS)

Ratautas, Karolis; Gedvilas, Mindaugas; Stankevičiene, Ina; Jagminienė, Aldona; Norkus, Eugenijus; Pira, Nello Li; Sinopoli, Stefano; Račiukaitis, Gediminas

2017-01-01

Highlights: • PP doped with multiwall CNT can be activated with ns laser for electroless plating. • Developed material is cheap decision for MID applications. • Activation mechanism was preliminary proposed. • Demo for automotive application has been manufactured. - Abstract: Moulded interconnect devices (MID) offer the material, weight and cost saving by integration electronic circuits directly into polymeric components used in automotive and other consumer products. Lasers are used to write circuits directly by modifying the surface of polymers followed by an electroless metal plating. A new composite material – the polypropylene doped with multiwall carbon nanotubes was developed for the laser-induced selective metallization. Mechanism of surface activation by laser irradiation was investigated in details utilising pico- and nanoseconds lasers. Deposition of copper was performed in the autocatalytic electroless plating bath. The laser-activated polymer surfaces have been studied using the Raman spectroscopy and scanning electron microscope (SEM). Microscopic images revealed that surface becomes active only after its melting by a laser. Alterations in the Raman spectra of the D and G bands indicated the clustering of carbon additives in the composite material. Optimal laser parameters for the surface activation were found by measuring a sheet resistance of the finally metal-plated samples. A spatially selective copper plating was achieved with the smallest conductor line width of 22 μm at the laser scanning speed of 3 m/s and the pulse repetition rate of 100 kHz. Finally, the technique was validated by making functional electronic circuits by this MID approach.

[The measurement of thermal expansion coefficient of Co-Cr alloy fabricated by selective laser melting].

Science.gov (United States)

Tian, Xiao-mei; Zeng, Li; Wei, Bin; Huang, Yi-feng

2015-12-01

To investigate the thermal expansion coefficient of different processing parameters upon the Co-Cr alloy prepared by selective laser melting (SLM) technique, in order to provide technical support for clinical application of SLM technology. The heating curve of self-made Co-Cr alloy was protracted from room temperature to 980°C centigrade with DIL402PC thermal analysis instrument, keeping temperature rise rate and cooling rate at 5 K/min, and then the thermal expansion coefficient of 9 groups of Co-Cr alloy was measured from 20°C centigrade to 500°C centigrade and 600°C centigrade. The 9 groups thermal expansion coefficient values of Co-Cr alloy heated from 20°C centigrade to 500°C centigrade were 13.9×10(-6)/K,13.6×10(-6)/K,13.9×10(-6)/K,13.7×10(-6)/K,13.5×10(-6)/K,13.8×10(-6)/K,13.7×10(-6)/K,13.7×10(-6)/K,and 13.9×10(-6)/K, respectively; when heated from 20°C centigrade to 600°C centigrade, they were 14.2×10(-6)/K,13.9×10(-6)/K,13.8×10(-6)/K,14.0×10(-6)/K,14.1×10(-6)/K,14.1×10(-6)/K,13.9×10(-6)/K,14.2×10(-6)/K, and 13.7×10(-6)/K, respectively. The results showed that the Co-Cr alloy has good matching with the VITA VMK 95 porcelain powder and can meet the requirement of clinic use.

Laser Processing Technology using Metal Powders

Energy Technology Data Exchange (ETDEWEB)

Jang, Jeong-Hwan; Moon, Young-Hoon [Pusan National University, Busan (Korea, Republic of)

2012-03-15

The purpose of this paper is to review the state of laser processing technology using metal powders. In recent years, a series of research and development efforts have been undertaken worldwide to develop laser processing technologies to fabricate metal-based parts. Layered manufacturing by the laser melting process is gaining ground for use in manufacturing rapid prototypes (RP), tools (RT) and functional end products. Selective laser sintering / melting (SLS/SLM) is one of the most rapidly growing rapid prototyping techniques. This is mainly due to the processes's suitability for almost any materials, including polymers, metals, ceramics and many types of composites. The interaction between the laser beam and the powder material used in the laser melting process is one of the dominant phenomena defining feasibility and quality. In the case of SLS, the powder is not fully melted during laser scanning, therefore the SLS-processed parts are not fully dense and have relatively low strength. To overcome this disadvantage, SLM and laser cladding (LC) processes have been used to enable full melting of the powder. Further studies on the laser processing technology will be continued due to the many potential applications that the technology offers.

Laser-based additive manufacturing of metals

CSIR Research Space (South Africa)

Kumar, S

2010-11-01

Full Text Available For making metallic products through Additive Manufacturing (AM) processes, laser-based systems play very significant roles. Laser-based processes such as Selective Laser Melting (SLM) and Laser Engineered Net Shaping (LENS) are dominating processes...

Surface melting technique of small diameter stainless steel pipe by means of yttrium aluminium garnet laser

International Nuclear Information System (INIS)

Katahira, Fujito; Hirano, Kenji; Tanaka, Yasuhiro; Yoshida, Kazuo; Kuribayashi, Munetaka; Umemoto, Tadahiro

1994-01-01

A new method of surface melting by using a high power yttrium aluminium garnet laser was developed. This method is applicable to a long distance and narrow space, because of the good accessibility of the laser beam through optical fibre.A desensitization of sensitized type 304 stainless steel pipe was demonstrated by using this technique. A melted layer of thickness approximately 200μm had a very finite solidification structure, which contained approximately 1.5% δ-ferrite. The average chemical composition of this layer was almost the same as that of type 304 stainless steel, and a band of 300μm thickness under the melted layer underwent solution heat treatment (SHT).As a result of such surface melting, the melted layer exhibited superior resistance to intergranular stress corrosion cracking (IGSCC). Since the SHT layer is highly resistant to IGSCC generally, it may be possible to improve the IGSCC resistance of base metal to a comparatively deep extent (500μm from the surface) by this technique. ((orig.))

Surface melting technique of small diameter stainless steel pipe by means of yttrium aluminium garnet laser

Energy Technology Data Exchange (ETDEWEB)

Katahira, Fujito (Ishikawajima-Harima Heavy Industries Co. Ltd., 1 Shin-Nakahara-Cho, Isogo-Ku, Yokohama 235 (Japan)); Hirano, Kenji (Ishikawajima-Harima Heavy Industries Co. Ltd., 1 Shin-Nakahara-Cho, Isogo-Ku, Yokohama 235 (Japan)); Tanaka, Yasuhiro (Ishikawajima-Harima Heavy Industries Co. Ltd., 1 Shin-Nakahara-Cho, Isogo-Ku, Yokohama 235 (Japan)); Yoshida, Kazuo (Ishikawajima-Harima Heavy Industries Co. Ltd., 1 Shin-Nakahara-Cho, Isogo-Ku, Yokohama 235 (Japan)); Kuribayashi, Munetaka (Ishikawajima-Harima Heavy Industries Co. Ltd., 1 Shin-Nakahara-Cho, Isogo-Ku, Yokohama 235 (Japan)); Umemoto, Tadahiro (Ishikawajima-Harima Heavy Industries Co. Ltd., 1 Shin-Nakahara-Cho, Isogo-Ku, Yokohama 235 (Japan))

1994-12-01

A new method of surface melting by using a high power yttrium aluminium garnet laser was developed. This method is applicable to a long distance and narrow space, because of the good accessibility of the laser beam through optical fibre.A desensitization of sensitized type 304 stainless steel pipe was demonstrated by using this technique. A melted layer of thickness approximately 200[mu]m had a very finite solidification structure, which contained approximately 1.5% [delta]-ferrite. The average chemical composition of this layer was almost the same as that of type 304 stainless steel, and a band of 300[mu]m thickness under the melted layer underwent solution heat treatment (SHT).As a result of such surface melting, the melted layer exhibited superior resistance to intergranular stress corrosion cracking (IGSCC). Since the SHT layer is highly resistant to IGSCC generally, it may be possible to improve the IGSCC resistance of base metal to a comparatively deep extent (500[mu]m from the surface) by this technique. ((orig.))

Microstructural and surface modifications and hydroxyapatite coating of Ti-6Al-4V triply periodic minimal surface lattices fabricated by selective laser melting.

Science.gov (United States)

Yan, Chunze; Hao, Liang; Hussein, Ahmed; Wei, Qingsong; Shi, Yusheng

2017-06-01

Ti-6Al-4V Gyroid triply periodic minimal surface (TPMS) lattices were manufactured by selective laser melting (SLM). The as-built Ti-6Al-4V lattices exhibit an out-of-equilibrium microstructure with very fine α' martensitic laths. When subjected to the heat treatment of 1050°C for 4h followed by furnace cooling, the lattices show a homogenous and equilibrium lamellar α+β microstructure with less dislocation and crystallographic defects compared with the as-built α' martensite. The as-built lattices present very rough strut surfaces bonded with plenty of partially melted metal particles. The sand blasting nearly removed all the bonded metal particles, but created many tiny cracks. The HCl etching eliminated these tiny cracks, and subsequent NaOH etching resulted in many small and shallow micro-pits and develops a sodium titanate hydrogel layer on the surfaces of the lattices. When soaked in simulated body fluid (SBF), the Ti-6Al-4V TPMS lattices were covered with a compact and homogeneous biomimetic hydroxyapatite (HA) layer. This work proposes a new method for making Ti-6Al-4V TPMS lattices with a homogenous and equilibrium microstructure and biomimetic HA coating, which show both tough and bioactive characteristics and can be promising materials usable as bone substitutes. Copyright © 2017 Elsevier B.V. All rights reserved.

Investigation of platinum alloys for melting of inclusion free laser glass: Final report

International Nuclear Information System (INIS)

Izumitani, T.; Toratani, H.; Meissner, H.E.

1986-01-01

The objective of this work is to evaluate the suitability of Pt alloys as crucible materials for melting LHG-8 phosphate laser glass. The tendency of forming metallic inclusions and ionic dissolution of alloy components in the glass is to be compared with that of pure Pt. Ionic Pt is introduced into the glass melt by direct dissolution of Pt at the crucible-melt interface and by vapor phase transport. It was felt that a Pt-alloy may behave sufficiently differently from Pt that a number of alloys should be studied. Pt inclusions may originate from Pt which reprecipitates from the glass melt on cooling or change in redox-conditions; from volatilized Pt which deposits in colder zones of the melting environment as crystallites which may drop back into the glass melt; and/or from Pt particles which are mechanically removed from the crucible and drop into the glass melt. Besides pure Pt, the following alloys have been tested: Pt/ 10 Ir, Pt/ 10 Rh, Pt/ 5 Au, Pt-ZGS, Pt/ 5 Au-ZGS, Pt/ 10 Rh-ZGS

Orthogonal cutting of laser beam melted parts

Science.gov (United States)

Götze, Elisa; Zanger, Frederik; Schulze, Volker

2018-05-01

The finishing process of parts manufactured by laser beam melting is of high concern due to the lack of surface accuracy. Therefore, the focus of this work lies on the influence of the build-up direction of the parts and their effect on the finishing process. The orthogonal cutting reveals findings in the fields of chip formation, involved forces and temperatures appearing during machining. In the investigations, the cutting depth was varied between 0.05 and 0.15 mm representing a finishing process and the cutting velocity ranges from 30 to 200 m/min depending on the material. The experiments contain the materials stainless steel (AISI 316L), titanium (Ti6Al4V) and nickel-base alloy (IN718). The two materials named latter are of high interest in the aerospace sector and at the same time titanium is used in the medical field due to its biocompatibility. For the materials IN718 and Ti6Al4V a negative rake angle of -7.5° and for stainless steel a rake angle of 12.5° are chosen for the cutting experiments. The results provide the base for processing strategies. Therefore, the specimens were solely laser beam melted without post-processing like heat treatment. The evaluation of the experiments shows that an increase in cutting speed has different effects depending on the material. For stainless steel the measured forces regarding the machining direction to the layers approach the same values. In contrast, the influence of the layers regarding the forces appearing during orthogonal cutting of the materials IN718 and Ti6Al4V differ for lower cutting speeds.

Influence of heat treatments on the microstructure and tensile behaviour of selective laser melting-produced TI-6AL-4V parts

Directory of Open Access Journals (Sweden)

Ter Haar, Gerrit Matthys

2016-11-01

Full Text Available In industry, post-process heat treatments of Ti-6Al-4V are performed with the aim of improving its tensile behaviour. While heat treatments of wrought Ti6Al4V have been standardised (e.g., Aerospace Material Specification H-81200, heat treatments of selective laser melting (SLM-produced Ti-6Al-4V lacks research and understanding. Significant concern exists about SLM Ti6-Al-4V’s achievable ductility attributed to its martensitic (α’ phase. In this research, heat treatments at a range of temperatures are applied to SLM-produced Ti-6Al-4V tensile samples. Microstructural analysis (both optically and through electron backscatter diffraction was used to identify links between heat treatments and microstructure. Subsequently, uniaxial tensile tests were performed to determine the respective tensile properties of all samples. Correlations in the data show a significant loss in strength with respect to an increase in annealing temperature due to grain growth, while no noticeable trend was observed for fracture strain with regard to annealing temperatures.

Comparison of boron diffusion in silicon during shallow p{sup +}/n junction formation by non-melt excimer and green laser annealing

Energy Technology Data Exchange (ETDEWEB)

Aid, Siti Rahmah; Matsumoto, Satoru [Department of Electronics and Electrical Engineering, Keio University, 3-14-1 Hiyoshi, Kouhoku-ku, Yokohama, Kanagawa 223-8522 (Japan); Fuse, Genshu [SEN Corporation, SBS Tower 9F, 4-10-1 Yoga, Setagaya-ku, Tokyo 158-0097 (Japan); Sakuragi, Susumu [Sumitomo Heavy Industries Ltd., 19 Natsushima-cho, Yokosuka, Kanagawa 237-8555 (Japan)

2011-12-15

The combination of Ge pre-amorphization implantation, low-energy boron implantation, and non-melt laser annealing is a promising method for forming ultrashallow p{sup +}/n junctions in silicon. In this study, shallow p{sup +}/n junctions were formed by non-melt annealing implanted samples using a green laser (visible laser). The dopant diffusion, activation, and recrystallization of an amorphous silicon layer were compared with those obtained in our previous study in which non-melt annealing was performed using a KrF excimer laser (UV laser). The experimental results reveal that only slight diffusion of boron in the tail region occurred in green-laser-annealed samples. In contrast, remarkable boron diffusion occurred in KrF-laser-annealed samples for very short annealing times. Recrystallization of the amorphous silicon layer was slower in green-laser-annealed samples than in KrF-laser-annealed samples. We consider the penetration depth and the pulse duration are important factors that may affect boron diffusion. (Copyright copyright 2011 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

Laser Beam Melting of Multi-Material Components

Science.gov (United States)

Laumer, Tobias; Karg, Michael; Schmidt, Michael

First results regarding the realisation of multi-material components manufactured by Laser Beam Melting of polymers and metals are published. For realising composite structures from polymer powders by additive manufacturing, at first relevant material properties regarding compatibility have to be analysed. The paper shows the main requirements for compatibility between different materials and offers first results in form of a compatibility matrix of possible combinations for composite structures. For achieving gradient properties of additively manufactured metal parts by using composite materials the composition of alloying components in the powder and adapted process strategies are varied. As an alternative to atomizing pre-alloyed materials, mixtures of different powders are investigated.

Grain structure evolution in Inconel 718 during selective electron beam melting

Energy Technology Data Exchange (ETDEWEB)

Helmer, H.; Bauereiß, A., E-mail: Andreas.Bauereiss@fau.de; Singer, R.F.; Körner, C.

2016-06-21

Selective electron beam melting (SEBM) is an additive manufacturing method where complex parts are built from metal powders in layers of typically 50 µm. An electron beam is used for heating (about 900 °C building temperature) and selective melting of the material. The grain structure evolution is a result of the complex thermal and hydrodynamic conditions in the melt pool. We show how different scanning strategies can be used to produce either a columnar grain structure with a high texture in building direction or an equiaxed fine grained structure. Numerical simulations of the selective melting process are applied to study the fundamental mechanisms responsible for differing grain structures. It is shown, that the direction of the thermal gradient during solidification can be altered by scanning strategies to acquire either epitaxial growth or stray grains. We show that it is possible to locally alter the grain structure of a part, thus allowing tailoring of the mechanical properties.

Scratch Hardness and Wear Performance of Laser-Melted Steels : Effects of Anisotropy

NARCIS (Netherlands)

Beurs, H. de; Minholts, G.; Hosson, J.Th.M. De

Effects of the orientation of dendrites on the scratch hardness and wear performance of laser-melted steels have been investigated. Scratch experiments have been carried out with a Vickers indenter and wear experiments with a pin-on-disk tester. The deformed structure is investigated, using

Surface chemistry of Ti6Al4V components fabricated using selective laser melting for biomedical applications.

Science.gov (United States)

Vaithilingam, Jayasheelan; Prina, Elisabetta; Goodridge, Ruth D; Hague, Richard J M; Edmondson, Steve; Rose, Felicity R A J; Christie, Steven D R

2016-10-01

Selective laser melting (SLM) has previously been shown to be a viable method for fabricating biomedical implants; however, the surface chemistry of SLM fabricated parts is poorly understood. In this study, X-ray photoelectron spectroscopy (XPS) was used to determine the surface chemistries of (a) SLM as-fabricated (SLM-AF) Ti6Al4V and (b) SLM fabricated and mechanically polished (SLM-MP) Ti6Al4V samples and compared with (c) traditionally manufactured (forged) and mechanically polished Ti6Al4V samples. The SLM-AF surface was observed to be porous with an average surface roughness (Ra) of 17.6±3.7μm. The surface chemistry of the SLM-AF was significantly different to the FGD-MP surface with respect to elemental distribution and their existence on the outermost surface. Sintered particles on the SLM-AF surface were observed to affect depth profiling of the sample due to a shadowing effect during argon ion sputtering. Surface heterogeneity was observed for all three surfaces; however, vanadium was witnessed only on the mechanically polished (SLM-MP and FGD-MP) surfaces. The direct and indirect 3T3 cell cytotoxicity studies revealed that the cells were viable on the SLM fabricated Ti6Al4V parts. The varied surface chemistry of the SLM-AF and SLM-MP did not influence the cell behaviour. Copyright © 2016 The Authors. Published by Elsevier B.V. All rights reserved.

Surface Hardening by Laser Skin Melting

Science.gov (United States)

1979-07-01

typical cross-sectional view of a melt region. Various solutions includina Murakami’s reaqent, Vilella’s reagent and an oxalic acid solution were used...each type selectively revealinq different microstructu- ral features. A second etch in an oxalic acid /hydrochloric acid solution was used in the...genization due to vigorous hydrothermal mixing and liquid super- heating. Computations by Greenwald (13) from a heat flow model are graphically represented

On the analysis of the activation mechanisms of sub-melt laser anneals

DEFF Research Database (Denmark)

Clarysse, T.; Bogdanowicz, J.; Goosens, J.

2008-01-01

electrically active concentration level as well as the concurrent mobility is dependent on the dopant concentration level. This implies that the activation of B through the laser anneal process in the explored temperature–time space is governed by kinetic processes (i.e. the dissolution of B–I pairs......In order to fabricate carrier profiles with a junction depth (15 nm) and sheet resistance value suited for sub-32 nm Si-CMOS technology, the usage of sub-melt laser anneal is a promising route to explore. As laser annealed junctions seem to outperform standard anneal approaches, a detailed......) and not by the (temperature related) solid solubility....

[Comparison of the clinical effects of selective laser melting deposition basal crowns and cobalt chromium alloy base crowns].

Science.gov (United States)

Li, Jing-min; Wang, Wei-qian; Ma, Jing-yuan

2014-06-01

To evaluate the clinical effects of selective laser melting (SLM) deposition basal crowns and cobalt chromium alloy casting base crowns. One hundred and sixty eight patients treated with either SLM deposition basal crowns (110 teeth) or cobalt chromium alloy casting basal crowns (110 teeth) were followed-up for 1 month, 6 months, 12 months and 24 months. The revised standard of American Public Health Association was used to evaluate the clinical effect of restoration, including the color of porcelain crowns, gingival inflammation, gingival margin discoloration, and crack or fracture. Data analysis was conducted with SPSS 20 software package for Student's t test and Chi-square test. Six cases were lost to follow-up. The patients who were treated with SLM deposition basal crowns (104 teeth) and cobalt chromium alloy casting base crowns (101 teeth) completed the study. Patients were more satisfied with SLM deposition cobalt chromium alloy porcelain crowns. There was 1 prosthesis with poor marginal fit after 24 months of restoration in SLM crowns. There were 6 prostheses with edge coloring and 8 with poor marginal fit in cobalt chromium alloy casting base crowns, which was significantly different between the 2 groups(P<0.05). The SLM deposition copings results in smaller edge coloring and better marginal fit than those of cobalt-chrome copings. Patients are pleased with short-term clinical results.

Melting Can Hinder Impact-Induced Adhesion

Science.gov (United States)

Hassani-Gangaraj, Mostafa; Veysset, David; Nelson, Keith A.; Schuh, Christopher A.

2017-10-01

Melting has long been used to join metallic materials, from welding to selective laser melting in additive manufacturing. In the same school of thought, localized melting has been generally perceived as an advantage, if not the main mechanism, for the adhesion of metallic microparticles to substrates during a supersonic impact. Here, we conduct the first in situ supersonic impact observations of individual metallic microparticles aimed at the explicit study of melting effects. Counterintuitively, we find that under at least some conditions melting is disadvantageous and hinders impact-induced adhesion. In the parameter space explored, i.e., ˜10 μ m particle size and ˜1 km /s particle velocity, we argue that the solidification time is much longer than the residence time of the particle on the substrate, so that resolidification cannot be a significant factor in adhesion.

Design and Fabrication of a Precision Template for Spine Surgery Using Selective Laser Melting (SLM).

Science.gov (United States)

Wang, Di; Wang, Yimeng; Wang, Jianhua; Song, Changhui; Yang, Yongqiang; Zhang, Zimian; Lin, Hui; Zhen, Yongqiang; Liao, Suixiang

2016-07-22

In order to meet the clinical requirements of spine surgery, this paper proposes the fabrication of the customized template for spine surgery through computer-aided design. A 3D metal printing-selective laser melting (SLM) technique was employed to directly fabricate the 316L stainless steel template, and the metal template with tiny locating holes was used as an auxiliary tool to insert spinal screws inside the patient's body. To guarantee accurate fabrication of the template for cervical vertebra operation, the contact face was placed upwards to improve the joint quality between the template and the cervical vertebra. The joint surface of the printed template had a roughness of Ra = 13 ± 2 μm. After abrasive blasting, the surface roughness was Ra = 7 ± 0.5 μm. The surgical metal template was bound with the 3D-printed Acrylonitrile Butadiene Styrene (ABS) plastic model. The micro-hardness values determined at the cross-sections of SLM-processed samples varied from HV0.3 250 to HV0.3 280, and the measured tensile strength was in the range of 450 MPa to 560 MPa, which showed that the template had requisite strength. Finally, the metal template was clinically used in the patient's surgical operation, and the screws were inserted precisely as the result of using the auxiliary template. The geometrical parameters of the template hole (e.g., diameter and wall thickness) were optimized, and measures were taken to optimize the key geometrical units (e.g., hole units) in metal 3D printing. Compared to the traditional technology of screw insertion, the use of the surgical metal template enabled the screws to be inserted more easily and accurately during spinal surgery. However, the design of the high-quality template should fully take into account the clinical demands of surgeons, as well as the advice of the designing engineers and operating technicians.

In-situ formation of Ni4Ti3 precipitate and its effect on pseudoelasticity in selective laser melting additive manufactured NiTi-based composites

Science.gov (United States)

Gu, Dongdong; Ma, Chenglong

2018-05-01

Selective laser melting (SLM) additive manufacturing technology was applied to synthesize NiTi-based composites via using ball-milled Ti, Ni, and TiC mixed powder. By transmission electron microscope (TEM) characterization, it indicated that the B2 (NiTi) matrix was obtained during SLM processing. In spite of more Ti content (the Ti/Ni ratio >1), a mass of Ni-rich intermetallic compounds containing Ni4Ti3 with nanostructure features and eutectic Ni3Ti around in-situ Ti6C3.75 dendrites were precipitated. Influence of the applied laser volume energy density (VED) on the morphology and content of Ni4Ti3 precipitate was investigated. Besides, nanoindentation test of the matrix was performed in order to assess pseudoelastic recovery behavior of SLM processed NiTi-based composites. At a relatively high VED of 533 J/mm3, the maximum pseudoelastic recovery was obtained due to the lowest content of Ni4Ti3 precipitates. Furthermore, the precipitation mechanism of in-situ Ni4Ti3 was present based on the redistribution of titanium element and thermodynamics analysis, and then the relationship of Ni4Ti3 precipitate, VED and pseudoelastic recovery behavior was also revealed.

Microstructures, hardness and bioactivity of hydroxyapatite coatings deposited by direct laser melting process

International Nuclear Information System (INIS)

Tlotleng, Monnamme; Akinlabi, Esther; Shukla, Mukul; Pityana, Sisa

2014-01-01

Hydroxyapatite (HAP) coatings on bioinert metals such as Ti–6Al–4V are necessary for biomedical applications. Together, HAP and Ti–6Al–4V are biocompatible and bioactive. The challenges of depositing HAP on Ti–6Al–4V with traditional thermal spraying techniques are well founded. In this paper, HAP was coated on Ti–6Al–4V using direct laser melting (DLM) process. This process, unlike the traditional coating processes, is able to achieve coatings with good metallurgical bonding and little dilution. The microstructural and mechanical properties, chemical composition and bio-activities of the produced coatings were studied with optical microscopy, scanning electron microscope equipped with energy dispersive X-ray spectroscopy, and Vickers hardness machine, and by immersion test in Hanks' solution. The results showed that the choice of the laser power has much influence on the evolving microstructure, the mechanical properties and the retainment of HAP on the surface of the coating. Also, the choice of laser power of 750 W led to no dilution. The microhardness results inferred a strong intermetallic–ceramic interfacial bonding; which meant that the 750 W coating could survive long in service. Also, the coating was softer at the surface and stronger in the heat affected zones. Hence, this process parameter setting can be considered as an optimal setting. The soak tests revealed that the surface of the coating had unmelted crystals of HAP. The CaP ratio conducted on the soaked coating was 2.00 which corresponded to tetra calcium phosphate. This coating seems attractive for metallic implant applications. - Highlights: • Characteristics of HAP coatings produced on Ti-6Al-4V achieved with direct laser melting are reported. • Optimal process parameters necessary to achieve biocompatible coating are reported. • The SEM micrograph of the soaked HAP coating revealed partially melted crystals of HAP. • The HAP coating was retained at the surface of

Microstructures, hardness and bioactivity of hydroxyapatite coatings deposited by direct laser melting process

Energy Technology Data Exchange (ETDEWEB)

Tlotleng, Monnamme, E-mail: MTlotleng@csir.co.za [Laser Materials Processing Group, National Laser Center CSIR, Pretoria 0001 (South Africa); Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park, Kingsway Campus, Johannesburg 2006 (South Africa); Akinlabi, Esther [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park, Kingsway Campus, Johannesburg 2006 (South Africa); Shukla, Mukul [Department of Mechanical Engineering Technology, University of Johannesburg, Doornfontein Campus, Johannesburg 2006 (South Africa); Department of Mechanical Engineering, MNNIT, Allahabad, UP 211004 (India); Pityana, Sisa [Laser Materials Processing Group, National Laser Center CSIR, Pretoria 0001 (South Africa); Department of Chemical and Metallurgical Engineering, Tshwane University of Technology, Pretoria 0001 (South Africa)

2014-10-01

Hydroxyapatite (HAP) coatings on bioinert metals such as Ti–6Al–4V are necessary for biomedical applications. Together, HAP and Ti–6Al–4V are biocompatible and bioactive. The challenges of depositing HAP on Ti–6Al–4V with traditional thermal spraying techniques are well founded. In this paper, HAP was coated on Ti–6Al–4V using direct laser melting (DLM) process. This process, unlike the traditional coating processes, is able to achieve coatings with good metallurgical bonding and little dilution. The microstructural and mechanical properties, chemical composition and bio-activities of the produced coatings were studied with optical microscopy, scanning electron microscope equipped with energy dispersive X-ray spectroscopy, and Vickers hardness machine, and by immersion test in Hanks' solution. The results showed that the choice of the laser power has much influence on the evolving microstructure, the mechanical properties and the retainment of HAP on the surface of the coating. Also, the choice of laser power of 750 W led to no dilution. The microhardness results inferred a strong intermetallic–ceramic interfacial bonding; which meant that the 750 W coating could survive long in service. Also, the coating was softer at the surface and stronger in the heat affected zones. Hence, this process parameter setting can be considered as an optimal setting. The soak tests revealed that the surface of the coating had unmelted crystals of HAP. The CaP ratio conducted on the soaked coating was 2.00 which corresponded to tetra calcium phosphate. This coating seems attractive for metallic implant applications. - Highlights: • Characteristics of HAP coatings produced on Ti-6Al-4V achieved with direct laser melting are reported. • Optimal process parameters necessary to achieve biocompatible coating are reported. • The SEM micrograph of the soaked HAP coating revealed partially melted crystals of HAP. • The HAP coating was retained at the surface of

Selective Laser Melting: a regular unit cell approach for the manufacture of porous, titanium, bone in-growth constructs, suitable for orthopedic applications.

Science.gov (United States)

Mullen, Lewis; Stamp, Robin C; Brooks, Wesley K; Jones, Eric; Sutcliffe, Christopher J

2009-05-01

In this study, a novel porous titanium structure for the purpose of bone in-growth has been designed, manufactured and evaluated. The structure was produced by Selective Laser Melting (SLM); a rapid manufacturing process capable of producing highly intricate, functionally graded parts. The technique described utilizes an approach based on a defined regular unit cell to design and produce structures with a large range of both physical and mechanical properties. These properties can be tailored to suit specific requirements; in particular, functionally graded structures with bone in-growth surfaces exhibiting properties comparable to those of human bone have been manufactured. The structures were manufactured and characterized by unit cell size, strand diameter, porosity, and compression strength. They exhibited a porosity (10-95%) dependant compression strength (0.5-350 Mpa) comparable to the typical naturally occurring range. It is also demonstrated that optimized structures have been produced that possesses ideal qualities for bone in-growth applications and that these structures can be applied in the production of orthopedic devices. (c) 2008 Wiley Periodicals, Inc.

Influence of surface melting effects and availability of reagent ions on LDI-MS efficiency after UV laser irradiation of Pd nanostructures.

Science.gov (United States)

Silina, Yuliya E; Koch, Marcus; Volmer, Dietrich A

2015-03-01

In this study, the influence of surface morphology, reagent ions and surface restructuring effects on atmospheric pressure laser desorption/ionization (LDI) for small molecules after laser irradiation of palladium self-assembled nanoparticular (Pd-NP) structures has been systematically studied. The dominant role of surface morphology during the LDI process, which was previously shown for silicon-based substrates, has not been investigated for metal-based substrates before. In our experiments, we demonstrated that both the presence of reagent ions and surface reorganization effects--in particular, melting--during laser irradiation was required for LDI activity of the substrate. The synthesized Pd nanostructures with diameters ranging from 60 to 180 nm started to melt at similar temperatures, viz. 890-898 K. These materials exhibited different LDI efficiencies, however, with Pd-NP materials being the most effective surface in our experiments. Pd nanostructures of diameters >400-800 nm started to melt at higher temperatures, >1000 K, making such targets more resistant to laser irradiation, with subsequent loss of LDI activity. Our data demonstrated that both melting of the surface structures and the presence of reagent ions were essential for efficient LDI of the investigated low molecular weight compounds. This dependence of LDI on melting points was exploited further to improve the performance of Pd-NP-based sampling targets. For example, adding sodium hypophosphite as reducing agent to Pd electrolyte solutions during synthesis lowered the melting points of the Pd-NP materials and subsequently gave reduced laser fluence requirements for LDI. Copyright © 2015 John Wiley & Sons, Ltd.

Quantum Hooke's Law to Classify Pulse Laser Induced Ultrafast Melting

Science.gov (United States)

Hu, Hao; Ding, Hepeng; Liu, Feng

2015-02-01

Ultrafast crystal-to-liquid phase transition induced by femtosecond pulse laser excitation is an interesting material's behavior manifesting the complexity of light-matter interaction. There exist two types of such phase transitions: one occurs at a time scale shorter than a picosecond via a nonthermal process mediated by electron-hole plasma formation; the other at a longer time scale via a thermal melting process mediated by electron-phonon interaction. However, it remains unclear what material would undergo which process and why? Here, by exploiting the property of quantum electronic stress (QES) governed by quantum Hooke's law, we classify the transitions by two distinct classes of materials: the faster nonthermal process can only occur in materials like ice having an anomalous phase diagram characterized with dTm/dP < 0, where Tm is the melting temperature and P is pressure, above a high threshold laser fluence; while the slower thermal process may occur in all materials. Especially, the nonthermal transition is shown to be induced by the QES, acting like a negative internal pressure, which drives the crystal into a ``super pressing'' state to spontaneously transform into a higher-density liquid phase. Our findings significantly advance fundamental understanding of ultrafast crystal-to-liquid phase transitions, enabling quantitative a priori predictions.

Microstructure and property evolutions of titanium/nano-hydroxyapatite composites in-situ prepared by selective laser melting.

Science.gov (United States)

Han, Changjun; Wang, Qian; Song, Bo; Li, Wei; Wei, Qingsong; Wen, Shifeng; Liu, Jie; Shi, Yusheng

2017-07-01

Titanium (Ti)-hydroxyapatite (HA) composites have the potential for orthopedic applications due to their favorable mechanical properties, excellent biocompatibility and bioactivity. In this work, the pure Ti and nano-scale HA (Ti-nHA) composites were in-situ prepared by selective laser melting (SLM) for the first time. The phase, microstructure, surface characteristic and mechanical properties of the SLM-processed Ti-nHA composites were studied by X-ray diffraction, transmission electron microscope, atomic force microscope and tensile tests, respectively. Results show that SLM is a suitable method for fabricating the Ti-nHA composites with refined microstructure, low modulus and high strength. A novel microstructure evolution can be illustrated as: Relatively long lath-shaped grains of pure Ti evolved into short acicular-shaped and quasi-continuous circle-shaped grains with the varying contents of nHA. The elastic modulus of the Ti-nHA composites is 3.7% higher than that of pure Ti due to the effect of grain refinement. With the addition of 2% nHA, the ultimate tensile strength significantly reduces to 289MPa but still meets the application requirement of bone implants. The Ti-nHA composites exhibit a remarkable improvement of microhardness from 336.2 to 600.8 HV and nanohardness from 5.6 to 8.3GPa, compared to those of pure Ti. Moreover, the microstructure and property evolution mechanisms of the composites with the addition of HA were discussed and analyzed. It provides some new knowledge to the design and fabrication of biomedical material composites for bone implant applications. Copyright © 2017 Elsevier Ltd. All rights reserved.

Laser melt injection of ceramic particles in metals : Processing, microstructure and properties