A. Gatto

3D printing technique applied to rapid casting

Purpose – The purpose of this paper is to verify the feasibility and evaluate the dimensional accuracy of two rapid casting (RC) solutions based on 3D printing technology: investment casting starting from 3D‐printed starch patterns and the ZCast process for the production of cavities for light‐alloys castings.Design/methodology/approach – Starting from the identification and design of a benchmark, technological prototypes were produced with the two RC processes. Measurements on a coordinate measuring machine allowed calculating the dimensional tolerances of the proposed technological chains. The predictive performances of computer aided engineering (CAE) software were verified when applied to the ZCast process modelling.Findings – The research proved that both the investigated RC solutions are effective in obtaining cast technological prototypes in short times and with low costs, with dimensional tolerances that are completely consistent with metal casting processes.Practical implications – The research a...

Benchmarking of rapid prototyping techniques in terms of dimensional accuracy and surface finish

Abstract Dimensional accuracy and surface finish are the cornerstone of Rapid Prototyping (RP) especially if the models will be used for the production of tools as mould or EDM electrodes. The paper deals with the development, manufacture and testing of benchmark to investigate dimensional accuracy and surface finish. A new technique of checking the machine quality of a RP workpiece according to the ANSI-ISO standards is presented. Moreover the surface of RP model were observed by SEM microscope.

High-speed turning experiments on metal matrix composites

Abstract The hard abrasive ceramic component which increases the mechanical characteristics of metal matrix composites (MMC) causes quick wear and premature tool failure in the machining operations. The aim of the paper is to compare the behaviour of high rake angle carbide tools with their diamond coated versions in high-speed machining of an Al 2 O 3 Al 6061 MMC. The influence of the cutting parameters, in particular cutting feed and speed, on tool wear and surface finish has been investigated. The higher abrasion resistance of the coatings results in increased tool life performances and different chip formation mechanisms.

Advanced coated ceramic tools for machining superalloys

The main limitation on the use of nickel-base superalloys, such as INCONEL 718, is the difficulty in conventional-type machining. The use of high cutting speed to achieve both machining adiabatic conditions and high productivity is necessary for their applications. This non-conventional type machining results in a short life-span of tools, even for those expensive ceramic ones with reinforced SiC whiskers (SiCw) suitable for use at high cutting speeds. The aim of the paper is to present the results of a new idea proposed by the authors to obtain an increase in tool life at high cutting speed by minimizing the temperature effects on composite reinforcement mechanisms. The 2090 SiC whiskers reinforced A12O3 tools were CrN and (Ti,AI)N coated using the PVD technique, and comparative machining tests on INCONEL 718 were carried out using uncoated and coated tools. After machining, the tools were observed with a scanning electron microscope (SEM), and EDAX (X-ray) semiquantitative analyses were performed. The behaviour of the CrN and (Ti,AI)N layers using various cutting conditions was analysed and different wear mechanisms along the tool chip contact length were observed. The cause and the mechanisms of wear were deduced and mathematic models linking tool life with process parameters were suggested.

Structural characterization of biomedical Co-Cr-Mo components produced by direct metal laser sintering.

Direct metal laser sintering (DMLS) is a technique to manufacture complex functional mechanical parts from a computer-aided design (CAD) model. Usually, the mechanical components produced by this procedure show higher residual porosity and poorer mechanical properties than those obtained by conventional manufacturing techniques. In this work, a Co-Cr-Mo alloy produced by DMLS with a composition suitable for biomedical applications was submitted to hardness measurements and structural characterization. The alloy showed a hardness value remarkably higher than those commonly obtained for the same cast or wrought alloys. In order to clarify the origin of this unexpected result, the sample microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX). For the first time, a homogeneous microstructure comprised of an intricate network of thin ε (hcp)-lamellae distributed inside a γ (fcc) phase was observed. The ε-lamellae grown on the {111}γ planes limit the dislocation slip inside the γ (fcc) phase, causing the measured hardness increase. The results suggest possible innovative applications of the DMLS technique to the production of mechanical parts in the medical and dental fields.

Cutting mechanisms and surface features of WED machined metal matrix composites

Abstract Metal matrix composites are manufactured in a variety of grades and forms, but machining is usually necessary to obtain finished engineering components. The presence of the hard reinforcing ceramic makes these materials difficult for conventional machining. Wire electro discharge machining (WEDM) is used for the processing of heat-treated high-quality alloys or for the machining of complex shapes in advanced materials. This paper describes WEDM tests performed under one roughing and two finishing conditions on two composites, SiC/2009Al alloy with 15% whiskers and with 20% particles reinforcement. Some roughed and some finished surfaces were glass-bead peened. To understand the reinforcement and the behaviour of the matrix during the machining of both composites, the machined surfaces, their sections and profiles were examined by scanning electron microscopy, and energy dispersive semi-quantitative analyses of X-rays were also carried out. The surface roughness for the process parameters used are indicated.

Chip formation analysis in high speed machining of a nickel base superalloy with silicon carbide whisker-reinforced alumina

Abstract High speed turning tests were performed on a heat resistant alloy (Inconel 718), using SiC (20%) whiskers reinforced ceramic tools. The main aims of these tests were the following: (1) mapping cutting speed-feed and machined volume in order to find a region free from tool breakage; (2) analysing tool wear and chip formation mechanisms; and (3) from the experimental results modelling analytically both chip formation processes and tool wear mechanism. Tool and chip were observed at the SEM and EDAX semiquantitative analyses were carried out to evaluate micro-welds on the chip and areas of welded or scattered material over the tool. Micro-hardness mapping was carried out on the longitudinal cross-section of the chips to monitor its dependence by process parameters. Variable wear mechanisms along the tool-chip contact length that were attributed to variations in plastic deformation energy were observed. There variations were analytically modelled in orthogonal cutting conditions. Longitudinal and tranverse shear planes into the chip were also observed. The causes and the mechanisms of wear, chip formation and the hardening of work material were deduced. The presence of whiskers pull out mechanisms due to temperature effects in the tool-chip interface were also observed.

Effects of thermal treatments on microstructure and mechanical properties of a Co-Cr-Mo-W biomedical alloy produced by laser sintering.

Direct Metal Laser Sintering (DMLS) technology based on a layer by layer production process was used to produce a Co-Cr-Mo-W alloy specifically developed for biomedical applications. The alloy mechanical response and microstructure were investigated in the as-sintered state and after post-production thermal treatments. Roughness and hardness measurements, and tensile and flexural tests were performed to study the mechanical response of the alloy while X-ray diffraction (XRD), electron microscopy (SEM, TEM, STEM) techniques and microanalysis (EDX) were used to investigate the microstructure in different conditions. Results showed an intricate network of ε-Co (hcp) lamellae in the γ-Co (fcc) matrix responsible of the high UTS and hardness values in the as-sintered state. Thermal treatments increase volume fraction of the ε-Co (hcp) martensite but slightly modify the average size of the lamellar structure. Nevertheless, thermal treatments are capable of producing a sensible increase in UTS and hardness and a strong reduction in ductility. These latter effects were mainly attributed to the massive precipitation of an hcp Co3(Mo,W)2Si phase and the contemporary formation of Si-rich inclusions.

Ex situ bioengineering of bioartificial endocrine glands: A new frontier in regenerative medicine of soft tissue organs

Ex situ bioengineering is one of the most promising perspectives in the field of regenerative medicine allowing for organ reconstruction outside the living body; i.e. on the laboratory bench. A number of hollow viscera of the cardiovascular, respiratory, genitourinary, and digestive systems have been successfully bioengineered ex situ, exploiting biocompatible scaffolds with a 3D morphology that recapitulates that of the native organ (organomorphic scaffold). In contrast, bioengineering of entire soft tissue organs and, in particular endocrine glands still remains a substantial challenge. Primary reasons are that no organomorphic scaffolding for endocrine viscera have as yet been entirely assembled using biocompatible materials, nor is there a bioreactor performance capable of supporting growth within the thickness range of the regenerating cell mass which has proven to be reliable enough to ensure formation of a complete macroscopic gland ex situ. Current technical options for reconstruction of endocrine viscera include either biocompatible 3D reticular scaffolds lacking any organomorphic geometry, or allogenic/xenogenic acellular 3D matrices derived from a gland similar to that to be bioengineered, eventually recellularized by autologous/heterologous cells. In 2007, our group designed, using biocompatible material, an organomorphic scaffold-bioreactor unit for bioengineering ex situ the human thyroid gland, chosen as a model for its simple anatomical organization (repetitive follicular cavities). This unit reproduces both the 3D native geometry of the human thyroid stromal/vascular scaffold, and the natural thyrocyte/vascular interface. It is now under intense investigation as an experimental tool to test cellular 3D auto-assembly of thyroid tissue and its related vascular system up to the ex situ generation of a 3D macroscopic thyroid gland. We believe that these studies will lay the groundwork for a new concept in regenerative medicine of soft tissue and endocrine organs; i.e. that the organomorphism of a biocompatible scaffold-bioreactor complex is essential to both the 3D organization of seeded stem cells/precursor cells and their phenotypic fate as glandular/parenchymal/vascular elements, eventually leading to a physiologically competent and immuno-tolerant bioconstruct, macroscopically suitable for transplantation and clinical applications.

A combined additive layer manufacturing / indirect replication method to prototype 3D vascular-like structures of soft tissue and endocrine organs: A combined additive layer manufacturing (ALM)/ indirect replication method to prototype 3D vascular-like structures of soft tissue and endocrine organs is presented in this paper

We describe an innovative methodology combining Additive Layer Manufacturing (ALM) and indirect replication to reconstruct reticular-like, three-dimensional (3D) structures mimicking the vascular network of soft tissue and endocrine organs. Using a fractal-like algorithm capable of modelling the intraparenchymal vascular distribution of these viscera, single intraglandular branches of the human thyroid arteries were prototyped with synthetic resin, based on the algorithmic standard to layer (STL) output and ALM techniques. Satisfactory dimensional accuracy was obtained for these models, which were used as masters to evaluate protocols for their indirect replication, through both single and double procedures. Additional studies were conducted using casts of the human kidney arteries, obtained by injection / corrosion of the isolated organ. Satisfactory 3D reproduction of the external morphology of the kidney vessels was achieved. We conclude that our approach has the potential to develop up to the reconstruction with biomaterials of an entire, intraparenchymal vascular tree of soft tissue and endocrine organs.