Ehsan Toyserkani

3-D finite element modeling of laser cladding by powder injection: effects of laser pulse shaping on the process

This paper introduces a 3-D transient finite element model of laser cladding by powder injection to investigate the effects of laser pulse shaping on the process. The proposed model can predict the clad geometry as a function of time and process parameters including laser pulse shaping, travel velocity, laser pulse energy, powder jet geometry, and material properties. In the proposed strategy, the interaction between powder and melt pool is assumed to be decoupled and as a result, the melt pool boundary is first obtained in the absence of powder spray. Once the melt pool boundary is obtained, it is assumed that a layer of coating material is deposited on the intersection of the melt pool and powder stream in the absence of the laser beam in which its thickness is calculated based on the powder feedrate and elapsed time. The new melt pool boundary is then calculated by thermal analysis of the deposited powder layer, substrate and laser heat flux. The process is simulated for different laser pulse frequencies and energies. The results are presented and compared with experimental data. The quality of clad bead for different parameter sets is experimentally evaluated and shown as a function of effective powder deposition density and effective energy density. The comparisons show excellent agreement between the modeling and experimental results for cases in which a high quality clad bead is expected.

Three-dimensional finite element modeling of laser cladding by powder injection: Effects of powder feedrate and travel speed on the process

This article addresses a novel three-dimensional transient finite element model of the laser cladding by powder injection process. The proposed model can predict clad geometry as a function of time and process parameters including beam velocity, laser power, powder jet geometry, laser pulse shaping, and material properties. In the proposed method, the interaction between powder and melt pool are assumed to be decoupled and as a result, the melt pool boundary is first obtained in the absence of powder spray. Once the melt pool boundary is calculated, it is assumed that a layer of coating material based on powder feedrate and elapsed time is deposited on the intersection of the melt pool and powder stream in the absence of laser beam. The new melt pool boundary is then calculated by thermal analysis of the deposited powder layer, substrate and laser heat flux. The results of numerical modeling for different process velocities and different powder feedrates are presented and compared with experimental result...

Solid freeform fabrication and characterization of porous calcium polyphosphate structures for tissue engineering purposes.

Solid freeform fabrication (SFF) enables the fabrication of anatomically shaped porous components required for formation of tissue engineered implants. This article reports on the characterization of a three-dimensional-printing method, as a powder-based SFF technique, to create reproducible porous structures composed of calcium polyphosphate (CPP). CPP powder of 75-150 microm was mixed with 10 wt % polyvinyl alcohol (PVA) polymeric binder, and used in the SFF machine with appropriate settings for powder mesh size. The PVA binder was eliminated during the annealing procedure used to sinter the CPP particles. The porous SFF fabricated components were characterized using scanning electron microscopy, micro-CT scanning, X-ray diffraction, and mercury intrusion porosimetry. In addition, mechanical testing was conducted to determine the compressive strength of the CPP cylinders. The 35 vol % porous structures displayed compressive strength on average of 33.86 MPa, a value 57% higher than CPP of equivalent volume percent porosity made through conventional gravity sintering. Dimensional deviation and shrinkage analysis was conducted to identify anisotropic factors required for dimensional compensation during SFF sample formation and subsequent sintering. Cell culture studies showed that the substrate supported cartilage formation in vitro, which was integrated with the top surface of the porous CPP similar to that observed when chondrocytes were grown on CPP formed by conventional gravity sintering methods as determined histologically and biochemically.

Prediction of melt pool depth and dilution in laser powder deposition

This paper presents a mathematical model of laser powder deposition (LPD) to predict temperature field, melt pool depth and dilution. The model validated by experiments is developed using the moving heat source method. In this method, the temperature distribution inside the clad and the substrate is obtained using the superposition principle and the solution of the heat diffusion due to a point heat source. The model, which can be used in real-time applications, predicts the melt pool depth and dilution as a function of clad height and clad width, which in practice can be measured by a vision system. Numerical and experimental analyses show a non-linear behaviour of the melt pool depth as a function of process speed. This indicates that the melt pool depth has a maximum at a certain process speed. The comparisons between the numerical and experimental results show that this model is capable of predicting the characteristics of the LPD process accurately. Using the model, some general curves that show the behaviours of the melt pool depth and dilution as a function of clad height, scanning speed and laser power are illustrated.

Mechanical characteristics of solid-freeform-fabricated porous calcium polyphosphate structures with oriented stacked layers

This study addresses the mechanical properties of calcium polyphosphate (CPP) structures formed by stacked layers using a powder-based solid freeform fabrication (SFF) technique. The mechanical properties of the 35% porous structures were characterized by uniaxial compression testing for compressive strength determination and diametral compression testing to determine tensile strength. Fracture cleavage surfaces were analyzed using scanning electron microscopy. The effects of the fabrication process on the microarchitecture of the CPP samples were also investigated. Results suggest that the orientation of the stacked layers has a substantial influence on the mechanical behavior of the SFF-made CPP samples. The samples with layers stacked parallel to the mechanical compressive load are 48% stronger than those with the layers stacked perpendicular to the load. However, the samples with different stacking orientations are not significantly different in tensile strength. The observed anisotropic mechanical properties were analyzed based on the physical microstructural properties of the CPP structures.

Three-dimensional numerical approach for geometrical prediction of multilayer laser solid freeform fabrication process

This article presents the development of a three-dimensional numerical method for predicting transient geometrical and thermal characteristics of multilayer laser solid freeform fabrication as a function of process parameters and material properties. In the proposed method, the thermal domain is numerically obtained, assuming the interaction between the laser beam and powder stream is to be decoupled. Once the melt pool boundary is obtained, the physical domain is discretized in a cross-sectional direction. Based on the powder feed rate, elapsed time, and intersection of the melt pool and powder stream area substrate, layers of additive material are then added onto the nonplanar domain. A standard object is fit to each added layer to facilitate the numerical analysis of successive layers. Variations in physical parameters due to formation of nonplanar surfaces are incorporated into the model to increase the accuracy and reliability of the simulated results. The developed model was used to predict the geometrical and thermal properties of a four-layer thin wall of AISI 4340 steel. The results show that the temperature and the thickness of the deposited layers sensibly increase at the end point of layers 2, 3, and 4. Also, the powder catchment efficiency for the first layer is significantly lower than those of successive layers. The experimental results demonstrate the validity of the developed numerical methodology.This article presents the development of a three-dimensional numerical method for predicting transient geometrical and thermal characteristics of multilayer laser solid freeform fabrication as a function of process parameters and material properties. In the proposed method, the thermal domain is numerically obtained, assuming the interaction between the laser beam and powder stream is to be decoupled. Once the melt pool boundary is obtained, the physical domain is discretized in a cross-sectional direction. Based on the powder feed rate, elapsed time, and intersection of the melt pool and powder stream area substrate, layers of additive material are then added onto the nonplanar domain. A standard object is fit to each added layer to facilitate the numerical analysis of successive layers. Variations in physical parameters due to formation of nonplanar surfaces are incorporated into the model to increase the accuracy and reliability of the simulated results. The developed model was used to predict the geom...

Characterizations of additive manufactured porous titanium implants

This article describes physical, chemical, and mechanical characterizations of porous titanium implants made by an additive manufacturing method to gain insight into the correlation of process parameters and final physical properties of implants used in orthopedics. For the manufacturing chain, the powder metallurgy technology was combined with the additive manufacturing to fabricate the porous structure from the pure tanium powder. A 3D printing machine was employed in this study to produce porous bar samples. A number of physical parameters such as titanium powder size, polyvinyl alcohol (PVA) amount, sintering temperature and time were investigated to control the mechanical properties and porosity of the structures. The produced samples were characterized through porosity and shrinkage measurements, mechanical compression test and scanning electron microscopy (SEM). The results showed a level of porosity in the samples in the range of 31-43%, which is within the range of the porosity of the cancelluous bone and approaches the range of the porosity of the cortical bone. The results of the mechanical test showed that the compressive strength is in the wide range of 56-509 MPa implying the effect of the process parameters on the mechanical strengths. This technique of manufacturing of Ti porous structures demonstrated a low level of shrinkage with the shrinkage percentage ranging from 1.5 to 5%.

Optimal design of laser solid freeform fabrication system and real-time prediction of melt pool geometry using intelligent evolutionary algorithms

With the rapid growth of laser applications and the introduction of high efficiency lasers (e.g. fiber lasers), laser material processing has gained increasing importance in a variety of industries. Among the applications of laser technology, laser cladding has received significant attention due to its high potential for material processing such as metallic coating, high value component repair, prototyping, and even low-volume manufacturing. In this paper, two optimization methods have been applied to obtain optimal operating parameters of Laser Solid Freeform Fabrication Process (LSFF) as a real world engineering problem. First, Particle Swarm Optimization (PSO) algorithm was implemented for real-time prediction of melt pool geometry. Then, a hybrid evolutionary algorithm called Self-organizing Pareto based Evolutionary Algorithm (SOPEA) was proposed to find the optimal process parameters. For further assurance on the performance of the proposed optimization technique, it was compared to some well-known vector optimization algorithms such as Non-dominated Sorting Genetic Algorithm (NSGA-II) and Strength Pareto Evolutionary Algorithm (SPEA 2). Thereafter, it was applied for simultaneous optimization of clad height and melt pool depth in LSFF process. Since there is no exact mathematical model for the clad height (deposited layer thickness) and the melt pool depth, the authors developed two Adaptive Neuro-Fuzzy Inference Systems (ANFIS) to estimate these two process parameters. Optimization procedure being done, the archived non-dominated solutions were surveyed to find the appropriate ranges of process parameters with acceptable dilutions. Finally, the selected optimal ranges were used to find a case with the minimum rapid prototyping time. The results indicate the acceptable potential of evolutionary strategies for controlling and optimization of LSFF process as a complicated engineering problem.

Cladding of an Fe-aluminide coating on mild steel using pulsed laser assisted powder deposition

Abstract Iron-aluminide has the potential to be used as a superior high temperature oxidation and sulfidation resistant coating on less corrosion resistant materials. A process for producing a dense, hard, iron-aluminide coating on a mild steel substrate has been successfully developed using pulsed laser assisted powder deposition (LAPD). The clad deposition rate, measured by clad height, increased with an increase in duty cycle of the laser, either through an increase in pulse duration or frequency, an increase in powder feed rate and decrease in substrate velocity. A simple analysis using concepts of an effective interaction time, energy and powder deposition density, all of which were determined by laser duty cycle, powder feed rate and substrate velocity, was developed. Taken together these three parameters allow a determination of the processing conditions that will give rise to a high quality FeAl clad on mild steel with a specified height.

Solid freeform fabrication of porous calcium polyphosphate structures for bone substitute applications: In vivo studies

Porous calcium polyphosphate (CPP) structures with 30 volume percent porosity and made by solid freeform fabrication (SFF) were implanted in rabbit femoral condyle sites for 6-wk periods. Two forms of SFF implants with different stacked layer orientation were made in view of prior studies reporting on anisotropic/orthotropic mechanical properties of structures so formed. In addition, porous CPP implants of equal volume percent porosity made by conventional sintering and machining methods were prepared. Bone ingrowth and in vivo degradation of the three different implant types were compared using back-scattered scanning electron microscopy (BS-SEM) of implant samples and quantitative analysis of the images. The results indicated bone ingrowth with all samples resulting in 30-40% fill of available porosity by bone within the 6-wk period. In the 6-wk in vivo period, approximately 7-9% loss of CPP by degradation had occurred.