G. Miranda

Tribological behavior of Ti6Al4V cellular structures produced by Selective Laser Melting

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 Youngs 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.

Finite element analysis of the residual thermal stresses on functionally gradated dental restorations

The aim of this work was to study, using the finite element method (FEM), the distribution of thermal residual stresses arising in metal-ceramic dental restorations after cooling from the processing temperature. Three different interface configurations were studied: with conventional sharp transition; one with a 50% metal-50% ceramic interlayer; and one with a compositionally functionally gradated material (FGM) interlayer. The FE analysis was performed based on experimental data obtained from Dynamic Mechanical Analysis (DMA) and Dilatometry (DIL) studies of the monolithic materials and metal/ceramic composites. Results have shown significant benefits of using the 50% metal-50% ceramic interlayer and the FGM interlayer over the conventional sharp transition interface configuration in reduction of the thermal residual stress and improvement of stress profiles. Maximum stresses magnitudes were reduced by 10% for the crowns with 50% metal-50% ceramic interlayer and by 20% with FGM interlayer. The reduction in stress magnitude and smoothness of the stress distribution profile due to the gradated architectures might explain the improved behavior of these novel dental restorative systems relative to the conventional one, demonstrated by in-vitro studies already reported in literature.

Effect of sintering stage in NiTi short-fibre-reinforced aluminium–silicon composites interface properties

This study is concerned with the influence of sintering stage duration on the interface load transfer capacity between NiTi fibres and AlSi matrix alloy and thus in the final composite strength. Short-fibre-NiTi/AlSi composites were produced by a pressure-assisted sintering process, under vacuum, for sintering stages of 20, 25 and 60 min. All the obtained composites, with different sintering stages, have shown the occurrence of load transfer from the matrix to fibres, indicating the development of an effective interface between fibre and matrix. Performed shear tests have shown a decaying of shear strength with increasing sintering stage, in the selected range of sintering times, with the lowest sintering time leading to higher properties. It was also concluded that with increasing sintering stage, the interface volume around the fibres increases and the load transfer capacity decreases.

Carbon nanotube dispersion in aluminum matrix composites—Quantification and influence on strength

ABSTRACT Carbon nanotube (CNT) incorporation in metal matrix composites is hampered by the development of attractive van der Waals forces, which lead to the formation of CNT agglomerates. Therefore, a detailed quantification and characterization of CNT agglomerates and consequently CNT dispersion can enlighten their influence in composites strength. This work presents a comprehensive study, quantifying agglomerates by size, for three different composites (2, 4, and 6 CNT vol%), made with an aluminum-silicon matrix by a powder metallurgy route. From the obtained experimental data, an empirical model that attempts to predict the tensile strength of these composites from CNT agglomerates analysis is presented.

Wear behavior of Ti6Al4V biomedical alloys processed by selective laser melting, hot pressing and conventional casting

Abstract The aim of this work was to study the influence of the processing route on the microstructural constituents, hardness and tribological (wear and friction) behavior of Ti6Al4V biomedical alloy. In this sense, three different processing routes were studied: conventional casting, hot pressing and selective laser melting. A comprehensive metallurgical, mechanical and tribological characterization was performed by X-ray diffraction analysis, Vickers hardness tests and reciprocating ball-on-plate wear tests of Ti6Al4V/Al 2 O 3 sliding pairs. The results showed a great influence of the processing route on the microstructural constituents and consequent differences on hardness and wear performance. The highest hardness and wear resistance were obtained for Ti6Al4V alloy produced by selective laser melting, due to a markedly different cooling rate that leads to significantly different microstructure when compared to hot pressing and casting. This study assesses and confirms that selective laser melting is potential to produce customized Ti6Al4V implants with improved wear performance.

Mechanisms governing the tensile, fatigue, and wear behavior of carbon nanotube reinforced aluminum alloy

ABSTRACT This work is concerned with understanding the influence of reinforcement mechanisms of carbon nanotubes (CNTs) on mechanical, wear, and fatigue tests on an Aluminium-Silicon (AlSi) alloy. The reinforcement mechanism is presented through the observation of fracture morphology of the different tests. Results of mechanical properties, fatigue life performance, and wear loss is presented and discussed. It is shown that the CNTs reinforcement effect is active simultaneously in all previous properties and the reinforcement physical mechanism seems to be essentially due to a reinforcement effect of the interface that seems to be similar in all mentioned mechanical solicitations.

Properties assessment of nickel particulate-reinforced aluminum composites produced by hot pressing

Nickel particulate-reinforced aluminum-silicon composites, with 5, 12.5 and 20 wt%Nickel were produced by a hot pressing route. Microstructural characterization showed a uniform distribution of the Nickel particulates in the aluminum-silicon matrix. Ultimate tensile strength and hardness of the composites were found higher than for the aluminum-silicon alloy, while ductility suffered a decrease. Fracture surface analysis showed evidences of load transfer from the matrix to the reinforcement indicating the development of an effective interfacial bonding between Nickel particulates and aluminum-silicon matrix. Energy dispersive spectrometer and X-ray diffraction analyses performed in the particle/matrix interface revealed that it was formed by Al3Ni intermetallic. It was found that the amount of Al3Ni intermetallic has a paramount influence in the composites properties.

Evaluation of CNT Dispersion Methodology Effect on Mechanical Properties of an AlSi Composite

The aim of this paper was to evaluate the effect of different dispersion methodologies on mechanical properties of the aluminum-silicon (AlSi) composites reinforced by multi-walled carbon nanotubes (MWCNTs) coated with Ni. Different mixing procedures of MWCNTs with AlSi powder were tested, and AlSi-CNT composites were produced by hot pressing—powder metallurgy technique. The shear tests were performed to get the mechanical properties. Scanning electron microscopy with x-ray energy dispersive spectroscopy analysis and thermal analysis was used to investigate the microstructure of AlSi-CNT composites, interface reactions, and fracture morphology after shear tests. The experimental results proved that an improvement of dispersion of CNTs was achieved by using a combination of different mixing processes.

Bioactive materials driven primary stability on titanium biocomposites

The Ti6Al4V alloy constitutes an alternative choice to the most common metal-polymer solutions for total hip arthroplasty (THA) due to good biocompatibility, optimal mechanical properties and high load bearing capacity. However, as Ti6Al4V is not bioactive in its conventional form, hydroxyapatite (HAp) and tricalcium phosphate (TCP) have been widely used as coatings of metal prostheses due to their osteogenic properties and ability to form strong bonds with bone tissue. A promising approach consists in creating a bioactive surface metal matrix composite Ti6Al4V+β-TCP or Ti6Al4V+HAp, obtained by hot pressing (HP) of powders. In this work, the tribological performance of Ti6Al4V+β-TCP and Ti6Al4V+HAp composites is studied to evaluate the frictional response and surface damage representative of prosthesis implantation, key factors in bone fixation. Biocomposites with 10vol% β-TCP and 10vol% Hap, as well as base titanium alloy, were prepared by HP with two surface finishing conditions - polished (Ra=0.3-0.5μm) and sandblasted (Ra=2.1-2.5μm) - for tribological testing against bovine cortical bone tissue. The static friction increases with surface roughness (from 0.20 to 0.60), whereas the kinetic regime follows an inverse trend for the biocomposites. In contrast with current knowledge, this study shows that an implant design solution based on Ti6Al4V+β-TCP or Ti6Al4V+HAp biocomposites with polished surfaces results in an improved primary stability of implants, when compared to traditional rough surfaces. Moreover, it is also expected that the secondary stability will improve due to the adhesion between bone and HAp/β-TCP, increasing the overall stability of the implant.

Pressure and sintering temperature influence on the interface reaction of SiCp/410L stainless steel composites

This study is concerned with the reactivity between SiC particles and 410L stainless steel alloy. An interval of sintering temperatures (900, 1000, 1100, and 1180℃) was scoped in order to study the temperature influence on the interface reaction under different compaction pressures (400, 800, and 1200 MPa). SiCp/410L SS composites were produced by powder metallurgy. Interface area fraction (%) results and microstructural characterization showed that the interface reaction is strongly dependent on temperature. At 900℃ no reaction SiCp/410L SS was found. At 1000℃ SiCp reacts with 410L SS matrix and with increasing temperature the extent of reaction becomes higher. However, at 1180℃ SiCp dissolves completely leading to specimen deformation. The higher interface area fraction was obtained at a sintering temperature of 1100℃ and a compaction pressure of 1200 MPa. This study presents an advantageous and original combination of materials and process that allows combining compaction pressure and sintering temperature in order to control the interface.