Sara M. Gaytan

Metal Fabrication by Additive Manufacturing Using Laser and Electron Beam Melting Technologies

Selective laser melting (SLM) and electron beam melting (EBM) are relatively new rapid, additive manufacturing technologies which can allow for the fabrication of complex, multi-functional metal or alloy monoliths by CAD-directed, selective melting of precursor powder beds. By altering the beam parameters and scan strategies, new and unusual, even non-equilibrium microstructures can be produced; including controlled microstructural architectures which ideally extend the contemporary materials science and engineering paradigm relating structure-properties-processing-performance. In this study, comparative examples for SLM and EBM fabricated components from pre-alloyed, atomized precursor powders are presented. These include Cu, Ti-6Al-4V, alloy 625 (a Ni-base superalloy), a Co-base superalloy, and 17-4 PH stainless steel. These systems are characterized by optical metallography, scanning and transmission electron microscopy, and X-ray diffraction.

Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays

In this paper, we examine prospects for the manufacture of patient-specific biomedical implants replacing hard tissues (bone), particularly knee and hip stems and large bone (femoral) intramedullary rods, using additive manufacturing (AM) by electron beam melting (EBM). Of particular interest is the fabrication of complex functional (biocompatible) mesh arrays. Mesh elements or unit cells can be divided into different regions in order to use different cell designs in different areas of the component to produce various or continually varying (functionally graded) mesh densities. Numerous design elements have been used to fabricate prototypes by AM using EBM of Ti-6Al-4V powders, where the densities have been compared with the elastic (Young) moduli determined by resonant frequency and damping analysis. Density optimization at the bone–implant interface can allow for bone ingrowth and cementless implant components. Computerized tomography (CT) scans of metal (aluminium alloy) foam have also allowed for the building of Ti-6Al-4V foams by embedding the digital-layered scans in computer-aided design or software models for EBM. Variations in mesh complexity and especially strut (or truss) dimensions alter the cooling and solidification rate, which alters the α-phase (hexagonal close-packed) microstructure by creating mixtures of α/α′ (martensite) observed by optical and electron metallography. Microindentation hardness measurements are characteristic of these microstructures and microstructure mixtures (α/α′) and sizes.

Fabrication of Metal and Alloy Components by Additive Manufacturing: Examples of 3D Materials Science

Objective This paper provides a brief review of relatively new additive manufacturing technologies for the fabrication of unusual and complex metal and alloy products by laser and electron beam melting. A number of process features and product microstructures are illustrated utilizing 3D optical and transmission electron microscope image compositions representing examples of 3D materials science. Methods Processing methods involving electron beam melting (EBM) and a process referred to as direct metal laser sintering (DMLS), often called selective laser melting (SLM) are described along with the use of light (optical) microscopy (OM), transmission electron microscopy (TEM), and X-ray diffraction (XRD) to elucidate microstructural phenomena. Results Examples of EBM and SLM studies are presented in 3D image compositions. These include EBM of Ti-6Al-4V, Cu, Co-base superalloy and Inconel 625; and SLM of 17-4 PH stainless steel, Inconel 718 and Inconel 625. Conclusions 3D image compositions constituting 3D materials science provide effective visualization for directional solidification-related phenomena associated with the EBM and SLM fabrication of a range of metals and alloys, especially microstructures and microstructural architectures.

Next generation orthopaedic implants by additive manufacturing using electron beam melting

This paper presents some examples of knee and hip implant components containing porous structures and fabricated in monolithic forms utilizing electron beam melting (EBM). In addition, utilizing stiffness or relative stiffness versus relative density design plots for open-cellular structures (mesh and foam components) of Ti-6Al-4V and Co-29Cr-6Mo alloy fabricated by EBM, it is demonstrated that stiffness-compatible implants can be fabricated for optimal stress shielding for bone regimes as well as bone cell ingrowth. Implications for the fabrication of patient-specific, monolithic, multifunctional orthopaedic implants using EBM are described along with microstructures and mechanical properties characteristic of both Ti-6Al-4V and Co-29Cr-6Mo alloy prototypes, including both solid and open-cellular prototypes manufactured by additive manufacturing (AM) using EBM.

Evaluation of Titanium Alloys Fabricated Using Rapid Prototyping Technologies—Electron Beam Melting and Laser Beam Melting

This study characterized properties of Ti-6Al-4V ELI (extra low interstitial, ASTM grade 23) specimens fabricated by a laser beam melting (LBM) and an electron beam melting (EBM) system for dental applications. Titanium alloy specimens were made into required size and shape for each standard test using fabrication methods. The LBM specimens were made by an LBM machine utilizing 20 µm of Ti-6Al-4V ELI powder. Ti-6Al-4V ELI specimens were also fabricated by an EBM using 40 µm of Ti-6Al-4V ELI powder (average diameter, 40 µm: Arcam AB®) in a vacuum. As a control, cast Ti-6Al-4V ELI specimens (Cast) were made using a centrifugal casting machine in an MgO-based mold. Also, a wrought form of Ti-6Al-4V ELI (Wrought) was used as a control. The mechanical properties, corrosion properties and grindability (wear properties) were evaluated and data was analyzed using ANOVA and a non-parametric method (α = 0.05). The strength of the LBM and wrought specimens were similar, whereas the EBM specimens were slightly lower than those two specimens. The hardness of both the LBM and EBM specimens was similar and slightly higher than that of the cast and wrought alloys. For the higher grindability speed at 1,250 m/min, the volume loss of Ti64 LBM and EBM showed no significant differences among all the fabrication methods. LBM and EBM exhibited favorable results in fabricating dental appliances with excellent properties as found for specimens made by other fabricating methods.

Advanced metal powder based manufacturing of complex components by electron beam melting

Abstract Electron beam melting of Ti–6Al–4V powder (∼30 μm diameter) to create complex, three-dimensional components layer by layer using CAD is described along with the characterisation of these products (builds) by optical and electron microscopy, and mechanical testing. Build defects, including porous (unmelted or unsintered) zones, inclusions and gas bubbles trapped in the atomised powder particles and retained in the build, are illustrated. Reticulated mesh geometries and their applications are described along with examples having biomedical applications. Microstructures of solid components and mesh arrays are described. Powder chemistries and solid build chemistries are also examined and shown to be constant for up to 40 cycles of powder reuse, but there was a 10–15% reduction in Al content in the solid builds at optimised build conditions. Quality control and related issues are also described using duplicate products for destructive testing correlated with removable quality control tabs on the builds.

Microstructures and Properties of 17-4 PH Stainless Steel Fabricated by Selective Laser Melting

Objective This research examines 17-4 PH stainless steel powders produced by atomization in either argon or nitrogen atmospheres (producing martensitic (α-Fe) or mostly austenitic (γ-Fe) phase powders, respectively) and correspondingly fabricated by selective laser melting (SLM) in either a nitrogen or argon atmosphere. Methods Pre-alloyed 17-4 stainless steel powders prepared by atomization in either argon or nitrogen atmospheres were fabricated by SLM. The initial powder microstructures and phase structures were examined by light (optical) microscopy (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD). Prototypes fabricated by SLM were similarly characterized, and in addition transmission electron microscopy (TEM) characterization was also performed. Results Martensitic powder fabricated by SLM in nitrogen gas produced a martensitic product while pre-alloyed austenitic powder produced a primarily austenitic product. In contrast, both powders produced martensitic products when fabricated by SLM in argon gas. This unusual behavior occurred because of the rapid cooling affected by nitrogen versus argon cover gas as a consequence of a 40% greater thermal conductivity of nitrogen gas versus argon gas. SLM fabricated martensitic products exhibited HRC 30 in contrast to HRC 43 when aged at 482°C for 1 hour. Austenitic products did not exhibit age-hardening. Conclusions Using an argon cover gas, SLM-fabricated products are martensitic (and magnetic) with either an austenitic or martensitic pre-alloyed 17-4 PH stainless steel powder. Using a nitrogen cover gas, the product phase is the same as the precursor powder phase (austenitic or martensitic).

Interplay between cellular activity and three-dimensional scaffold-cell constructs with different foam structure processed by electron beam melting

The cellular activity, biological response, and consequent integration of scaffold-cell construct in the physiological system are governed by the ability of cells to adhere, proliferate, and biomineralize. In this regard, we combine cellular biology and materials science and engineering to fundamentally elucidate the interplay between cellular activity and interconnected three-dimensional foamed architecture obtained by a novel process of electron beam melting and computational tools. Furthermore, the organization of key proteins, notably, actin, vinclulin, and fibronectin, involved in cellular activity and biological functions and relationship with the structure was explored. The interconnected foamed structure with ligaments was favorable to cellular activity that includes cell attachment, proliferation, and differentiation. The primary rationale for favorable modulation of cellular functions is that the foamed structure provided a channel for migration and communication between cells leading to highly mineralized extracellular matrix (ECM) by the differentiating osteoblasts. The filopodial interaction amongst cells on the ligaments was a governing factor in the secretion of ECM, with consequent influence on maturation and mineralization.

Concept and Model of a Metamaterial-Based Passive Wireless Temperature Sensor for Harsh Environment Applications

Wireless passive temperature sensors are receiving increasing attention due to the ever-growing need of improving energy efficient and precise monitoring of temperature in high-temperature energy conversion systems, such as gas turbines and coal-based power plants. Unfortunately, the harsh environment, such as high temperature and corrosive atmosphere present in these systems, has significantly limited the reliability and increased the costs of current solutions. Therefore, this paper presents the concept and design of a low cost, passive, and wireless temperature sensor that can withstand high temperature and harsh environments. The temperature sensor was designed following the principle of metamaterials by utilizing closed ring resonators in a dielectric ceramic matrix. The proposed wireless, passive temperature sensor behaves like an

Contributions of Light Microscopy to Contemporary Materials Characterization: The New Directional Solidification

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