Effect of Industrial Heat Treatment and Barrel Finishing on the Mechanical Performance of Ti6Al4V Processed by Selective Laser Melting

Additive manufacturing is now capable of delivering high-quality, complex-shaped metallic components. The titanium alloy Ti6Al4V is an example of a printable metal being broadly used for advanced structural applications. A sound characterization of static mechanical properties of additively manufactured material is crucial for its proper application, and here specifically for Ti6Al4V. This includes a complete understanding of the influence of postprocess treatment on the material behavior, which has not been reached yet. In the present paper, the postprocess effects of surface finish and heat treatment on the mechanical performance of Ti6Al4V after selective laser melting were investigated. Some samples were subjected to barrel finishing at two different intensities, while different sets of specimens underwent several thermal cycles. As a reference, a control group of specimens was included, which did not undergo any postprocessing. The treatments were selected to be effective and easy to perform, being suitable for real industrial applications. Tensile tests were performed on all the samples, to obtain yield stress, ultimate tensile strength and elongation at fracture. The area reduction of the barrel-finished samples, after being tested, was measured by using a 3D scanner, as a further indication of ductility. Experimental results are reported and discussed, highlighting the effect of postprocessing treatments on the mechanical response. We then propose the optimal postprocessing procedure to enhance ductility without compromising strength, for structures manufactured from Ti6Al4V with selective laser melting

Design and fabrication by selective laser melting of a LIDAR reflective unit using metal matrix composite material

The selective laser melting is an additive manufacturing technology able to directly fabricate full dense metal part from a virtual model. The geometrical complexity degree of freedom allows the implementation to several industrial applications such as the laser imaging detection and ranging systems. A key component of this system is the reflective unit produced with traditional technology (surface with ribs) with optimized geometry for lightweight, which must be further lightened while continuing to meet functional requirements. Aim of this work is to reach these goals by using an integrated product/process methodology which considers all the fabrication steps. A complete redesign allowed to exploit the additive manufacturing advantages of a metal matrix composite based on AA 2000 series combined with a high content of ceramic. The increased mechanical properties, such as the tensile strength of 484 MPa and Young modulus of 96GPa, combined with a lattice structure empowered the SLM capability. The component was validated via finite element method simulation focused on the most critical polishing operation. Results on static and dynamic analysis showed the 25% lightened mirror satisfies the requirements. The testing on the physical prototype confirmed the enhanced mechanical properties and the interferometric measurement proved the mirror functionality with a surface front error less than the required wavelength of 1550 nm. The work evidenced that polishing and the assembly configurations must be selected with particular care; otherwise, the final outcome is compromised for this SLMed component

New trends in 4D printing: A critical review

In a variety of industries, Additive Manufacturing has revolutionized the whole design-fabrication cycle. Traditional 3D printing is typically employed to produce static components, which are not able to fulfill the dynamic structures requirements and relevant applications such as soft grippers, self-assembly systems, and smart actuators. To address this limitation, an innovative technology has emerged and is called “4D printing”. It processes smart materials by using 3D printing for fabricating smart structures that can be reconfigured by applying different inputs such as heat, humidity, magnetic, electricity, light etc. At present, 4D printing is still a growing technology and it presents numerous challenges regarding materials, design, simulation, fabrication processes, applied strategies and reversibility. In this work a critical review about 4D printing technologies, materials and applications is discussed

Additive manufacturing for lightweighting satellite platform

Lightweight structures with an internal lattice infill and a closed shell have received a lot of attention in the last 20 years for satellites, due to their improved stiffness, buckling strength, multifunctional design, and energy absorption. The geometrical freedom typical of Additive Manufacturing allows lighter, stiffer, and more effective structures to be designed for aerospace applications. The Laser Powder Bed Fusion technology, in particular, enables the fabrication of metal parts with complex geometries, altering the way the mechanical components are designed and manufactured. This study proposed a method to re-design the original satellite structures consisting of walls and ribs with an enclosed lattice design. The proposed new structures must comply with restricted requirements in terms of mechanical properties, dimensional accuracy, and weight. The most challenging is the first frequency request which the original satellite design, based on traditional fabrication, does not satisfy. To overcome this problem a particular framework was developed for locally thickening the critical zones of the lattice. The use of the new design permitted complying with the dynamic behavior and to obtain a weight saving maintaining the mechanical properties. The Additive Manufacturing fabrication of this primary structure demonstrated the feasibility of this new technology to satisfy challenging requests in the aerospace field

Additive manufacturing for sustainable energy production in pico hydroelectric power plants

Additive manufacturing has proven to be a reliable method of producing components that are often difficult to produce using traditional methods. The growing worldwide energy demand requires the development of new innovative approaches to sustainably produce energy. This necessitates the development of small pico-hydroelectric power plants, which are more sustainable and practical for decentralized energy production. This study investigates the capacity of additive manufacturing to fabricate tiny, miniature hydroelectric power turbines using Selective Laser Melting. The study goes on to explore ways to make it more sustainable, such as modifying process parameters to achieve a minimum surface roughness and using a parametric design approach. The results of the methods used were validated by measuring the surface roughness and dimensional accuracy using profilometry and reverse engineering techniques. The findings showed that the methods used in this study could be used to obtain a customizable solution for manufacturing pico-turbines sustainably without the need for additional postprocessing

Sol–gel silica coatings for corrosion protection of aluminum parts manufactured by selective laser melting (SLM) technology

Metal additive manufacturing is a rapidly growing field based on the fabrication of complex parts with improved performance. The advantages of using this technology include the production of shapes that cannot be produced by traditional machining technologies, the possibility of using trabecular reinforcing structures, and the ability to make parts with topological optimization that allow for increased performance and decreased mass of the parts produced. Metal parts produced by selective laser melting technology exhibit high surface roughness, which limits their direct implementation. Corrosion protection of these surfaces is difficult, especially for galvanic processes. This paper analyzes the possibility of using sol–gel silica (silicon oxide) coatings to effectively protect various surfaces of aluminum alloys produced by selective laser melting technology. Silicon oxide sol–gel protective coatings have demonstrated excellent chemical stability and corrosion resistance, being able to be applied in very thin layers. These properties make them excellent candidates for protecting additive-manufactured metal parts, especially as-built surfaces with a high surface roughness. Nanostructured silica sol–gel protective coatings have demonstrated excellent corrosion resistance and have the potential to replace the highly toxic chromium-based galvanic treatments. Using nanostructured silica sol–gel coatings, aluminum parts can be seamlessly integrated into circular-economy cycles

interface roughness parameters and shear strength

The interlayer bond strength between binder and wearing course and several possible treatments of enhancing the contact surface roughness and the interlocking are investigated. For this purpose, conventional methods, such as shear tests, but also laser image acquisition of the binder upper surface have been used. The mechanical outcomes of a shear test device and the binder surface roughness parameters, have been compared looking for a relation between the shear performance and the surface characteristics. The comparison between the roughness average and the root mean square of the profile heights with the maximum shear stress shows the achievement of the same strength level for treatments with similar roughness parameters, as proved by the statistical analysis. Furthermore, the comparison between the roughness parameter kurtosis and the maximum height of the profile with the slope of the response curve before the peak and residual shear stress, demonstrates a better locking for more high peaks

Anxiety, depression and worries in advanced Parkinson Disease during COVID-19 pandemic

Background The psychological impact of the COVID-19 outbreak and lockdown on frail populations with advanced Parkinson disease (APD) and their caregivers may present with peculiar features and require specific interventions. Methods We enrolled here 100 APD patients and 60 caregivers. Seventy-four patients were treated with device-aided therapies (DAT) and 26 with standard medical treatment (SMT). Through a telephonic interview, subjects underwent the Hospital Anxiety and Depression Scale (HADS-A; HADS-D), and an ad hoc questionnaire to explore thoughts and emotions related to the pandemic. Results Depression was observed in 35% of APD patients and anxiety in 39%, with a significant reduction of the latter after the lockdown (p= 0.023). We found a significant correlation between the type of therapy and the HADS-A score (p= 0.004). Patients’ main worries were as follows: a possible higher risk of COVID-19 infection (25%), interruption of non-pharmacological treatments (35%), interruption of outpatient clinics (38%), PD complications related to COVID-19 (47%). Patients treated with DAT manifested worries about device-related issues and risk for caregivers’ infection. The 40% of caregivers showed anxiety, while the 21.7% of them showed depression. Conclusion Our study reveals a higher prevalence of anxiety and the presence of peculiar worries and needs in APD patients during the pandemic alongside psychological sequelae of their caregivers. These findings are important for neurologists and healthcare services to foster strategies for the management of psychological distress in both patients and caregivers

Prevalence, associated factors and outcomes of pressure injuries in adult intensive care unit patients: the DecubICUs study

Funder: European Society of Intensive Care Medicine; doi: http://dx.doi.org/10.13039/501100013347Funder: Flemish Society for Critical Care NursesAbstract: Purpose: Intensive care unit (ICU) patients are particularly susceptible to developing pressure injuries. Epidemiologic data is however unavailable. We aimed to provide an international picture of the extent of pressure injuries and factors associated with ICU-acquired pressure injuries in adult ICU patients. Methods: International 1-day point-prevalence study; follow-up for outcome assessment until hospital discharge (maximum 12 weeks). Factors associated with ICU-acquired pressure injury and hospital mortality were assessed by generalised linear mixed-effects regression analysis. Results: Data from 13,254 patients in 1117 ICUs (90 countries) revealed 6747 pressure injuries; 3997 (59.2%) were ICU-acquired. Overall prevalence was 26.6% (95% confidence interval [CI] 25.9–27.3). ICU-acquired prevalence was 16.2% (95% CI 15.6–16.8). Sacrum (37%) and heels (19.5%) were most affected. Factors independently associated with ICU-acquired pressure injuries were older age, male sex, being underweight, emergency surgery, higher Simplified Acute Physiology Score II, Braden score 3 days, comorbidities (chronic obstructive pulmonary disease, immunodeficiency), organ support (renal replacement, mechanical ventilation on ICU admission), and being in a low or lower-middle income-economy. Gradually increasing associations with mortality were identified for increasing severity of pressure injury: stage I (odds ratio [OR] 1.5; 95% CI 1.2–1.8), stage II (OR 1.6; 95% CI 1.4–1.9), and stage III or worse (OR 2.8; 95% CI 2.3–3.3). Conclusion: Pressure injuries are common in adult ICU patients. ICU-acquired pressure injuries are associated with mainly intrinsic factors and mortality. Optimal care standards, increased awareness, appropriate resource allocation, and further research into optimal prevention are pivotal to tackle this important patient safety threat