Repercussions of powder contamination on the fatigue life of additive manufactured maraging steel

A wide range of materials is suitable for processing by powder bed fusion (PBF) techniques. Among the latest formulations, maraging steel 18Ni-300, which is a martensite-hardenable alloy, is often used when both high fracture toughness and high strength are required, or if dimensional changes need to be minimised. In direct tooling, 18Ni-300 can be successfully employed in numerous applications, for example in the production of dies for injection moulding and for casting of aluminium alloys; moreover, it is particularly valuable for high-performance engineering parts. Even though bibliographic data are available on the effects that parameters, employed in PBF processes, have on the obtained density, roughness, hardness and microstructure of 18Ni-300, there is still a lack of knowledge on the fatigue life of PBF manufactured parts. This paper describes the fatigue behaviour of 18Ni-300 steel manufactured by PBF, as compared by forging. Relevant negative effects of the cross-contamination of the raw material are originally identified in this paper, which emphasizes the inadequacy of current acceptability protocols for PBF powders. In the absence of contamination, endurance achieved by PBF is found equal to that by forging and consistent with tooling requirements as set out by industrial partners, based on injection moulding process modelling

Reinforcement effectiveness on mechanical performances of composites obtained by powder bed fusion

New material formulations to be used in Additive Manufacturing machines are one of the major interests in this fast growing field. The possibility to tune functional and mechanical properties, by the addition of reinforcements to a polymeric matrix, is hindered by the low provisional capability of the additive manufactured composite. The inherent anisotropy of layer manufacturing combines with mechanisms of filler dispersion and of filler/matrix adhesion in a complex scenario. The paper entails a critical evaluation of mechanical properties measured for several polymeric composites produced by Powder Bed Fusion, in the perspective of provisional models commonly accepted for composite materials. The models are reviewed versus experimental and literature data. The provisional effectiveness is generally good, except for the case of nanometric or surface treated fillers, or of specific anisotropic microstructures obtained by layer manufacturing

A statistical approach for modeling individual vertical walking forces

This paper proposes a statistical approach for modeling vertical walking forces induced by single pedestrians. To account for the random nature of human walking, the individual vertical walking force is modeled as a series of steps and the gait parameters are assumed to vary at each step. Walking parameters are statistically calibrated with respect to the results of experimental tests performed with a force plate system. Results showed that the walking parameters change during walking and are correlated with each other. The force model proposed in this paper is a step-by-step model based on the description of the multivariate distribution of the walking features through a Gaussian Mixture model. The performance of the proposed model is compared to that of a simplified load model and of two force models proposed in the literature in a numerical case study. Results demonstrate the importance of an accurate modeling of both the single step force and the variability of the individual walking force

Design for additive manufacturing and for machining in the automotive field

High cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-build finishing operations of LPBF parts are the object of increasing attention to avoid the risk of bottlenecks in the machining step. An aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing. Simulation of the build process allowed to choose the orientation and the support location for potential lowest deformation and residual stresses. Design for Finishing was adopted in order to facilitate the machining operations after additive construction. The optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability. A cost and time comparison versus CNC alone attested to the convenience of LPBF unless single parts had to be produced

A trip in voice phytotheraphy: TRPA1 ion channel as a target for bioactive compounds in herbal remedies for voice care

Voice is the sound we produce to communicate meanings and ideas and has a capital importance in human social development. Herbs have been used for voice care since ancient times and many herbal remedies are still in use, both as folk medicine and as sources of botanicals used in commercial products. In Europe Sisymbrium officinale (L.) Scop (the "singers'plant\u201d) is the most popular herbal remedy for voice care, but many other plants are employed in phytopreparations. The mechanisms of action of these botanicals include anti-bacterial, anti-inflammatory, mucolytic, antinociceptive and other general activities; nevertheless, mechanisms that could be specifically referred to voice are often unknown. We collected information on plants used worldwide for voice care; the plants have been organized in a database (Herbs for Voice Database) and classified according to the bioactive compounds, their molecular targets and the pathologies they are recommended for. The data were analyzed with the aim to identify some possible common mechanism of action and the molecular targets involved. The analysis of data shows that an important pathway involves the somatosensory TRPA1 (Transient Receptor Potential Ankyrin type 1) ion channel, a well-known mediator of irritation, inflammatory and neurogenic pain. Agonists of this ion channel have been identified in 27 over 44 plants, corresponding to 61,3% of the plants in the database. Also TRPM8 (Transient Receptor Potential Melastatin type 8), involved in the perception of coolness, was identified among the molecular targets. This finding reinforces the hypothesis that these somatosensory ion channels could be involved in relevant mechanisms of action of these traditional remedies and open new perspectives in the rational study of voice phytopharmacology and therapy. This research was funded by FONDAZIONE CARIPLO (Milano, I), University of Milano (I) and Conservatorio di Musica G. Verdi (Milano, I), grant number 2017-1653

Biomedical Co-Cr-Mo Components Produced by Direct Metal Laser Sintering

Direct Metal Laser Sintering (DMLS) is an additive manufacturing technique based on a laser power source that sinters powdered materials using a 3D CAD model. The mechanical components produced by this procedure typically show higher residual porosity and poorer mechanical properties than those obtained by traditional manufacturing techniques. In this study, samples were produced by DMLS starting from a Co-Cr-Mo powder (in the \u3b3 phase) with a composition suitable for biomedical applications. Samples were submitted to hardness measurements and structural characterization. The samples showed a hardness value remarkably higher that those commonly obtained for the same cast or wrought alloys. In fact, the HRC value measured for the samples is 47 HRC, while the usual range for CAST Co-Cr-Mo is from 25 to 35 HRC. The samples microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX) in order to clarify the origin of this unexpected result. The laser treatment induced a melting of the metallic Co-Cr-Mo powder, generating a phase transformation from the \u3b3 (fcc) to the e (hcp) phase. The rapid cooling of the melted powder produced the formation of e (hcp) nano-lamellae inside the \u3b3 (fcc) phase. The nano-lamellae formed an intricate network responsible for 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, where a high degree of personalization is required

Environmental sustainability of orthopedic devices produced with powder bed fusion

Additive manufacturing consists in melting metallic powders to produce objects from 3D data, layer upon layer. Its industrial applications range from automotive, biomedical (e.g., prosthetic implants for dentistry and orthopedics), aeronautics and others. This study uses life cycle assessment to evaluate the possible improvement in environmental performance of laser-based powder bed fusion additive manufacturing systems on prosthetic device production. Environmental impacts due to manufacturing, use, and end of life of the designed solution were assessed. In addition, two powder production technologies, gas atomization (GA) and plasma atomization (PA), were compared in order to establish the most sustainable one. Production via traditional subtractive technologies and the additive manufacturing production were also compared. 3D building was found to have a significant environmental advantage compared to the traditional technology. The powder production process considerably influences on a damage point of view the additive manufacturing process; however, its impact can be mitigated if GA powders are employed