Influence of the Experimental Setup on the Damping Properties of SLM Lattice Structures

Background: Metal lattice structures obtained through Selective Laser Melting may increase the strength-to-weight ratio of advanced 3D printed parts, as well as their damping properties. Recent experimental results showed that AlSi10Mg and AISI 316L lattices are characterized by higher Rayleigh damping coefficients with respect to the fully dense material. However, some unclear or contradictory results were found, depending on the experimental setup adopted for modal analysis. Objective: In this work the influence of the experimental setup when performing modal analysis on different SLM AISI 316L lattice structures was deeply investigated. The study provides a critical comparison of various experimental modal analysis approaches, allowing to evaluate the influence of external damping sources and material internal damping phenomena. Methods: The dynamic behaviour of SLM AISI 316L specimens incorporating lattice structures was estimated by means of pulse testing and sinusoidal excitation through an electromagnetic shaker. The validity of the viscous damping model was assessed by means of sinusoidal excitation with different levels of vibration velocity. Moreover, the influence of experimental setup on modal analysis results was critically evaluated, by considering different actuators, contact and non-contact sensors and boundary/clamping conditions. Results: The classical viscous damping model describes with good approximation the damping properties of SLM lattice structures. When exciting single specimens in free-free conditions, those embedding lattice structure and unmelted metal powder filler were characterized by superior internal damping properties with respect to the specimens incorporating the lattice structure without any filler, which was however more effective than the full density equivalent material. Most of the other experimental setups introduced additional external damping sources, that could alter this important outcome. Conclusions: SLM lattice structures embedded into 3D printed components provide superior damping properties against mechanical and acoustic vibrations and the metal powder filler does significantly enhance such damping capacity. A correct estimation of material internal damping was achieved by applying non-contact sensors and free-free boundary conditions, whereas other experimental setups were partly inadequate

Upgraded Kalman filtering of cutting forces in milling

Advanced piezoelectric dynamometers with a wide frequency bandwidth are required for cutting force measurement in high-speed milling and micromilling applications. In many applications, the signal bandwidth is limited by the dynamic response of the mechanical system, thus compensation techniques are necessary. The most effective compensation techniques for a full 3D force correction require an accurate and complex identification phase. Extended Kalman filtering is a better alternative for input force estimation in the presence of unknown dynamic disturbances. The maximum bandwidth that can be currently achievable by Kalman filtering is approximately 2 kHz, due to crosstalk disturbances and complex dynamometer\u2019s dynamics. In this work, a novel upgraded Kalman filter based on a more general model of dynamometer dynamics is conceived, by also taking into account the influence of the force application point. By so doing, it was possible to extend the frequency bandwidth of the device up to more than 5 kHz along the main directions and up to more than 3 kHz along the transverse directions, outperforming state-of-the-art methods based on Kalman filtering

Passive chatter suppression of thin-walled parts by means of high-damping lattice structures obtained from selective laser melting

Chatter vibrations arising during machining operations are detrimental for cutting process performance, since they may cause poor surface quality of the machined part and severe damages to machine tool elements. Passive approaches for chatter suppression are based on the integration of special mechanical components with high-damping properties within the machining system. They represent a good solution to this problem thanks to their intrinsic simplicity. Recently, the application of metallic lattice structures inside 3D printed parts obtained from the Selective Laser Melting technology have proven superior damping properties with respect to the same full density material. Here, this idea is further explored by considering the novel configuration where the unmelted powder grains are retained inside the lattice structure by an external shell, acting as a multiplicity of microscopic mechanical dampers. This concept is applied for passive chatter suppression of thin-walled parts that are of particular relevance for industry. Preliminary experimental investigation was first carried out on simple beam-like specimens, and then on thin-walled benchmarks that were identified through modal analysis and tested under real cutting conditions. The main conclusion is that the novel proposed configuration (lattice plus unmelted powder) has higher damping properties with respect to the full density and lattice alternatives. Accordingly, it may be successfully applied for passive chatter suppression in real machining operations

A novel thermo-geometrical model for accurate keyhole porosity prediction in Laser Powder-Bed Fusion

When performing Laser Powder-Bed Fusion, undesired physical phenomena, such as balling, preballing and keyhole, must be avoided in order to achieve high-quality products. To date, keyhole-free process parameters can be identified either using demanding empirical methods or complex numerical simulations, while only a few analytical models can be found in literature for this purpose. In this work, state-of-the-art analytical models for predicting keyhole porosity were summarized and proved to be rather inaccurate because they are only based on thermodynamic principles, whereas they neglect the geometry and both the kinetics and kinematics of the keyhole cavity, which do also influence cavity collapse and porosity formation. Here an innovative physics-based semi-analytical model for predicting the formation of keyhole-related porosities was conceived, in which both thermodynamic and geometrical factors are taken into account. The proposed model was validated by performing single tracks experiments on Ti6Al4V according to a full factorial DoE on laser power and scanning speed. Produced samples were cross-sectioned and analyzed to evaluate keyhole porosity formation. The comparison between experimental data and model predictions confirmed the higher accuracy of the new model with respect to state of the art models. Besides improving the understanding of the keyhole phenomenon, the proposed model may provide a novel, effective and simple tool for fast process parameter optimization in industry

Effects of post-printing heat treatment on microstructure, corrosion and wet wear behavior of CoCrW alloy produced by L-PBF process

CoCr alloys are widely used as human implants because of both their superior corrosion resistance and superior mechanical properties (fatigue, wear resistance, etc.) respect to other metal alloys used in biomedical field. In particular, CoCrW alloys are used mainly to produce dental implants. In this study, the effects of thermal treatment on the corrosion resistance and wet wear resistance of CoCrW alloys produced via Laser-Powder Bed Fusion (L-PBF) were investigated, and the corrosion resistance and wet wear resistance of the L-PBF specimens were compared with those of the specimens obtained after forging. The heat treatment involved the solubilization of the alloy at 1150 °C in an Ar-saturated atmosphere, followed by furnace cooling. A detailed microstructural characterization of the L-PBF specimens was carried out using a light microscope and a scanning electron microscope in both the horizontal and vertical growth directions. Scanning Kelvin probe measurements were performed on the heat-treated specimens obtained by three-dimensional printing and forging. The void contents of the specimens were evaluated using the Archimedes’ method and image analysis. Vickers (HV2) hardness measurements were performed to evaluate the mechanical properties of the specimens. The corrosion properties of the specimens were evaluated by carrying out potentiodynamic tests in two different corrosive media (aqueous solution (9 g/L NaCl) at pH = 2 and 7). The corroded areas of the specimens were then examined using scanning electron microscopy (SEM). Finally, tribological tests were performed using the pin (Ti counter material)-on-flat configuration under dry and wet conditions, using the same corrosive environments as those used in the potentiodynamic tests and two different stroke lengths. The worn samples were characterized using SEM to investigate their wear mechanisms, and a stylus profilometer was used to determine the wear rates of the materials. The experimental results showed that the additively manufactured CoCrW L-PBF alloy had higher corrosion resistance than the wrought material. In addition, the additively manufactured material showed better dry and wet wear performances than the wrought material. Nevertheless, the heat treatment did not affect the properties evaluated in this study

Single tracks data obtained by selective laser melting of Ti6Al4V with a small laser spot diameter

Nowadays, advanced metal components with high geometrical complexity can be 3D printed by using the Selective Laser Melting (SLM) technology. Despite SLM resolution and accuracy are generally limited to some tenths of mm, it should be possible to produce finer and more precise details by applying lasers with a small spot diameter. However, to present date the data collected with small laser spot diameters are poor. In this work, experimental data describing the effects of laser power and scan speed on single track formation when applying a small laser spot diameter of 50 \ub5m on Ti6Al4V powder are reported. SEM images and the extracted geometrical data characterizing the obtained single tracks are provided here, as well as their microstructural analysis and microhardness measurements

Effect of Thermal Treatment on Corrosion Behavior of AISI 316L Stainless Steel Manufactured by Laser Powder Bed Fusion

The effect of post-processing heat treatment on the corrosion behavior of AISI 316L stainless steel manufactured by laser powder bed fusion (L-PBF) is investigated in this work. Produced stainless steel was heat treated in a broad temperature range (from 200 °C to 1100 °C) in order to evaluate the electrochemical behavior and morphology of corrosion. The electrochemical behavior was investigated by potentiodynamic and galvanostatic polarization in a neutral and acidic (pH 1.8) 3.5% NaCl solution. The microstructure modification after heat treatment and the morphology of attack of corroded samples were evaluated by optical and scanning electron microscopy. The fine cellular/columnar microstructure typically observed for additive-manufactured stainless steel evolves into a fine equiaxed austenitic structure after thermal treatment at high temperatures (above 800 °C). The post-processing thermal treatment does not negatively affect the electrochemical behavior of additive-manufactured stainless steel even after prolonged heat treatment at 1100 °C for 8 h and 24 h. This indicates that the excellent barrier properties of the native oxide film are retained after heat treatment

Effect of powder recycling on inclusion content and distribution in AISI 316L produced by L-PBF technique

AISI 316 L stainless steel is widely used as material to produce components by means of additive manufacturing. To increase the circular economy, the powders are collected and re-used after the printing process, thus the effect of powder recycling on microstructure and properties of printed components is of the utmost importance. This work focused the attention on non-metallic inclusions by examining virgin and recycled powders, and products printed by using both types of powders in a laser powder bed fusion (L-PBF) process. Recycled powders exhibit an irregular shape due to fragmentation, spatters and satellites and, compared to the virgin ones, have a higher gas (O, H and C) content. Both powders contain non-metallic inclusions with a larger quantity in the recycled ones. The printed samples have a similar microstructure, however those produced by using recycled powders exhibit voids of larger size and a little greater amount of inclusions. XRD and EDS examinations of inclusions extracted from the metallic matrix showed that they consist of a mix of amorphous and crystalline silica. Large part of these particles are already present in virgin powders and only a minor part forms during repeated printing operations. Accordingly, the quality of virgin powders is the factor that mainly affects the inclusion content of printed products indicating that the powder production process is the most critical stage of the whole manufacturing process

Three-row versus two-row circular staplers for left-sided colorectal anastomosis: a propensity score-matched analysis of the iCral 2 and 3 prospective cohorts

Background: Since most anastomoses after left-sided colorectal resections are performed with a circular stapler, any technological change in stapling devices may influence the incidence of anastomotic adverse events. The aim of the present study was to analyze the effect of a three-row circular stapler on anastomotic leakage and related morbidity after left-sided colorectal resections. Materials and methods: A circular stapled anastomosis was performed in 4255 (50.9%) out of 8359 patients enrolled in two prospective multicenter studies in Italy, and, after exclusion criteria to reduce heterogeneity, 2799 (65.8%) cases were retrospectively analyzed through a 1:1 propensity score-matching model including 20 covariates relative to patient characteristics, to surgery and to perioperative management. Two well-balanced groups of 425 patients each were obtained: group (A) – true population of interest, anastomosis performed with a three-row circular stapler; group (B) – control population, anastomosis performed with a two-row circular stapler. The target of inferences was the average treatment effect in the treated (ATT). The primary endpoints were overall and major anastomotic leakage and overall anastomotic bleeding; the secondary endpoints were overall and major morbidity and mortality rates. The results of multiple logistic regression analyses for the outcomes, including the 20 covariates selected for matching, were presented as odds ratios (OR) and 95% confidence intervals (95% CI). Results: Group A versus group B showed a significantly lower risk of overall anastomotic leakage (2.1 vs. 6.1%; OR 0.33; 95% CI 0.15–0.73; P = 0.006), major anastomotic leakage (2.1 vs. 5.2%; OR 0.39; 95% CI 0.17–0.87; P = 0.022), and major morbidity (3.5 vs. 6.6% events; OR 0.47; 95% CI 0.24–0.91; P = 0.026). Conclusion: The use of three-row circular staplers independently reduced the risk of anastomotic leakage and related morbidity after left-sided colorectal resection. Twenty-five patients were required to avoid one leakage

Why High-Performance Modelling and Simulation for Big Data Applications Matters

Modelling and Simulation (M&S) offer adequate abstractions to manage the complexity of analysing big data in scientific and engineering domains. Unfortunately, big data problems are often not easily amenable to efficient and effective use of High Performance Computing (HPC) facilities and technologies. Furthermore, M&S communities typically lack the detailed expertise required to exploit the full potential of HPC solutions while HPC specialists may not be fully aware of specific modelling and simulation requirements and applications. The COST Action IC1406 High-Performance Modelling and Simulation for Big Data Applications has created a strategic framework to foster interaction between M&S experts from various application domains on the one hand and HPC experts on the other hand to develop effective solutions for big data applications. One of the tangible outcomes of the COST Action is a collection of case studies from various computing domains. Each case study brought together both HPC and M&S experts, giving witness of the effective cross-pollination facilitated by the COST Action. In this introductory article we argue why joining forces between M&S and HPC communities is both timely in the big data era and crucial for success in many application domains. Moreover, we provide an overview on the state of the art in the various research areas concerned