Influence of a pulsed laser regime on surface finish induced by thedirect metal deposition process on a Ti64 alloy

tThe direct metal deposition (DMD) laser technique is a free-form metal deposition process, which allowsgenerating a prototype or small series of near net-shape structures. Despite numerous advantages, oneof the most critical issues of the technique is that produced pieces have a deleterious surface finish whichrequires post machining steps. Following recent investigations where the use of laser pulses instead of acontinuous regime was successful to obtain smoother DMD structures, this paper relates investigationson the influence of a pulsed laser regime on the surface finish induced by DMD on a widely used titaniumalloy (Ti64). Findings confirm that using high mean powers improves surface finish but also indicate aspecific effect of the laser operating mode: using a quasi-continuous pulsed mode instead of fully-cw laserheating is an efficient way for surface finish improvement. For similar average powers, the use of a pulsedmode with large duty cycles is clearly shown to provide smoothening effects. The formation of larger andstable melt pools having less pronounced lateral curvatures, and the reduction of thermal gradients andMarangoni flow in the external side of the fusion zone were assumed to be the main reasons for surfacefinish improvement. Additional results indicate that combining the benefits from a pulsed regime and auniform laser irradiation does not provide further reduction of surface roughness

Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy

The direct metal deposition (DMD) with laser is a free-form metal deposition process for manufacturing dense pieces, which allows generating a prototype or small series of near net-shape structures. One of the most critical issues is that produced pieces have a deleterious surface finish which systematically requires post machining steps. This problem has never been fully addressed before. The present work describes investigations on the DMD process, using an Yb-YAG disk laser, and a widely used titanium alloy (Ti–6Al–4V) to understand the influence of the main process parameters on the surface finish quality. The focus of our work was: (1) to understand the physical mechanisms responsible for deleterious surface finishes, (2) to propose different experimental solutions for improving surface finish. In order to understand the physical mechanisms responsible for deleterious surface finishes, we have carried out: (1) a precise characterization of the laser beam and the powder stream; (2) a large number of multi-layered walls using different process parameters (P(W), V(m/min), Dm (g/min), Gaussian or uniform beam distribution); (3) a real time fast camera analysis of melt pool dynamics and melt-pool – powder stream coupling; (4) a characterization of wall morphologies versus process parameters using 2D and 3D profilometry. The results confirm that surface degradation depends on two distinct aspects: the sticking of nonmelted or partially melted particles on the free surfaces, and the formation of menisci with more or less pronounced curvature radii. Among other aspects, a reduction of layer thickness and an increase of melt-pool volumes to favor re-melting processes are shown to have a beneficial effect on roughness parameters. Last, a simple analytical model was proposed to correlate melt-pool geometries to resulting surface finishes

Reflection of an ultrasonic wave on the bone-implant interface: Effect of the roughness parameters

Quantitative ultrasound can be used to characterize the evolution of the bone-implant interface (BII), which is a complex system due to the implant surface roughness and to partial contact between bone and the implant. The aim of this study is to derive the main determinants of the ultrasonic response of the BII during osseointegration phenomena. The influence of (i) the surface roughness parameters and (ii) the thickness W of a soft tissue layer on the reflection coefficient r of the BII was investigated using a two-dimensional finite element model. When W increases from 0 to 150 μm, r increases from values in the range [0.45; 0.55] to values in the range [0.75; 0.88] according to the roughness parameters. An optimization method was developed to determine the sinusoidal roughness profile leading to the most similar ultrasonic response for all values of W compared to the original profile. The results show that the difference between the ultrasonic responses of the optimal sinusoidal profile and of the original profile was lower to typical experimental errors. This approach provides a better understanding of the ultrasonic response of the BII, which may be used in future numerical simulation realized at the scale of an implant

Absorptivity measurement of solid and powder bed under IR laser beam

The effective absorptivity of IR laser light for different powder beds were studied. The reflectivity of aluminum, titanium, stainless steel and copper alloys was measured using an appropriate Ulbricht sphere. Laser irradiation was reliably detected by a photodiode. Reflectivity was carefully measured as a function of illuminated area and powder bed density. Several powder size distributions and powder thicknesses were chosen to evaluate the impact on the laser absorption. Two spot diameters were tested to evaluate the variation of the reflectivity. The absorptivity of the powder bed was significantly higher than the absorptivity of a uniform surface for similar material due to multiple scattering. In addition, the substrate is responsible for a non-negligible variation in the powder bed absorption. The inhomogeneity of the powder bed strongly modified the laser absorption for a small spot size. The absorption fluctuated during the transition from the powder state to the molten pool state

Study of laser interaction in water flow confinement at high repetition rate

This paper presents a study on the confined interaction with water flow for two successive laser pulses. The dynamic of the renewal of water films after shock produced by the laser is observed using a high speed camera. Pressure produced by the two pulses is measured from rear free surface velocity measurements using a velocimeter interferometry system for any reflector. The results show a threshold delay between the two laser pulses for which laser/target coupling of the second pulse decreases. This depends on the spot diameter, the laser intensity, and flow rate. This threshold can be calculated from the maximum jet diameter and flow rate. At an incident power density of 3 GW/cm2, a spot diameter of 1 mm, and a flow rate of 10 m/s, the maximum repetition rate ensuring target/coupling of successive laser pulses can be 1 kHz. The results open perspective for laser shock peening at high repetition rates

Optimization and comparison of porosity rate measurement methods of Selective Laser Melted metallic parts

The systematic occurrence of porosities inside selective laser melted (SLM) parts is a well-known phenomenon. In order to improve the density of SLM parts, it is important not only to assess the physical origin of the different types of porosities, but also to be able to measure as precisely as possible the porosity rate so that one may select the optimum manufacturing parameters. Considering 316 L steel parts built with different input energies, the current paper aims to (1) present the different types of porosities generated by SLM and their origins, (2) compare different methods for measuring parts density and (3) propose optimal procedures. After a preliminary optimization step, three methods were used for quantifying porosity rate: the Archimedes method, the helium pycnometry and micrographic observations. The Archimedes method shows that results depend on the nature and temperature of the fluid, but also on the sample volume and its surface roughness. During the micrographic observations, it has been shown that the results depend on the magnification used and the number of micrographs considered. A comparison of the three methods showed that the optimized Archimedes method and the helium pycnometry technique gave similar results, whereas optimized micrographic observations systematically underestimated the porosity rate. In a second step, samples were analyzed to illustrate the physical phenomena involved in the generation of porosities. It was confirmed that: (1) low Volume Energy Density (VED) causes non-spherical porosities due to insufficient fusion, (2) in intermediary VED the small amount of remaining blowhole porosities come from gas occlusion in the melt-pool and (3) in excessive VED, cavities are formed due to the key-hole welding mode

Experimental and Numerical Analysis of Gas/Powder Flow for Different LMD Nozzles

The Laser Metal Deposition (LMD) process is an additive manufacturing method, which generates 3D structures through the interaction of a laser beam and a gas/powder stream. The stream diameter, surface density and focal plan position affect the size, efficiency and regularity of the deposit tracks. Therefore, a precise knowledge of the gas/powder streams characteristics is essential to control the process and improve its reliability and reproducibly for industrial applications. This paper proposes multiple experimental techniques, such as gas pressure measurement, optical and weighting methods, to analyze the gas and particle velocity, the powder stream diameter, its focal plan position and density. This was carried out for three nozzle designs and multiple gas and powder flow rates conditions. The results reveal that (1) the particle stream follows a Gaussian distribution while the gas velocity field is closer to a top hat one; (2) axial, carrier and shaping gas flow significantly impact the powder stream’s focal plan position; (3) only shaping gas, powder flow rates and nozzle design impact the powder stream diameter. 2D axisymmetric models of the gas and powder streams with RANS turbulent model are then performed on each of the three nozzles and highlight good agreements with experimental results but an over-estimation of the gas velocity by pressure measurements

High temperature oxidation resistance and microstructure of laser-shock peened Ti-Beta-21S

Improving the high temperature (HT) resistance of titanium alloys is currently a technological challenge for extending their use in aerospace engines. Ti-Beta-21S is a metastable β titanium alloy specifically designed for high temperature applications up to 593 °C. We report the effect of a surface treatment by laser-shock peening (LSP) on the high temperature behavior of Ti-Beta-21S in order to increase further its maximum service temperature. The oxidation kinetics at 700 °C for duration up to 3000 h showed that the LSP treatment increases the oxidation resistance of Ti-Beta-21S. The effects of the LSP treatment on the alloy microstructure, its evolution at high temperature and the diffusion of light atmospheric elements (oxygen and nitrogen) are also reported

Pre-Clinical Evaluation of a 213Bi-Labeled 2556 Antibody to HIV-1 gp41 Glycoprotein in HIV-1 Mouse Models as a Reagent for HIV Eradication

Any strategy for curing HIV infection must include a method to eliminate viral-infected cells. Based on our earlier proof-of-principle results targeting HIV-1 infected cells with radiolabeled antibody (mAb) to gp41 viral antigen, we embarked on identifying a suitable candidate mAb for preclinical development.Among the several human mAbs to gp41 tested, mAb 2556 was found to have high affinity, reactivity with multimeric forms of gp41 present on both the surface of virus particles and cells expressing HIV-1 Env, and recognition of a highly conserved epitope of gp41 shared by all HIV-1 subtypes. Also, mAb 2556 was the best in competition with HIV-1+ serum antibodies, which is an extremely important consideration for efficacy in the treatment of HIV patients. When radiolabeled with alpha-emitting radionuclide 213-Bismuth ((213)Bi) - (213)Bi-2556 efficiently and specifically killed ACH-2 human lymphocytes chronically infected with HIV-1, and HIV-1 infected human peripheral blood mononuclear cells (hPBMCs). The number of binding sites for (213)Bi-2556 on the surface of the infected cells was >10(6). The in vivo experiments were performed in two HIV-1 mouse models--splenic and intraperitoneal. In both models, the decrease in HIV-1 infected hPBMCs from the spleens and peritoneum, respectively, was dose-dependent with the most pronounced killing of hPBMCs observed in the 100 µCi (213)Bi-2556 group (P = 0.01). Measurement of the blood platelet counts and gross pathology of the treated mice demonstrated the lack of toxicity for (213)Bi-2556.We describe the preclinical development of a novel radiolabeled mAb reagent that could potentially be part of an HIV eradication strategy that is ready for translation into the clinic as the next step in its development. As viral antigens are very different from "self" human antigens - this approach promises high selectivity, increased efficacy and low toxicity, especially in comparison to immunotoxins

Influence of Mechanical Surface Treatment on High-Temperature Oxidation of Pure Titanium

The excellent combination of light-weight and good mechanical properties makes titanium alloys attractive for compressor section components in gas turbine engines (temperature between 250 and 600 °C). However, above 600 °C, the formation of an unprotective oxide layer facilitates the oxygen diffusion into the alloy. In this experimental study, pure titanium was treated with mechanical surface treatment to promote better protection against oxidation at high temperature. Shot-peened and laser-shock peened specimens were compared to untreated samples in terms of oxidation behavior at high temperature. We used thermal gravimetric analysis to oxidize the samples at 700 °C for 100 h. Subsequently, XRD, optical microscopy, SEM/EDS, NRA, micro-Raman spectroscopy, and micro-hardness were used to characterize the oxide scale and the alpha-case layer formed during the high-temperature exposure. The shot-peened samples oxidized less (−45%) than the untreated and laser-shock peened samples. This behavior was attributed to the formation of a continuous nitride layer between oxide and metal