An innovative method to build support structures with a pulsed laser in the selective laser melting process

In selective laser melting machines, continuous laser are usually used to melt the powder. The support structures, which are inevitable when dealing with elaborated pieces, necessitate a complex design by CAD in order to be easily removed. This paper propose an innovative laser manufacturing method by combining pulsed and continuous modes of radiation. Continuous radiations are used for the object-to-build itself, in order to guarantee the requested mechanical properties. Pulsed radiations are used to build the support structures. The resulting support structures have sufficient mechanical properties to withstand the deposition system and to evacuate heat, and are easy to remove from the denser parts. This building method reduces drastically time to market since the same laser can be used in two modes and because pulsed radiation allows very high scanning speed with high power during the building of support structure

CFD simulation of the airflow through the human respiratory tract

This study compares the effect of extra-thoracic airways (ETA) on the flow field through the lower airways by carrying out simulations of the airflow through the human respiratory tract. Three geometries, consisting of the ETA, CT-derived lower airway, and a combination of the two were utilized in simulations that were performed for transient breathing in addition to constant inspiration/expiration. Physiologically-appropriate regional ventilation for two different flow rates was induced at the distal boundaries by imposing appropriate lobar specific flow rates. Two breathing rates were considered, i.e., 7.5 and 15 breaths per minute with a tidal volume of 0.5 liter. For comparison, the flow rates for constant inspiration/expiration were selected to be identical to the peak flow rates during the transient breathing. Significant differences indicate that simulations that utilize constant inspiration or expiration may not be appropriate for gaining insight into the flow patterns through the human airways

Study of the consolidation process under macro- and microscopic thermal effects in selective laser sintering and selective laser melting

Selective Laser Sintering (SLS) and Selective Laser Melting (SLM) are parent Additive Manufacturing processes using a laser to solidify metallic, ceramic, polymer or composite powders. During the process, the object is built layer by layer. A laser source is responsible for the consolidation, by local heating. The light is deviated by a scanning head according to the instructions of an STL file. Then partial fusion of the particles takes place, followed by a solidification of the liquid created. Kinetics of these steps are very high and play an important role in the final microstructure (rearrangement of the particles, pore creation, residual stresses). In the case of polymers and composites the technique is now well understood and widely used, but for metals and ceramics it suffers from a lack of precision, surface roughness and poor mechanical properties. The goal of this Ph.D. work is to understand the effect of the thermal gradients on the consolidation process, using different laser parameters (power, pulse frequency, scan speed,…). In SLS, microscopic thermal gradients arise, due to the fact that the laser is pulsed and that only the exterior of the powder particles is molten. A thermal model to describe the interaction between a laser beam and a (spherical) grain is proposed. This model allows for the incorporation of the latent heat of fusion and for a realistic surrounding. The absorbed laser intensity is modeled by means of the Mie theory. Experiments where two particles of powder are isolated and illuminated by the laser are carried out in order to measure the interparticular necks and the volume of liquid formed for different repetition rates. The thermal model leads to good predictions of the particles final sintering state. Fluid flow models are investigated in order to determine the dynamic of the molten liquid. The main issue is to explain the capillary flow mechanisms leading from the molten material to the neck formation. Two models are derived to simulate the fluid flow between the particles. The first one simulates a capillary flow between two parallel plates. The second one deals with energetic considerations arising from Frenkel's principle. In both cases, the final output is the liquid life-time necessary to get the interparticular neck lengths experimentally observed. We point out that the two models predict the same liquid lifetime, although they are derived with different hypotheses. In SLM, continuous lasers are used and one has to deal with macroscopic thermal gradients, since the particles are completely molten. A very high laser power is used and the negative thermal effects (like thermal stresses or balling effects) are important. A solution to control them is to adjust the scanning strategy. Four scanning strategies are investigated for material with different thermal conductivities. The three-dimensional model used to describe the laser-matter interactions and the temperature evolution of the scanned powder bed allows for a finite latent heat (Stefan-problem) and for conductivity modifications due to the consolidation. We show that this finite element thermal model can be efficiently used to anticipate most of the problems (like cracks or balling) arising in practice. The benefit of avoiding thermal gradients is shown, in particular by EBSD analysis. Finally, applications of the SLS/SLM technique on different pieces built during this work are shown. A new way to build support structure is also proposed

Long-term survival from gastrocolic fistula secondary to adenocarcinoma of the transverse colon

BACKGROUND: Gastrocolic fistula is a rare presentation of both benign and malignant diseases of the gastrointestinal tract. Malignant gastrocolic fistula is most commonly associated with adenocarcinoma of the transverse colon in the Western World. Despite radical approaches to treatment, long-term survival is rarely documented. CASE PRESENTATION: We report a case of a 24-year-old woman who presented with the classic triad of symptoms associated with gastrocolic fistula. Radical en-bloc surgery and adjuvant chemotherapy were performed. She is still alive ten years after treatment. CONCLUSIONS: Gastrocolic fistula is an uncommon presentation of adenocarcinoma of the transverse colon. Radical en-bloc surgery with adjuvant chemotherapy may occasionally produce long-term survival

Study of the inter-particle necks in selective laser sintering

Purpose – Since pulsed lasers are mainly used in selective laser sintering (SLS) – contrarily to selective laser melting (SLM) – only the exterior of the powder particles is molten while their core stays solid. The purpose of this paper is to investigate the binding mechanism between two particles of titanium powder. Design/methodology/approach – A dedicated experimental setup is used to isolate the particles. They are then irradiated by the laser. SEM micrographs are taken at each step and image analysis is performed. The obtained results are compared with the predictions of a thermal model allowing for the incorporation of the latent heat of fusion and for a realistic surrounding. The absorbed laser intensity is modeled by means of the Mie theory. Findings – The growing of the interparticular necks and the volume of liquid formed for different repetition rates are measured and compared with numerical simulations. A good agreement is found. A new method to easily find the absorption coefficient of the laser into the grain and the heat exchange coefficient with the exterior is developed. Originality/value – This paper leads to a better understanding of the necking phenomena involved in the SLS consolidation process. An experimental set-up has been developed to observe and quantify the final state of a small amount of laser sintered grains. This process has been shown to be replicable and trustful. The thermal model leads to good predictions of the particle final sintering state

An innovative method to build support structures with a pulsed laser in the selective laser melting process

In selective laser melting machines, continuous laser are usually used to melt the powder. The support structures, which are inevitable when dealing with elaborated pieces, necessitate a complex design by CAD in order to be easily removed. This paper propose an innovative laser manufacturing method by combining pulsed and continuous modes of radiation. Continuous radiations are used for the object-to-build itself, in order to guarantee the requested mechanical properties. Pulsed radiations are used to build the support structures. The resulting support structures have sufficient mechanical properties to withstand the deposition system and to evacuate heat, and are easy to remove from the denser parts. This building method reduces drastically time to market since the same laser can be used in two modes and because pulsed radiation allows very high scanning speed with high power during the building of support structures

Jamasp Namag

1700 BC, Mohammad Hasan Khan Sanieo Doleh (Ed.)