Titanium Alloys Manufactured by In Situ Alloying During Laser Powder Bed Fusion

Published ArticleThis work is focused on the investigation and understanding of in situ processes in Ti-15%Mo and Ti6Al4V-1.38%Cu alloys by laser powder bed fusion (LPBF). In both materials, Mo and Cu were introduced as elemental powders into the precursor powder mixture. The effect of process parameters, i.e., energy input on surface morphology and homogeneity, was investigated. The importance of different thermophysical properties of blended powders is also discussed. The chemical composition of phases and phase distribution in sintered materials were investigated by means of scanning electron microscopy. The mechanical properties of in situ alloyed as-built LPBF specimens were determined. The results obtained developed knowledge that is important for understanding the in situ alloying process during LPBF, and they create a base for synthesizing new materials

In situ heat treatment in selective laser melted martensitic AISI 420 stainless steels

Published ArticleThe article explores an evolution of a microstructure in AISI 420martensitic stainless steel during selective laser melting. Several upper layers had hardness of 750 HV and contained 21±12 vol.% austenite phase. The final bulk microstructure consisted of thermally decomposed martensitewith hardness of 500–550HV and unusually high, 57±8 vol.%,amount of austenite. Obtained results indicate that duringmanufacturing a partitioning and austenite reversion took place, owing to the thermal cycling of the inner regions duringmanufacturing. Numerical simulation was found plausible to analyze and explain thermally activated processes that occurred in situ. Results of numerical simulation of the thermal cycles in dependence on the processing parameters suggested a possibility to control the thermal processes by variation of the laser energy input

MICROSTRUCTURAL AND THERMAL STABILITY OF SELECTIVE LASER MELTED 316L STAINLESS STEEL SINGLE TRACKS#

Published ArticleTo remove residual stresses, an as-built SLM object is usually post-treated. This treatment can affect the microstructure, changing the final mechanical characteristics. This investigation is focused on the microstructural characterisation of 316L austenitic stainless steel in as-built and annealed conditions. The SLM microstructure was relatively stable up to 900°C, when cell boundaries start to disappear. At higher temperatures, an insignificant grain coarsening was detected. These microstructural changes caused a gradual drop in the hardness. The obtained result is background for the future development of post-treatment regimens to achieve a high level in the final mechanical properties of SLM objects

Qualification of Ti6Al4V ELI Alloy Produced by Laser Powder Bed Fusion for Biomedical Applications

Published ArticleTi6Al4V ELI samples were manufactured by Laser Powder Bed Fusion (LPBF) in vertical and horizontal directions and subjected to various heat treatments. Detailed analyses of porosity, microstructure, residual stress, tensile properties, fatigue and fractured surfaces were performed based on X-ray micro computed tomography, scanning electron microscopy and X-ray diffraction methods. Types of fractures and tensile fracture mechanisms in LPBF Ti6Al4V ELI alloy were studied. Detailed analysis of the microstructure and the corresponding mechanical properties were compared with standard specifications for conventional Ti6Al4V alloy (grade 5 and 23) for surgical implant applications. Conclusions regarding mechanical properties and heat treatment of LPBF Ti6Al4V ELI for biomedical applications were made

Manufacturing, microstructure and mechanical properties of selective laser melted Ti6Al4V-Cu

Conference ProceedingsTi6Al4V is a commonly used biomedical alloy because of its suitable mechanical and biocompatible properties. Infection at the bone–implant interface is the most probable reason for implant failure directly after implantation. Copper is a proven anti-bacterial agent and in small amounts is not toxic to the human body. Copper additions reduce the risk of bacterial infection and implant failure. Thus advanced implants can be constructed to have a biocompatibility and antibacterial properties. Optimal process parameters are needed to be established for in-situ alloying of Ti6Al4V-Cu to form dense parts with suitable mechanical properties. The effect of laser scanning speeds and hatch distance on morphology of single layers was investigated. The surface roughness, chemical composition and distribution of Cu near the surface and within the synthesized layer, as well as micro hardness were considered. An employed rescanning strategy showed improved alloy homogeneity and surface quality. On the base of these data 3D samples were produced. Microstructure and mechanical properties of as-built parts were analysed

Fracture Mechanisms In The As-Built And Stress-Relieved Laser Powder Bed Fusion Ti6Al4V ELI Alloy

Published ArticleThe influence of a stress-relief treatment on impact and fatigue properties of Ti6Al4V ELI samples manufactured by laser powder bed fusion was analyzed. The heat treatment resulted in removal of residual stresses, coarsening of needles and formation of precipitations between needles. In both, impact and fatigue tests, crack development was correlated to microstructural features. Fracture analysis was carried out by means of optical and electron microscopy to reveal the influence of microstructure on crack development. Ductile fracture was the dominating fracture mode at impact testing. Pore formation and coalescence were the main crack formation mechanisms. The microstructural changes led to a decrease in impact toughness after heat treatment. Presumably, this was a result of the precipitations between needles. Fatigue results showed multiple crack nucleation at the surface in both, as-built and stress-relieved material. The crack propagation rate was slightly higher and the crack was less deflected in the stress-relieved material due to the stress relief and coarsening of the microstructure

Oxygen and nitrogen concentrations in the Ti-6Al-4V alloy manufactured by direct metal laser sintering (DMLS) process

Published ArticleTwo machines from two scientific centers (Russia and South Africa) were used for the manufacturing of the Ti6Al4V alloys by the direct metal laser sintering. The chemical composition of powders complies with the ASTM F-136 (grade 5), ASTM B348 (grade 23) standard for medical applications. Analysis of the oxygen and nitrogen contamination in DMLS alloys was done with Van de Graaff accelerator with two Mega Volts. It is found that structures of the samples manufactured with two different machines used the same regimes are close to each other. TEM studies found the metastable martensitic structure and silicon nitride Si3N4. It was found that the oxygen and nitrogen contents in both samples are within the normal range for medical grade titanium alloys

Topology Optimization and Characterization of Ti6Al4V ELI Cellular Lattice Structures by Laser Powder Bed Fusion for Biomedical Applications

Published ArticleTopology optimization approach was used for the design of Ti6Al4V ELI lattice structures with stiffness and density close to the human bone for implant applications. Three lattice designs with volume densities of 35 %, 40 % and 45 % and corresponding elastic modulus of 18.6 GPa, 23.1 GPa 27.4 GPa close to the human bone were generated. Laser powder bed fusion (LPBF) technique was used for the manufacturing of the specimens. Physical measurements and mechanical characterization of specimens were assessed by microCT analyses and compression test, perpendicular and parallel to the building direction of the specimens. LPBF Ti6Al4V ELI manufactured lattice structures showed deviations in wall thickness in comparison with the generated designs, leading to an increase in relative porosity but also a decrease in elastic modulus in comparison with the original designs. Horizontal walls of the lattice structures showed higher wall thickness in comparison with the vertical walls, leading to anisotropic behaviour of the lattice structures. Higher elastic modulus and compression strength were obtained when thicker walls were oriented along the loading direction of the compression test, showing a complete failure by dividing the specimens into two neighbouring halves. All specimens showed 45° diagonal shear fracture along the structure. On the other hand, higher energy absorption at first maximum compression strength peak was observed when samples were tested parallel to the building direction (when thinner walls were oriented along the loading compression direction). Results showed that designed lattice structures can possess the levels of human bones’ stiffness and therefore can reduce/avoid stress shielding on implant applications