Design and compressive behavior of controllable irregular porous scaffolds: based on Veronoi-tessellation and for additive manufacturing

Adjustment of the mechanical properties (apparent elastic modulus and compressive strength) in porous scaffolds is important for artificial implants and bone tissue engineering. In this study, a top-down design method based on Voronoi-Tessellation was proposed. This method was successful in obtaining the porous structures with specified and functionally graded porosity. The porous specimens were prepared by selective laser melting technology. Quasi-static compressive tests were conducted as well. The experiment results revealed that the mechanical properties were affected by both porosity and irregularity. The irregularity coefficient proposed in this study can achieve good accommodation and balance of “irregularity” and “controllability”. The method proposed in this study provides an efficient approach for the bionic design and topological optimization of scaffolds

Alteration of Innate Immunity by Donor IL-6 Deficiency in a Presensitized Heart Transplant Model

Engraftment of IL-6 deficient donor into wild-type recipient could significantly improve allograft survival through T cell lineage particularly regulatory T cells (Tregs) in non-sensitized transplant host. However, its effect on innate immune responses remains uncertain. Our data revealed that donor IL-6 deficiency significantly increased infiltration of two subsets of MDSCs (CD11b+Gr1+myeloid-derived suppressor cells), CD11b+Gr1-low and CD11b+Gr1-int with strong immunosuppression activity in the transplanted graft. It resulted in a dramatic increase of CD11b+Gr1-low frequency and a significant decrease of the frequency of CD11b+Gr1-high and CD4-CD8-NK1.1+ cells in the recipient’s spleen. Unexpectedly, donor IL-6 deficiency could not significantly reduce macrophage frequency irrespective of in the host’s spleen or graft. Taken together, suppression of innate immune effector cells and enhanced activity of regulatory MDSCs contributed to tolerance induction by blockade of IL-6 signaling pathway. The unveiled novel mechanism of targeting IL-6 might shed light on clinical therapeutic application in preventing accelerated allograft rejection for those pre-sensitized transplant recipients

The size effect on forming quality of Ti–6Al–4V solid struts fabricated via laser powder bed fusion

Laser powder bed fusion (LPBF) is useful for manufacturing complex structures; however, factors affecting the forming quality have not been clearly researched. This study aimed to clarify the influence of geometric characteristic size on the forming quality of solid struts. Ti–6Al–4V struts with a square section on the side length (0.4 to 1.4 mm) were fabricated with different scan speeds. Micro-computed tomography was used to detect the struts’ profile error and defect distribution. Scanning electron microscopy and light microscopy were used to characterize the samples’ microstructure. Nanoindentation tests were conducted to evaluate the mechanical properties. The experimental results illustrated that geometric characteristic size influenced the struts’ physical characteristics by affecting the cooling condition. This size effect became obvious when the geometric characteristic size and the scan speed were both relatively small. The solid struts with smaller geometric characteristic size had more obvious size error. When the geometric characteristic size was smaller than 1 mm, the nanohardness and elastic modulus increased with the increase in scan speed, and decreased with the decline of the geometric characteristic size. Therefore, a relatively high scan speed should be selected for LPBF—the manufacturing of a porous structure, whose struts have small geometric characteristic size

Cause of angular distortion in fusion welding: asymmetric cross-sectional profile along thickness

Angular distortion is a common problem in fusion welding, especially when it comes to thick plates. Despite the fact that various processes and influencing factors have been discussed, the cause of the angular distortion has not been clearly revealed. In this research, the asymmetry of cross-sectional profile along thickness is considered of great importance to the angular distortion. A theoretical model concerning the melting-solidification process in fusion welding was established. An expression of the angular distortion was formulated and then validated by experiments of laser welding 316L stainless steel. The results show that the asymmetric cross-sectional profile is a major contributory factor towards the angular distortion mechanism. The asymmetry of cross-section profile along thickness causes the difference between two bending moments in the lower and upper parts of the joint. This is the difference that drives the angular distortion of the welded part. Besides, the asymmetry of cross-section profile is likely to be influenced by various processes and parameters, thereby changing the angular distortion

Distortion of thin-walled structure fabricated by selective laser melting based on assumption of constraining force-induced distortion

Metal additive manufacturing has shown great potential in aerospace, medical, and automobile industries; however, distortion of metal part has been an obstacle in widespread application of metal additive manufacturing. The mechanism of thin-walled structure distortion remains unrevealed. In this study, the origin of distortion of thin-walled structure was discussed, based on the previously proposed assumption of constraining force-induced distortion. The relation between the microstructure and macro-distortion has been linked via the constraining force. The influence of scan directions and structure sizes on the distortion was also studied, and the approaches to decrease the thin-walled structure were discussed. Use of the alternant scan strategy has been validated as an effective approach if the structure sizes cannot be adjusted

Properties of jet-plated Ni coating on Ti alloy (Ti6Al4V) with laser cleaning pretreatment

The surface mechanical properties of the Selective Laser Melting (SLM) formed Ti6Al4V samples were improved by adopting a novel laser cleaning pretreatment process combined with a jet electrodeposition process. This paper aimed to investigate the effects of different laser powers on the morphologies and adhesions of the nickel coatings. The advantages of the laser cleaning process are no grinding, no contact, high efficiency and environmental protection. The morphologies, adhesion, wear resistance, and hardness of the coatings were characterized. The results indicate that when the laser energy density reached 20% (4 J/cm2), the contaminations on the substrate and the oxide layer were removed and the crystalline grain of the coating was 15.3 nm. The shallow pits generated by laser burning increased the adhesion of the coatings. In addition, when the laser energy density increased to 6 J/cm2, a yellow oxide layer was produced on the surface of the cleaned titanium alloy. Moreover, the wear resistance of the titanium alloy after the nickel plating was improved. The wear volume was only 0.046 mm3, and the hardness increased to 1967.6 N/mm2

Mechanical properties of in-situ synthesis of Ti-Ti3Al metal composite prepared by selective laser melting

Titanium composite strengthened by Ti3Al precipitations is considered to be one of the excellent materials that is widely used in engineering. In this work, we prepared a kind of Ti-Ti3Al metallic composite by in-situ synthesis technology during the SLM (selective laser melting) process, and analyzed its microstructure, wear resistance, microhardness, and compression properties. The results showed that the Ti-Ti3Al composite, prepared by in-situ synthesis technology based on SLM, had more homogeneous Ti3Al-enhanced phase dispersion strengthening structure. The grain size of the workpiece was about 1 μm, and that of the Ti3Al particle was about 200 nm. Granular Ti3Al was precipitated after the aluminum-containing workpiece formed, with a relatively uniform distribution. Regarding the mechanical properties, the hardness (539 HV) and the wear resistance were significantly improved when compared with the Cp-Ti workpiece. The compressive strength of the workpiece increased from 886.32 MPa to 1568 MPa, and the tensile strength of the workpiece increased from 531 MPa to 567 MPa after adding aluminum. In the future, the combination of in-situ synthesis technology and SLM technology can be used to flexibly adjust the properties of Ti-based materials

Assumption of constraining force to explain distortion in laser additive manufacturing

Distortion is a common but unrevealed problem in metal additive manufacturing, due to the rapid melting in metallurgy and the intricate thermal-mechanical processes involved. We explain the distortion mechanism and major influencing factors by assumption of constraining force, which is assumed between the added layer and substrate. The constraining force was set to act on the substrate in a static structural finite element analysis (FEA) model. The results were compared with those of a thermal-mechanical FEA model and experiments. The constraining force and the associated static structural FEA showed trends in distortion and stress distribution similar to those shown by thermal-mechanical FEA and experiments. It can be concluded that the constraining force acting on the substrate is a major contributory factor towards the distortion mechanism. The constraining force seems to be primarily related to the material properties, temperature, and cross-sectional area of the added layer

Analysis of the porous structures from laser powder bed fusion additive manufacturing

Open and closed porous structures with lattice and honeycomb geometry can be built using laser powder bed fusion additive manufacturing processes. The porous structures can be used to tailor the mechanical properties of a component or provide other functionality, such as for bone ingrowth in medical implants. Porous structures were created and analysed in this paper both physically and using finite element modelling. It was found that the accuracy of the built parts was reasonable and within the manufacturing processes general tolerance of +/- μm. However, it was noticeable that the corners of the square shape pores were naturally filleted by the manufacturing process. The finite element model was developed using ANSYS software, stress concentrations were observed in the porous structures under loading. In addition to this, fragments of the material were present on the internal surfaces of the pores, which were formed from partially melted powder particles

Additive manufacturing of monolithic microwave dielectric ceramic filters via digital light processing

Microwave dielectric ceramics are employed in filters as electromagnetic wave propagation media. Based on additive manufacturing (AM) techniques, microwave dielectric ceramic filters with complex and precise structures can be fabricated to satisfy filtering requirements. Digital light processing (DLP) is a promising AM technique that is capable of producing filters with high accuracy and efficiency. In this paper, monolithic filters made from Al2O3 and TiO2, with a molar ratio of 9:1 (0.9 Al2O3-0.1 TiO2), were fabricated by DLP. The difference in the dielectric properties between the as-sintered and post-annealed samples at different temperatures was studied. The experimental results showed that when sintered at 1550 °C for 2 h and post annealed at 1000 °C for 5 h, 0.9 Al2O3-0.1 TiO2 exhibited excellent dielectric properties: εr = 12.4, Q × f = 111,000 GHz, τf = +1.2 ppm/°C. After comparing the measured results with the simulated ones in the passband from 6.5 to 9 GHz, it was concluded that the insertion loss (IL) and return loss (RL) of the filter meet the design requirements