Comparison of Microstructures and Mechanical Properties for Solid Cobalt-Base Alloy Components and Biomedical Implant Prototypes Fabricated by Electron Beam Melting

The microstructures and mechanical behavior of simple, as-fabricated, solid geometries (with a density of 8.4 g/cm3), as-fabricated and fabricated and annealed femoral (knee) prototypes all produced by additive manufacturing (AM) using electron beam melting (EBM) of Co-26Cr-6Mo-0.2C powder are examined and compared in this study. Microstructures and microstructural issues are examined by optical metallography, SEM, TEM, EDS, and XRD while mechanical properties included selective specimen tensile testing and Vickers microindentation (HV) and Rockwell C-scale (HRC) hardness measurements. Orthogonal (X-Y) melt scanning of the electron beam during AM produced unique, orthogonal and related Cr23C6 carbide (precipitate) cellular arrays with dimensions of ~2μm in the build plane perpendicular to the build direction, while connected carbide columns were formed in the vertical plane, parallel to the build direction.Mechanical Engineerin

Effect of Build Parameters and Build Geometries on Residual Microstructures and Mechanical Properties of Ti-6Al-4V Components Built by Electron Beam Melting (EBM)

In this study, involving additive manufacturing (AM) using electron beam melting (EBM), we have examined build defects which result from beam tripping, porosities (including unmelted or unsintered zones) due to excursions from optimal build parameters (especially variations in melt scan beam current and scan speed), and gas bubbles trapped in atomized Ti-6Al-4V starting powder as well as recycled powder, and retained in the build. At optimized build conditions we have also examined microstructure-mechanical property (hardness, tensile strength, and elongation) variations for multiple rake building and multiple melt scans using optical metallography and scanning and transmission electron microscopy (SEM and TEM). These build variances cause cooling rate variances which promote α-phase growth and variations in dislocation density, as well as α-to-α' (martensite) phase changes, all of which produce some degree of mechanical property variations. These features (especially α-to-α' phase changes) are notable on comparing solid builds in comparison with a variety of mesh arrays where strut dimension and build-element complexities alter the cooling rates in a significant way. We illustrate these microstructure variations with corresponding variations in microindentation hardness measurements made directly on fine mesh (strut) structures. Finally, we have examined Ti-6Al-4V powder chemistries and solid build chemistries which for single-pass melt scans at optimized build conditions are shown to be relatively constant up to 40 cycles of powder reuse with the exception of Al content which was reduced by 10 to 15% in solid builds at optimized conditions. However, Al loss in solid builds approached 25% for multiple (2 and 3) melt scans, while no changes in Ar gas-bubble density were observed with changes in α-phase (grain) width which increased from 3 µm for a single melt scan to 4.5 and 6 µm for 2 and 3 melt scans, respectively. Corresponding Rockwell C-scale (HRC) hardness varied from 37, 36, and 35, respectively; with ultimate tensile strengths exceeding 1.2 GPa at elongations of 12% or higher for this melt scan sequence.Mechanical Engineerin

Microstructure Architecture Development in Metals and Alloys By Additive Manufacturing Using Electron Beam Melting

The concept of materials with controlled microstructural architecture (MCMA) to develop and fabricate structural materials with novel and possibly superior properties and performance characteristics is a new paradigm or paradigm extension for materials science and engineering. In the conventional materials science and engineering paradigm, structure (microstructure), properties, processing, and performance features are linked in the development of desirable materials properties and performance through processing methodologies which manipulate microstructures. For many metal or alloy systems, thermomechanical treatment combining controlled amounts of plastic deformation with heat treatment or aging cycles can achieve improved mechanical properties beyond those attainable by conventional processing alone (such as rolling or forging for example) through controlled microstructure development. In this paper we illustrate a new concept involving the fabrication of microstructural architectures by the process development and selective manipulation of these microstructures ideally defining material design space. This allows for the additional or independent manipulation of material properties by additive manufacturing (AM) using electron beam melting (EBM). Specifically we demonstrate the novel development of a carbide (M23C6) architecture in the AM of a Co-base alloy and an oxide (Cu2O) precipitate-dislocation architecture in the AM of an oxygen-containing Cu. While more conventional processing can produce various precipitate microstructures in these materials, EBM produces spatial arrays of precipitate columns or columnar-like features often oriented in the build direction. These microstructural architectures are observed by optical microscopy and scanning and transmission electron microscopy. Prospects for EBM architecture development in precipitation-hardenable Al alloys is also discussed. In the EBM build process using precursor powders, the electron beam parameters (including beam focus, scan speed and sequencing) produce localized, requisite thermodynamic regimes which create or organize the precipitate-related spatial arrays. This feature demonstrates the utility of AM not only in the fabrication of complex components, but also prospects for selective property design using CAD for MCMA development: a new or extended processing-microstructure-property-performance paradigm for materials science and engineering in advanced manufacturing involving solid free-form fabrication (SFF).Mechanical Engineerin

Influence of the length of hospitalisation in post-discharge outcomes in patients with acute heart failure: Results of the LOHRCA study

Objective: To investigate the relationship between length of hospitalisation (LOH) and post-discharge outcomes in acute heart failure (AHF) patients and to ascertain whether there are different patterns according to department of initial hospitalisation. Methods: Consecutive AHF patients hospitalised in 41 Spanish centres were grouped based on the LOH (15 days). Outcomes were defined as 90-day post-discharge all-cause mortality, AHF readmissions, and the combination of both. Hazard ratios (HRs), adjusted by chronic conditions and severity of decompensation, were calculated for groups with LOH >6 days vs. LOH <6 days (reference), and stratified by hospitalisation in cardiology, internal medicine, geriatrics, or short-stay units. Results: We included 8563 patients (mean age: 80 (SD = 10) years, 55.5% women), with a median LOH of 7 days (IQR 4–11): 2934 (34.3%) had a LOH 15 days. The 90-day post-discharge mortality was 11.4%, readmission 32.2%, and combined endpoint 37.4%. Mortality was increased by 36.5% (95%CI = 13.0–64.9) when LOH was 11–15 days, and by 72.0% (95%CI = 42.6–107.5) when >15 days. Conversely, no differences were found in readmission risk, and the combined endpoint only increased 21.6% (95%CI = 8.4–36.4) for LOH >15 days. Stratified analysis by hospitalisation departments rendered similar post-discharge outcomes, with all exhibiting increased mortality for LOH >15 days and no significant increments in readmission risk. Conclusions: Short hospitalisations are not associated with worse outcomes. While post-discharge readmissions are not affected by LOH, mortality risk increases as the LOH lengthens. These findings were similar across hospitalisation departments

International nosocomial infection control consortium (INICC) report, data summary of 36 countries, for 2004-2009

The results of a surveillance study conducted by the International Nosocomial Infection Control Consortium (INICC) from January 2004 through December 2009 in 422 intensive care units (ICUs) of 36 countries in Latin America, Asia, Africa, and Europe are reported. During the 6-year study period, using Centers for Disease Control and Prevention (CDC) National Healthcare Safety Network (NHSN; formerly the National Nosocomial Infection Surveillance system [NNIS]) definitions for device-associated health care-associated infections, we gathered prospective data from 313,008 patients hospitalized in the consortium's ICUs for an aggregate of 2,194,897 ICU bed-days. Despite the fact that the use of devices in the developing countries' ICUs was remarkably similar to that reported in US ICUs in the CDC's NHSN, rates of device-associated nosocomial infection were significantly higher in the ICUs of the INICC hospitals; the pooled rate of central line-associated bloodstream infection in the INICC ICUs of 6.8 per 1,000 central line-days was more than 3-fold higher than the 2.0 per 1,000 central line-days reported in comparable US ICUs. The overall rate of ventilator-associated pneumonia also was far higher (15.8 vs 3.3 per 1,000 ventilator-days), as was the rate of catheter-associated urinary tract infection (6.3 vs. 3.3 per 1,000 catheter-days). Notably, the frequencies of resistance of Pseudomonas aeruginosa isolates to imipenem (47.2% vs 23.0%), Klebsiella pneumoniae isolates to ceftazidime (76.3% vs 27.1%), Escherichia coli isolates to ceftazidime (66.7% vs 8.1%), Staphylococcus aureus isolates to methicillin (84.4% vs 56.8%), were also higher in the consortium's ICUs, and the crude unadjusted excess mortalities of device-related infections ranged from 7.3% (for catheter-associated urinary tract infection) to 15.2% (for ventilator-associated pneumonia). Copyright © 2012 by the Association for Professionals in Infection Control and Epidemiology, Inc. Published by Elsevier Inc. All rights reserved

Automatic Layerwise Acquisition of Thermal and Geometric Data of the Electron Beam Melting Process using Infrared Thermography

Layerwise monitoring has become an area of interest in the field of additive manufacturing because of potential to further enable part qualification during every stage of fabrication. Spatial monitoring and qualification during part fabrication has never before been possible with traditional manufacturing processes such as milling or casting. An IR camera has been externally annexed atop an EBM system to obtain layerwise thermographs throughout the fabrication process. This paper demonstrates a process to compare each layer of fabrication using automatically acquired thermal images to the corresponding CAD file for each fabricated object. Two different methods of image analysis for part detection were compared (analysis on the basis of color and analysis by edge detection). Detection allowed the quantification of processing information (average temperature and surface anomalies) and geometric information (surface area and perimeter). A percent error of the compared surface area was found to range from 5%- 17%, and automatically acquired temperature measurements were within 7.8K of the recorded thermograph. The methods presented in this research showcase the beginning steps of integrated metrology in advanced manufacturing systems and automatic monitoring of per-part thermal behavior and part quality.Mechanical Engineerin

EBM Fabrication and Characterization of High Purity Niobium for Superconductor Applications

Superconducting radio frequency (SRF) cavities are used to accelerate charged particles to near the speed of light for elemental studies. Currently, SRF cavities are typically fabricated using different forming processes including deep-drawing and spinning to mechanically shape niobium into the desired geometry. This research presents the development of processing parameters for high purity niobium (powder size range of 25-125μm) using electron beam melting additive manufacturing technology. Fabrication parameters were improved to obtain dense parts in a time-efficient manner. A specific procedure was used to maintain powder purity, and powder chemistry was monitored at different stages of fabrication. In addition, a series of experiments were performed to obtain 99.9% dense parts and a maximum building height of ~85mm.Mechanical Engineerin