Parameters Optimization and Repeatability Study on Low-Weldable Nickel-Based Superalloy René 80 Processed via Laser Powder–Bed Fusion (L-PBF)

This work aims to investigate the processability of René 80 via laser powder–bed fusion (L-PBF). René 80 is a poorly weldable Ni-superalloy, currently processed via investment casting to fabricate turbine blades working at an operating temperature of about 850 °C. The L-PBF parameters optimization aims to increase part integrity and enhance processing repeatability. This part was tackled by creating a complete design of experiments (DOE) in which laser power, scan speed and hatching distance were varied accordingly. Optimizing the abovementioned parameters minimized the crack density and pore area fraction. Hence, five parameter sets leading to a crack density lower than 100 µm/mm2 and a pore fraction between 0.045% and 0.085% were selected. Furthermore, the intra-print repeatability was studied by producing three specimens’ repetitions for each optimal set of parameters in the same build. The porosity value obtained was constant among repetitions, and the crack density (around 75 µm/mm2) had a slight standard deviation. The third step of the research assessed the inter-prints repeatability by producing a replica of the five selected parameter sets in a different build and by comparing the results with those studied previously. According to this latter study, the porosity fraction (ca. 0.06%) was constant in intra- and inter-print conditions. Conversely, crack density was lower than 100 µm/mm2 only in three sets of parameters, regardless of the intra- or inter-build cross-check. Finally, the best parameter set was chosen, emphasizing the average flaw fraction (least possible value) and repeatability. Once the optimal densification of the samples was achieved, the alloy’s microstructural features were also investigated

Development and Characterisation of Aluminium Matrix Nanocomposites AlSi10Mg/MgAl2O4 by Laser Powder Bed Fusion

Recently, additive manufacturing techniques have been gaining attention for the fabrication of parts from aluminium alloys to composites. In this work, the processing of an AlSi10Mg based composite reinforced with 0.5% in weight of MgAl2O4 nanoparticles through laser powder bed fusion (LPBF) process is presented. After an initial investigation about the effect of process parameters on the densification levels, the LPBF materials were analysed in terms of microstructure, thermo-mechanical and mechanical properties. The presence of MgAl2O4 nanoparticles involves an increment of the volumetric energy density delivered to the materials, in order to fabricate samples with high densification levels similar to the AlSi10Mg samples. However, the application of different building parameters results in modifying the size of the cellular structures influencing the mechanical properties and therefore, limiting the strengthening effect of the reinforcement

Ti-6Al-4V lattice structures produced by EBM: Heat treatment and mechanical properties

Abstract Additive manufacturing (AM) processes allow producing the complex components in a layerwise fashion. The complexity includes the design of lighter and stronger components by using lattice structures that can be quickly realized through AM technologies. However, the mechanical behaviour of lattice structures is not completely known, especially in the post-treated state. Thus, this work aims to explore the effect of post-treatment on the compressive strength of specimens with lattice structures. The samples are produced using Ti-6Al-4V powder processed by Electron Beam Melting (EBM). The outcomes of this work confirm the correlation between the heat treatment and final mechanical properties

Additive Manufacturing of Al Alloys and Aluminium Matrix Composites (AMCs)

In this chapter a large description of additive manufacturing techniques for obtaining Al alloys and Al matrix composites is given. Results on mechanical properties, roughness and microstructure achievable with such fabrication route on Al alloys are reported

A Comparison of the Laser Powder Interaction in Laser Powder Bed Fusion and Direct Energy Deposition Processes

Metal additive manufacturing (AM) is a class of innovative production technologies that allows the production of metal components layer by layer directly from a Computer Aided Design (CAD) model. The AM process of aluminium and aluminium alloys gained much interest in past years especially thanks to the high geometrical freedom, the peculiar microstructures and enhanced mechanical properties it is possible to achieve. However, the quality of final metal components strongly depends on the stability and the quality of each single scan track. Therefore, the understanding of the laser-powder interaction and of the phenomena that arise in the melt pool is a key aspect for the development of these technologies. In this work, AlSi10Mg single scan tracks (SSTs), produced by laser powder bed fusion (LPBF) and direct energy deposition (DED), were analysed and compared in order to select the most suitable range of parameters for each building process

Comparative in vitro and ex vivo studies on the bactericidal activity of Tetraclean, a new generation endodontic irrigant, and sodium hypochlorite

The aim of this study was to compare the efficacy of a new generation endodontic irrigant, Tetraclean, to the widely used sodium hypochlorite. Tetraclean combines a powerful detergent effect with a strong antimicrobial efficacy, whereas sodium hypochlorite has several drawbacks and is sometimes ineffective in preventing microbial-mediated endodontic failure. The bactericidal activity of both irrigants against Enterococcus faecalis, the most commonly isolated species from root canals of teeth with post-treatment disease, was assessed i) in vitro, according to the European Standard lines for the evaluation of the bactericidal activity of chemical disinfectants, and ii) with an ex vivo model of extracted and decoronated human teeth, infected with E. faecalis and subsequently irrigated with either of the irrigants. Both irrigants display very similar bactericidal activity against E. faecalis in vitro. However, the ex vivo model shows that only in the teeth irrigated with Tetraclean did the bacterial burden gradually drop until no bacteria were detectable a few days post-irrigation. Vice versa, in the teeth irrigated with sodium hypochlorite, the drop in the bacterial burden was rapid but temporary and most of the teeth were colonized again by 48 hours post-irrigation

Parameters Optimization and Repeatability Study on Low-Weldable Nickel-Based Superalloy René 80 Processed via Laser Powder–Bed Fusion (L-PBF)

This work aims to investigate the processability of René 80 via laser powder–bed fusion (L-PBF). René 80 is a poorly weldable Ni-superalloy, currently processed via investment casting to fabricate turbine blades working at an operating temperature of about 850 °C. The L-PBF parameters optimization aims to increase part integrity and enhance processing repeatability. This part was tackled by creating a complete design of experiments (DOE) in which laser power, scan speed and hatching distance were varied accordingly. Optimizing the abovementioned parameters minimized the crack density and pore area fraction. Hence, five parameter sets leading to a crack density lower than 100 µm/mm2 and a pore fraction between 0.045% and 0.085% were selected. Furthermore, the intra-print repeatability was studied by producing three specimens’ repetitions for each optimal set of parameters in the same build. The porosity value obtained was constant among repetitions, and the crack density (around 75 µm/mm2) had a slight standard deviation. The third step of the research assessed the inter-prints repeatability by producing a replica of the five selected parameter sets in a different build and by comparing the results with those studied previously. According to this latter study, the porosity fraction (ca. 0.06%) was constant in intra- and inter-print conditions. Conversely, crack density was lower than 100 µm/mm2 only in three sets of parameters, regardless of the intra- or inter-build cross-check. Finally, the best parameter set was chosen, emphasizing the average flaw fraction (least possible value) and repeatability. Once the optimal densification of the samples was achieved, the alloy’s microstructural features were also investigated

A Robust Multifunctional Sandwich Panel Design with Trabecular Structures by the Use of Additive Manufacturing Technology for a New De-Icing System

Anti-ice systems assure a vital on-board function in most aircraft: ice prevention or de-icing is mandatory for all aerodynamic surfaces to preserve their performance, and for all the movable surfaces to allow the proper control of the plane. In this work, a novel multi-functional panel concept which integrates anti-icing directly inside the primary structure is presented. In fact, constructing the core of the sandwich with trabecular non-stochastic cells allows the presence of a heat exchanger directly inside the structure with a savings in weight and an improvement in thermal efficiency. This solution can be realized easily in a single-piece component using Additive Manufacturing (AM) technology without the need for joints, gluing, or welding. The objective of this study is to preliminarily investigate the mechanical properties of the core constructed with Selective Laser Melting (SLM); through the Design of Experiment (DOE), different design parameters were varied to understand how they affect the compression behaviour

Design and characterization of trabecular structures for an anti-icing sandwich panel produced by additive manufacturing

The need for a high-efficiency hot air anti-icing system is met by the use of sandwich panels with high surface area trabecular structures as core. Trabecular structures have good mechanical properties and are able to act as thermal exchange and structural support. A structural characterization of complex trabecular structures made by Additive Manufacturing is required. For this study, AlSi10Mg specimens were produced by Selective Laser Melting technology varying cell shapes (with or without vertical struts), cell sizes (4 and 5 mm) and struts size (1 and 1.2 mm). Compressive tests were performed on the specimens and fracture mechanisms for the two cell types were analyzed by optical microscope observation. The rupture modes of the specimensare strongly dependent on the cell shape as shown by the mechanical results and confirmed by comparison with the Gibson–Ashby model