A novel thermo-geometrical model for accurate keyhole porosity prediction in Laser Powder-Bed Fusion

When performing Laser Powder-Bed Fusion, undesired physical phenomena, such as balling, preballing and keyhole, must be avoided in order to achieve high-quality products. To date, keyhole-free process parameters can be identified either using demanding empirical methods or complex numerical simulations, while only a few analytical models can be found in literature for this purpose. In this work, state-of-the-art analytical models for predicting keyhole porosity were summarized and proved to be rather inaccurate because they are only based on thermodynamic principles, whereas they neglect the geometry and both the kinetics and kinematics of the keyhole cavity, which do also influence cavity collapse and porosity formation. Here an innovative physics-based semi-analytical model for predicting the formation of keyhole-related porosities was conceived, in which both thermodynamic and geometrical factors are taken into account. The proposed model was validated by performing single tracks experiments on Ti6Al4V according to a full factorial DoE on laser power and scanning speed. Produced samples were cross-sectioned and analyzed to evaluate keyhole porosity formation. The comparison between experimental data and model predictions confirmed the higher accuracy of the new model with respect to state of the art models. Besides improving the understanding of the keyhole phenomenon, the proposed model may provide a novel, effective and simple tool for fast process parameter optimization in industry

Effects of post-printing heat treatment on microstructure, corrosion and wet wear behavior of CoCrW alloy produced by L-PBF process

CoCr alloys are widely used as human implants because of both their superior corrosion resistance and superior mechanical properties (fatigue, wear resistance, etc.) respect to other metal alloys used in biomedical field. In particular, CoCrW alloys are used mainly to produce dental implants. In this study, the effects of thermal treatment on the corrosion resistance and wet wear resistance of CoCrW alloys produced via Laser-Powder Bed Fusion (L-PBF) were investigated, and the corrosion resistance and wet wear resistance of the L-PBF specimens were compared with those of the specimens obtained after forging. The heat treatment involved the solubilization of the alloy at 1150 °C in an Ar-saturated atmosphere, followed by furnace cooling. A detailed microstructural characterization of the L-PBF specimens was carried out using a light microscope and a scanning electron microscope in both the horizontal and vertical growth directions. Scanning Kelvin probe measurements were performed on the heat-treated specimens obtained by three-dimensional printing and forging. The void contents of the specimens were evaluated using the Archimedes’ method and image analysis. Vickers (HV2) hardness measurements were performed to evaluate the mechanical properties of the specimens. The corrosion properties of the specimens were evaluated by carrying out potentiodynamic tests in two different corrosive media (aqueous solution (9 g/L NaCl) at pH = 2 and 7). The corroded areas of the specimens were then examined using scanning electron microscopy (SEM). Finally, tribological tests were performed using the pin (Ti counter material)-on-flat configuration under dry and wet conditions, using the same corrosive environments as those used in the potentiodynamic tests and two different stroke lengths. The worn samples were characterized using SEM to investigate their wear mechanisms, and a stylus profilometer was used to determine the wear rates of the materials. The experimental results showed that the additively manufactured CoCrW L-PBF alloy had higher corrosion resistance than the wrought material. In addition, the additively manufactured material showed better dry and wet wear performances than the wrought material. Nevertheless, the heat treatment did not affect the properties evaluated in this study

Single tracks data obtained by selective laser melting of Ti6Al4V with a small laser spot diameter

Nowadays, advanced metal components with high geometrical complexity can be 3D printed by using the Selective Laser Melting (SLM) technology. Despite SLM resolution and accuracy are generally limited to some tenths of mm, it should be possible to produce finer and more precise details by applying lasers with a small spot diameter. However, to present date the data collected with small laser spot diameters are poor. In this work, experimental data describing the effects of laser power and scan speed on single track formation when applying a small laser spot diameter of 50 \ub5m on Ti6Al4V powder are reported. SEM images and the extracted geometrical data characterizing the obtained single tracks are provided here, as well as their microstructural analysis and microhardness measurements

Effect of Thermal Treatment on Corrosion Behavior of AISI 316L Stainless Steel Manufactured by Laser Powder Bed Fusion

The effect of post-processing heat treatment on the corrosion behavior of AISI 316L stainless steel manufactured by laser powder bed fusion (L-PBF) is investigated in this work. Produced stainless steel was heat treated in a broad temperature range (from 200 °C to 1100 °C) in order to evaluate the electrochemical behavior and morphology of corrosion. The electrochemical behavior was investigated by potentiodynamic and galvanostatic polarization in a neutral and acidic (pH 1.8) 3.5% NaCl solution. The microstructure modification after heat treatment and the morphology of attack of corroded samples were evaluated by optical and scanning electron microscopy. The fine cellular/columnar microstructure typically observed for additive-manufactured stainless steel evolves into a fine equiaxed austenitic structure after thermal treatment at high temperatures (above 800 °C). The post-processing thermal treatment does not negatively affect the electrochemical behavior of additive-manufactured stainless steel even after prolonged heat treatment at 1100 °C for 8 h and 24 h. This indicates that the excellent barrier properties of the native oxide film are retained after heat treatment

Synthetic torpor protects rats from exposure to accelerated heavy ions

Hibernation or torpor is considered a possible tool to protect astronauts from the deleterious effects of space radiation that contains high-energy heavy ions. We induced synthetic torpor in rats by injecting adenosine 5′-monophosphate monohydrate (5′-AMP) i.p. and maintaining in low ambient temperature room (+ 16 °C) for 6 h immediately after total body irradiation (TBI) with accelerated carbon ions (C-ions). The 5′-AMP treatment in combination with low ambient temperature reduced skin temperature and increased survival following 8 Gy C-ion irradiation compared to saline-injected animals. Analysis of the histology of the brain, liver and lungs showed that 5′-AMP treatment following 2 Gy TBI reduced activated microglia, Iba1 positive cells in the brain, apoptotic cells in the liver, and damage to the lungs, suggesting that synthetic torpor spares tissues from energetic ion radiation. The application of 5′-AMP in combination with either hypoxia or low temperature environment for six hours following irradiation of rat retinal pigment epithelial cells delays DNA repair and suppresses the radiation-induced mitotic catastrophe compared to control cells. We conclude that synthetic torpor protects animals from cosmic ray-simulated radiation and the mechanism involves both hypothermia and hypoxia

Effect of powder recycling on inclusion content and distribution in AISI 316L produced by L-PBF technique

AISI 316 L stainless steel is widely used as material to produce components by means of additive manufacturing. To increase the circular economy, the powders are collected and re-used after the printing process, thus the effect of powder recycling on microstructure and properties of printed components is of the utmost importance. This work focused the attention on non-metallic inclusions by examining virgin and recycled powders, and products printed by using both types of powders in a laser powder bed fusion (L-PBF) process. Recycled powders exhibit an irregular shape due to fragmentation, spatters and satellites and, compared to the virgin ones, have a higher gas (O, H and C) content. Both powders contain non-metallic inclusions with a larger quantity in the recycled ones. The printed samples have a similar microstructure, however those produced by using recycled powders exhibit voids of larger size and a little greater amount of inclusions. XRD and EDS examinations of inclusions extracted from the metallic matrix showed that they consist of a mix of amorphous and crystalline silica. Large part of these particles are already present in virgin powders and only a minor part forms during repeated printing operations. Accordingly, the quality of virgin powders is the factor that mainly affects the inclusion content of printed products indicating that the powder production process is the most critical stage of the whole manufacturing process

Why High-Performance Modelling and Simulation for Big Data Applications Matters

Modelling and Simulation (M&S) offer adequate abstractions to manage the complexity of analysing big data in scientific and engineering domains. Unfortunately, big data problems are often not easily amenable to efficient and effective use of High Performance Computing (HPC) facilities and technologies. Furthermore, M&S communities typically lack the detailed expertise required to exploit the full potential of HPC solutions while HPC specialists may not be fully aware of specific modelling and simulation requirements and applications. The COST Action IC1406 High-Performance Modelling and Simulation for Big Data Applications has created a strategic framework to foster interaction between M&S experts from various application domains on the one hand and HPC experts on the other hand to develop effective solutions for big data applications. One of the tangible outcomes of the COST Action is a collection of case studies from various computing domains. Each case study brought together both HPC and M&S experts, giving witness of the effective cross-pollination facilitated by the COST Action. In this introductory article we argue why joining forces between M&S and HPC communities is both timely in the big data era and crucial for success in many application domains. Moreover, we provide an overview on the state of the art in the various research areas concerned

Three-row versus two-row circular staplers for left-sided colorectal anastomosis: a propensity score-matched analysis of the iCral 2 and 3 prospective cohorts

Background: Since most anastomoses after left-sided colorectal resections are performed with a circular stapler, any technological change in stapling devices may influence the incidence of anastomotic adverse events. The aim of the present study was to analyze the effect of a three-row circular stapler on anastomotic leakage and related morbidity after left-sided colorectal resections. Materials and methods: A circular stapled anastomosis was performed in 4255 (50.9%) out of 8359 patients enrolled in two prospective multicenter studies in Italy, and, after exclusion criteria to reduce heterogeneity, 2799 (65.8%) cases were retrospectively analyzed through a 1:1 propensity score-matching model including 20 covariates relative to patient characteristics, to surgery and to perioperative management. Two well-balanced groups of 425 patients each were obtained: group (A) – true population of interest, anastomosis performed with a three-row circular stapler; group (B) – control population, anastomosis performed with a two-row circular stapler. The target of inferences was the average treatment effect in the treated (ATT). The primary endpoints were overall and major anastomotic leakage and overall anastomotic bleeding; the secondary endpoints were overall and major morbidity and mortality rates. The results of multiple logistic regression analyses for the outcomes, including the 20 covariates selected for matching, were presented as odds ratios (OR) and 95% confidence intervals (95% CI). Results: Group A versus group B showed a significantly lower risk of overall anastomotic leakage (2.1 vs. 6.1%; OR 0.33; 95% CI 0.15–0.73; P = 0.006), major anastomotic leakage (2.1 vs. 5.2%; OR 0.39; 95% CI 0.17–0.87; P = 0.022), and major morbidity (3.5 vs. 6.6% events; OR 0.47; 95% CI 0.24–0.91; P = 0.026). Conclusion: The use of three-row circular staplers independently reduced the risk of anastomotic leakage and related morbidity after left-sided colorectal resection. Twenty-five patients were required to avoid one leakage

Global patient outcomes after elective surgery: prospective cohort study in 27 low-, middle- and high-income countries.

BACKGROUND: As global initiatives increase patient access to surgical treatments, there remains a need to understand the adverse effects of surgery and define appropriate levels of perioperative care. METHODS: We designed a prospective international 7-day cohort study of outcomes following elective adult inpatient surgery in 27 countries. The primary outcome was in-hospital complications. Secondary outcomes were death following a complication (failure to rescue) and death in hospital. Process measures were admission to critical care immediately after surgery or to treat a complication and duration of hospital stay. A single definition of critical care was used for all countries. RESULTS: A total of 474 hospitals in 19 high-, 7 middle- and 1 low-income country were included in the primary analysis. Data included 44 814 patients with a median hospital stay of 4 (range 2-7) days. A total of 7508 patients (16.8%) developed one or more postoperative complication and 207 died (0.5%). The overall mortality among patients who developed complications was 2.8%. Mortality following complications ranged from 2.4% for pulmonary embolism to 43.9% for cardiac arrest. A total of 4360 (9.7%) patients were admitted to a critical care unit as routine immediately after surgery, of whom 2198 (50.4%) developed a complication, with 105 (2.4%) deaths. A total of 1233 patients (16.4%) were admitted to a critical care unit to treat complications, with 119 (9.7%) deaths. Despite lower baseline risk, outcomes were similar in low- and middle-income compared with high-income countries. CONCLUSIONS: Poor patient outcomes are common after inpatient surgery. Global initiatives to increase access to surgical treatments should also address the need for safe perioperative care. STUDY REGISTRATION: ISRCTN5181700

Home-based palliative approach for people with severe multiple sclerosis and their carers: Study protocol for a randomized controlled trial

Background: Preliminary evidence suggests that palliative care may be useful for people with severe multiple sclerosis (MS). The aim of this study is to determine the effectiveness of a home-based palliative approach (HPA) for people with severe MS and their carers. Methods/design: This is a single-blind randomized controlled trial with a nested qualitative study. Seventy-five severe MS-carer dyads are being randomized (at three centers, one in each area of Italy) to HPA or usual care (UC) in a 2:1 ratio. Each center has a specially trained team consisting of four professionals (physician, nurse, psychologist, social worker). The team makes a comprehensive assessment of the needs of the dyads. HPA content is then agreed on, discussed with the patient's caring physician, and delivered over six months. The intervention is not intended to replace existing services. At later visits, the team checks the HPA delivery and reviews/modifies it as necessary. Discussion: The results of our study will show whether the HPA is feasible and beneficial to people with severe MS and their carers living in the three Italian geographic areas. The nested qualitative study will add to the understanding of the strengths and limitations of the intervention