The Effects of Feature Sizes in Selectively Laser Melted Ti-6Al-4V Parts on the Validity of Optimised Process Parameters

Ti-6Al-4V is a popular alloy due to its high strength-to-weight ratio and excellent corrosion resistance. Many applications of additively manufactured Ti-6Al-4V using selective laser melting (SLM) have reached technology readiness. However, issues linked with metallurgical differences in parts manufactured by conventional processes and SLM persist. Very few studies have focused on relating the process parameters to the macroscopic and microscopic properties of parts with different size features. Therefore, the aim of this study was to investigate the effect of the size of features on the density, hardness, microstructural evolution, and mechanical properties of Ti-6Al-4V parts fabricated using a fixed set of parameters. It was found that there is an acceptable range of sizes that can be produced using a fixed set of parameters. Beyond a specific window, the relative density decreased. Upon decreasing the size of a cuboid from (5 × 5 × 5 mm) to (1 × 1 × 5 mm), porosity increased from 0.3% to 4.8%. Within a suitable size range, the microstructure was not significantly affected by size; however, a major change was observed outside the acceptable size window. The size of features played a significant role in the variation of mechanical properties. Under tensile loading, decreasing the gauge size, the ultimate and yield strengths deteriorated. This investigation, therefore, presents an understanding of the correlation between the feature size and process parameters in terms of the microscopic and macroscopic properties of Ti-6Al-4V parts manufactured using SLM. This study also highlights the fact that any set of optimized process parameters will only be valid within a specific size window

Processing of the ultra-light syntactic foam material Eccostock® FFP using selective laser sintering

Production of custom shaped, low density parts and components has a wide number of industrial applications, but also due to the nature of the material can be challenging [1]. Additive manufacturing forms final parts in a layer by layer process from a stack of 2D sections or slices and allows fabrication of almost any arbitrary 3D shape. Depending on the material and desired pore size, this technique can be used to prepare syntactic foams from open cellular structures as well as from composite materials with a high content of glass microspheres. Eccostock FFP is an off the shelf, epoxy-based composite free-flowing powder. Exposed to the temperatures about 100- 150 °C it cures into the rigid and ultra-light three phase syntactic foam (~ 0.1 g/cc). Material is standardly used for physical support and to provide thermal insulation for delicate electrical components in high vibration environments. In its powder form, it allows material to reach inside densely populated electronic packages and its low shrinkage means that electronic components will not be damaged during the curing procedure. The same characteristics also open the possibility to process this powder using the SLS system and benefit from the design freedom of the additive manufacturing technologies. Selective laser sintering (SLS) is one of the powder bed fusion processes, where parts are built using a laser beam as a heat source inducing fusion between powder particles. Powder is uniformly spread across the building platform and kept heated at a temperature just below the melting and curing point. Interaction with the laser selectively cures the polymer matrix entrapping glass microspheres, while the rest of the powder is unaffected and serves as a support. After each slice, the building platform lowers down a certain distance and a new powder layer is recoated on the surface [2]. In this work we optimised parameters for the processing of the Eccostock FFP powder in the standard SLS machine (EOS Formiga P100). Optimal process temperature and laser energy were defined. Using different sets of parameters we produced compression samples to evaluate mechanical properties of the final parts as well as the influence of the different printing parameters on the part density. We showed that syntactic foams parts can be produced using a relatively low processing temperature (below 70 °C) with short heating and cooling periods and exhibited good dimensional accuracy and shape freedom, making SLS an interesting technology to produce ultra-low density, custom shaped structures for industrial applications. Please click Additional Files below to see the full abstract

Defect evolution in laser powder bed fusion additive manufactured components during thermo-mechanical testing

The mechanical performance of additively manufactured (AM) components remains an issue, limiting the implementation of AM technologies. In this work, a new method is presented, to examine the evolution of defects in an Inconel 718 two-bar test specimen, manufactured by laser powder bed fusion AM, during thermo-mechanical testing. The test was interrupted at specific extensions of the specimen, and X-ray computed tomography measurements performed. This methodology has allowed, for the first time, the evolution of the defects in an AM specimen to be studied during a thermo-mechanical test. The number and size of the defects were found to increase with time as a result of the thermo-mechanical test conditions, and the location and evolution of these defects have been tracked. Defect tracking potentially allows for accurate prediction of failure positions, at the earliest possible stage of a thermo-mechanical test. Ultimately, when the ability to locate defects in this manner is coupled with manipulation of build parameters, laser powder bed fusion practitioners will be able to further optimise the manufacturing procedure in order to produce components of a higher structural integrity

Development, printability and post-curing studies of formulations of materials resistant to microbial attachment for use in inkjet based 3D printing

Purpose: This paper aims to print 3D structures from polymers that resist bacterial attachment by reactive jetting of acrylate monomers. Design/methodology/approach: The first step towards printing was ink development. Inks were characterised to carry out an estimation of their potential printability using the Z parameter to predict stable jetting conditions. Printability conditions were optimised for each ink using a Dimatix DMP-2800, which enabled 3D structures to be fabricated. Findings: UV photo-initiated polymers, which resist bacterial attachment, were found to be printable using piezo-based inkjet printers. The waveform required for each ink depends on the value of the Z parameter. Once the waveform and the printability parameters were optimised, 3D objects were fabricated. Research limitations/implications: This methodology has been confirmed as an effective method to 3D print materials that have been demonstrated to be bacteria resistant. However, ink curing depends on modification of some parameters (such as photoinitiator concentration or UV exposure time) which would result in an improvement of the curing process post jetting. Social implications: The combination of inkjet based 3D printing with new materials resistant to bacterial attachment means the possibility of building customised medical devices with a high level of complexity and bespoke features can be fully realised. The scope and variability of the devices produced will exceed what can be achieved using standard fabrication methodologies and can be applied to reduce the incidence of device associated infections and to address increased morbidity, mortality and health care costs associated with nosocomial infections. Originality/value: In this paper, the novel use of materials that resist bacterial attachment has been described to build 3D structures using material jetting. Its value lies on the potential impact this methodology could produce in the biomedical device and research fields

High Density Ti6Al4V via Slim Processing: Microstructure and Mechanical Properties

This paper investigates a density improvement method for Ti6Al4V alloy processed by the selective laser melting method. A modified inert gas inlet baffle has been employed to develop improved mechanical properties for these materials. Comparisons of the top surface and cross-section porosities of solid blocks processed by the original and modified gas inlet baffles indicate that the modified baffle greatly increases the properties of the processing blocks. Results showed that the porosity of the Ti6Al4V alloy was lower than 0.1% by area. The microstructure of the SLM Ti6Al4V alloy exhibited martensitic α' phase. The UTS tensile strength was 920-960MPa and the elongation at the fracture was 3-5%. The fracture surfaces of the tensile samples demonstrated a mixture of ductile and brittle fracture.Mechanical Engineerin

Current recommendations/practices for anonymising data from clinical trials in order to make it available for sharing:A scoping review

BACKGROUND/AIMS: There are increasing pressures for anonymised datasets from clinical trials to be shared across the scientific community, and differing recommendations exist on how to perform anonymisation prior to sharing. We aimed to systematically identify, describe and synthesise existing recommendations for anonymising clinical trial datasets to prepare for data sharing. METHODS: We systematically searched MEDLINE(®), EMBASE and Web of Science from inception to 8 February 2021. We also searched other resources to ensure the comprehensiveness of our search. Any publication reporting recommendations on anonymisation to enable data sharing from clinical trials was included. Two reviewers independently screened titles, abstracts and full text for eligibility. One reviewer extracted data from included papers using thematic synthesis, which then was sense-checked by a second reviewer. Results were summarised by narrative analysis. RESULTS: Fifty-nine articles (from 43 studies) were eligible for inclusion. Three distinct themes are emerging: anonymisation, de-identification and pseudonymisation. The most commonly used anonymisation techniques are: removal of direct patient identifiers; and careful evaluation and modification of indirect identifiers to minimise the risk of identification. Anonymised datasets joined with controlled access was the preferred method for data sharing. CONCLUSIONS: There is no single standardised set of recommendations on how to anonymise clinical trial datasets for sharing. However, this systematic review shows a developing consensus on techniques used to achieve anonymisation. Researchers in clinical trials still consider that anonymisation techniques by themselves are insufficient to protect patient privacy, and they need to be paired with controlled access

Combined inkjet printing and infrared sintering of silver nanoparticles using a swathe-by-swathe and layer-by-layer approach for 3-dimensional structures

Despite the advancement of additive manufacturing (AM)/3-dimensional (3D) printing, single-step fabrication of multifunctional parts using AM is limited. With the view of enabling multifunctional AM (MFAM), in this study, sintering of metal nanoparticles was performed to obtain conductivity for continuous line inkjet printing of electronics. This was achieved using a bespoke three dimensional (3D) inkjet-printing machine, JETx®, capable of printing a range of materials and utilizing different post processing procedures to print multi-layered 3D structures in a single manufacturing step. Multiple layers of silver were printed from an ink containing silver nanoparticles (AgNPs) and infra-red sintered using a swathe-by-swathe (SS) and layer-by-layer sintering (LS) regime. The differences in the heat profile for the SS and LS was observed to influence the coalescence of the AgNPs. Void percentage of both SS and LS samples was higher towards the top layer than the bottom layer due to relatively less IR exposure in the top than the bottom. The results depicted a homogeneous microstructure for LS of AgNPs and showed less deformation compared to the SS. Electrical resistivity of the LS tracks (13.6 ± 1μΩ cm) was lower than the SS tracks (22.5 ± 1 μΩ cm). This study recommends the use of LS method to sinter the AgNPs to obtain a conductive track in 25% less time than SS method for MFAM

Author Correction: Additive manufacture of complex 3D Au-containing nanocomposites by simultaneous two-photon polymerisation and photoreduction

A correction to this article has been published and is linked from the HTML and PDF versions of this paper. The error has not been fixed in the paper

multifunctional bioinstructive 3d architectures to modulate cellular behavior

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