Featured Application: This work is a detailed comparison of the direct laser and electron additive manufacturing methods, which could help scientific research institutes and companies choose the best 3D printer system for the fabrication of titanium implants.Abstract: Additive Manufacturing (AM) methods are generally used to produce an early sample or near net-shape elements based on three-dimensional geometrical modules. To date, publications on AM of metal implants have mainly focused on knee and hip replacements or bone scaffolds for tissue engineering. The direct fabrication of metallic implants can be achieved by methods, such as Selective Laser Melting (SLM) or Electron Beam Melting (EBM). This work compares the SLM and EBM methods used in the fabrication of titanium bone implants by analyzing the microstructure, mechanical properties and cytotoxicity. The SLM process was conducted in an environmental chamber using 0.4-0.6 vol % of oxygen to enhance the mechanical properties of a Ti-6Al-4V alloy. SLM processed material had high anisotropy of mechanical properties and superior UTS (1246-1421 MPa) when compared to the EBM (972-976 MPa) and the wrought material (933-942 MPa). The microstructure and phase composition depended on the used fabrication method. The AM methods caused the formation of long epitaxial grains of the prior β phase. The equilibrium phases (α + β) and non-equilibrium α' martensite was obtained after EBM and SLM, respectively. Although it was found that the heat transfer that occurs during the layer by layer generation of the component caused aluminum content deviations, neither methods generated any cytotoxic effects. Furthermore, in contrast to SLM, the EBM fabricated material met the ASTMF136 standard for surgical implant applications.

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In this paper, a novel method for high temperature fatigue strength assessment of nickel superalloy turbine blades after operation at different times (303 and 473 h) was presented. The studies included destructive testing (fatigue testing at temperature 950 °C under cyclic bending load), non-destructive testing (Fluorescent Penetrant Inspection and Eddy Current method), and finite element modelling. High temperature fatigue tests were performed within load range from 5200 to 6600 N using a special self-designed blade grip attached to the conventional testing machine. The experimental results were compared with the finite element model generated from the ANSYS software. It was found that failure of turbine blades occurred in the area with the highest stress concertation, which was accurately predicted by the finite element (FE) model.

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Selective Laser Melting (SLM) is a manufacturing technique that is currently used for the production of functional parts that are difficult to form by the traditional methods such as casting or CNC (Computer Numerical Control) cutting from a wide range of metallic materials. In our study, a mixture of commercially pure titanium (Ti) and 15% at. aluminum nitride (AlN) was Selective Laser Melted to form three-dimensional objects. The obtained 4 mm edge cubes with an energy density that varied from 70 to 140 J/mm3 were examined in terms of their microstructure, chemical and phase composition, porosity, and Vickers microhardness. Scanning Electron Microscopy (SEM) observations of the etched samples showed inhomogeneities in the form of pores and unmelted and partly melted AlN particles in the fine-grained dendritic matrix, which is typical for titanium nitrides and titanium aluminum nitrides. The AlN particles remained unmelted in samples, but no porosity was observed in the interface area between them and the dendritic matrix. Additionally, samples fabricated with the presintering step had zones with different sizes of dendrites, suggesting a differing chemical composition of the matrix and the possibility of the formation of the phases forming an Ti–Al–N ternary system. The chemical composition in the microareas of the samples was determined using Energy Dispersive X-Ray Spectroscopy (EDS) and revealed differences in the homogeneity of the samples depending on the SLM process parameters and the additional presintering step. The phase composition, examined using X-ray Diffraction analysis (XRD), showed that samples were formed from Ti, TiN, and AlN phases. Porosity tests carried out using a computer microtomography revealed porosities in a range from 7% to 17.5%. The formed material was characterized by a relatively high hardness exceeding 700 HV0.2 over the entire cross-section, which depended on the manufacturing conditions.

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The article presents the results of research on the influence of plastic deformation on the microstructure and tensile strength of Haynes 282 nickel superalloy produced by direct metal laser sintering (DMLS) and a conventional technique (casting). Samples were tested for dimensional accuracy using a 3D scanner. Then, the samples were subjected to plastic deformation by rolling. The microstructures of the DMLS and the as-cast samples were analysed using a scanning electron microscope. The strength properties of the samples were determined in a static tensile test. Microhardness measurements of the samples were also performed. Based on the analysis of the dimensional accuracy, it was found that the surface quality of the components produced by DMLS is dependent on the input parameters of the 3D printing process. Using the DMLS method, it is possible to produce Haynes 282 with a fine-crystalline microstructure containing dendrites. The fine-crystalline dendritic microstructure and low porosity showed very good tensile strength compared to the as-cast material. It was also found that the increase in the degree of plastic deformation of the as-cast Haynes 282 and the samples produced by the DMLS technique resulted in an increase in the strength of the tested samples, with reduced ductility.