Architectural bone parameters and the relationship to titanium lattice design for powder bed fusion additive manufacturing

McGregor, Martine; Patel, Shubham; McLachlin, Stewart D.; Vlasea, Mihaela

doi:10.1016/j.addma.2021.102273

Cited by 34 publications

(23 citation statements)

References 142 publications

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“…PBF-LB is an advanced additive manufacturing (AM) technology offering unique possibilities in the manufacturing of complex structures, enabling design optimization for maximized functionality [22][23][24]. Regarding orthopedic implants, AM is particularly interesting due to the possibility of producing patient-specific designs with optimized structures for cell proliferation and bone regeneration [25,26]. The PBF-LB process is already established as a viable option for the production of various types of orthopedic implants of metal alloys such as Ti-6Al-4V [22,27], with one of the best-known examples being Ti-6Al-4V hip implants with an optimized surface for improved secondary fixation through enhanced bone ingrowth [28,29].…”

Section: Introductionmentioning

confidence: 99%

An Enhanced Understanding of the Powder Bed Fusion–Laser Beam Processing of Mg-Y3.9wt%-Nd3wt%-Zr0.5wt% (WE43) Alloy through Thermodynamic Modeling and Experimental Characterization

Åhman

Thorsson²,

Mellin

et al. 2022

Materials

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Powder Bed Fusion–Laser Beam (PBF–LB) processing of magnesium (Mg) alloys is gaining increasing attention due to the possibility of producing complex biodegradable implants for improved healing of large bone defects. However, the understanding of the correlation between the PBF–LB process parameters and the microstructure formed in Mg alloys remains limited. Thus, the purpose of this study was to enhance the understanding of the effect of the PBF–LB process parameters on the microstructure of Mg alloys by investigating the applicability of computational thermodynamic modelling and verifying the results experimentally. Thus, PBF–LB process parameters were optimized for a Mg WE43 alloy (Mg-Y3.9 wt%-Nd3 wt%-Zr0.5 wt%) on a commercially available machine. Two sets of process parameters successfully produced sample densities > 99.4%. Thermodynamic computations based on the Calphad method were employed to predict the phases present in the processed material. Phases experimentally established for both processing parameters included α-Mg, Y2O3, Mg3Nd, Mg24Y5 and hcp-Zr. Phases α-Mg, Mg24Y5 and hcp-Zr were also predicted by the calculations. In conclusion, the extent of the applicability of thermodynamic modeling was shown, and the understanding of the correlation between the PBF–LB process parameters and the formed microstructure was enhanced, thus increasing the viability of the PBF–LB process for Mg alloys.

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Section: Introductionmentioning

confidence: 99%

An Enhanced Understanding of the Powder Bed Fusion–Laser Beam Processing of Mg-Y3.9wt%-Nd3wt%-Zr0.5wt% (WE43) Alloy through Thermodynamic Modeling and Experimental Characterization

Åhman

Thorsson²,

Mellin

et al. 2022

Materials

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“…This study demonstrates that the traditional notion of the 'optimal processing region' in AM need not be the region with minimal porosity. Deliberate porosity engineering may provide an alternative in AM processing, which on a larger scale, corresponds to lattice design [128] .…”

Section: Optimal Processing Windowmentioning

confidence: 99%

Process parameter optimization of metal additive manufacturing: a review and outlook

Chia¹,

Wu²,

Wang³

et al. 2022

J Mater Inf

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The selection of appropriate process parameters is crucial in metal additive manufacturing (AM) as it directly influences the defect formation and microstructure of the printed part. Over the past decade, research efforts have been devoted to identifying "optimal" processing regimes for different materials to achieve defect-free manufacturing, which mostly involve costly trial-and-error experiments and computationally expensive mechanistic simulations. Hence, it is apropos to critically review the methods used to achieve the optimal process parameters in AM. This work seeks to provide a structured analysis of current methodologies and discuss systematic approaches toward general optimization work in AM and the process parameter optimization of new AM alloys. A brief review of process-induced defects due to process parameter selection is given and the current methods for identifying "optimal processing windows" are summarized. Research works are analyzed under a standard optimization framework, including the design of experiments and characterization, modelling and optimization algorithms. The research gaps that preclude multi-objective optimization in AM are identified and future directions toward optimization work in AM are discussed. With growing capabilities in AM, we should reconsider what the definition of the "optimal processing region".

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“…From the first day to the present, the AM know-how of research circles for over 40 years, academic research studies increased the dominance of the researchers on the systems and the demands of the researchers to control the systems more by changing the process parameters (Oliveira et al , 2020). In some studies in the literature, the process parameters, part porosity, microstructure properties (Krishnan et al , 2014), surface quality, mechanical strength, the effects on part quality were investigated (Ning et al , 2005; Bhardwaj and Shukla, 2018; McGregor et al , 2021; Bulduk et al , 2019; Charles et al , 2019). In recent years, research studies on the effects of process parameters on product and design have been started.…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing on the façade: functional use of direct metal laser sintering hatch distance process parameters in building envelope

Çalışkan

Arpacıoğlu

2022

RPJ

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Purpose The purpose of this article is on the functional usability of metal additive manufacturing (AM) direct metal laser sintering (DMLS) production technology process parameters in the construction industry. In the study, the advantages of thermal optimization and weight reduction in the case of the use of foam metals obtained by changing the hatch distance the production process parameter, in the production of facade panels in the architectural field are revealed. Design/methodology/approach The methods in the study; production of the small scaled facade panels with nine different hatch distance parameters, determination of the thermal change with the infrared thermography method, microstructure examination, weight measurement. Findings The paper lays the groundwork for the manufacturability of lighter and lower thermal conductivity facade panels by changing the hatch distance parameters. Within the scope of the study, the definition of semi-open-cell foam aluminum and the product screening strategy offers innovation. Within the scope of the study, this scope is shared as an algorithmic summary. In addition, the study offers a new perspective within the scope of multiple optimizable panel production in facade panels with AM technology. Originality/value Hatch distance parameter change was first discussed in this study in the architectural field, and a semi-open cell foam aluminum panel was obtained with the scanning strategy determined within the scope of the study. This panel geometry, which is defined as semi-open cell foam aluminum, can be used as a design element by painting or coating the outer surface, it can be stated that it will also provide thermal and weight optimization.

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Architectural bone parameters and the relationship to titanium lattice design for powder bed fusion additive manufacturing

Cited by 34 publications

References 142 publications

An Enhanced Understanding of the Powder Bed Fusion–Laser Beam Processing of Mg-Y3.9wt%-Nd3wt%-Zr0.5wt% (WE43) Alloy through Thermodynamic Modeling and Experimental Characterization

An Enhanced Understanding of the Powder Bed Fusion–Laser Beam Processing of Mg-Y3.9wt%-Nd3wt%-Zr0.5wt% (WE43) Alloy through Thermodynamic Modeling and Experimental Characterization

Process parameter optimization of metal additive manufacturing: a review and outlook

Additive manufacturing on the façade: functional use of direct metal laser sintering hatch distance process parameters in building envelope

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