Manufacturing and characterization of similar to foam steel components processed through selective laser melting

Campanelli, Sabina Luisa; Cardaropoli, Francesco; Contuzzi, Nicola; Sergi, Vincenzo; Ludovico, Antonio Domenico

doi:10.1007/s00170-017-0311-4

Cited by 25 publications

(12 citation statements)

References 26 publications

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“…The chemical composition is listed in Table 2 . The powder has a low content of impurities (oxygen, hydrogen and nitrogen), which might avoid negative effect of embrittlement [ 34 ].…”

Section: Methodsmentioning

confidence: 99%

Mechanical Properties of Optimized Diamond Lattice Structure for Bone Scaffolds Fabricated via Selective Laser Melting

et al. 2018

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Developments in selective laser melting (SLM) have enabled the fabrication of periodic cellular lattice structures characterized by suitable properties matching the bone tissue well and by fluid permeability from interconnected structures. These multifunctional performances are significantly affected by cell topology and constitutive properties of applied materials. In this respect, a diamond unit cell was designed in particular volume fractions corresponding to the host bone tissue and optimized with a smooth surface at nodes leading to fewer stress concentrations. There were 33 porous titanium samples with different volume fractions, from 1.28 to 18.6%, manufactured using SLM. All of them were performed under compressive load to determine the deformation and failure mechanisms, accompanied by an in-situ approach using digital image correlation (DIC) to reveal stress–strain evolution. The results showed that lattice structures manufactured by SLM exhibited comparable properties to those of trabecular bone, avoiding the effects of stress-shielding and increasing longevity of implants. The curvature of optimized surface can play a role in regulating the relationship between density and mechanical properties. Owing to the release of stress concentration from optimized surface, the failure mechanism of porous titanium has been changed from the pattern of bottom-up collapse by layer (or cell row) to that of the diagonal (45°) shear band, resulting in the significant enhancement of the structural strength.

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“…The chemical composition is listed in Table 2 . The powder has a low content of impurities (oxygen, hydrogen and nitrogen), which might avoid negative effect of embrittlement [ 34 ].…”

Section: Methodsmentioning

confidence: 99%

Mechanical Properties of Optimized Diamond Lattice Structure for Bone Scaffolds Fabricated via Selective Laser Melting

et al. 2018

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“…Methods to produce open‐cell steel foams or similar lattice structures can be divided into solid state and liquid state processing routes . Recent advances in additive manufacturing techniques like selective laser melting (SLM) enable 3D printing of cellular structures with complex geometries . High‐density open‐cell steel foams can be produced by a powder metallurgy method using carbamide particles as space holder …”

Section: Introductionmentioning

confidence: 99%

Investment Casting and Mechanical Properties of Open‐Cell Steel Foams

Frömert¹,

Lott²,

Matz³

et al. 2019

Adv Eng Mater

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This study presents a novel manufacturing process for open-cell stainless steel foams using a modified investment casting process and a novel approach to identify transitions between elastic-plastic, plateau, and densification region in the stress-strain history of compressed foams, based on its strain and structural hardening behavior. The influence of microstructure on the mechanical properties under quasi-static compression loading (plateau stress, energy absorption, and strain hardening) of austenitic (AISI 304, 316L) and super duplex (AISI F55) stainless steels is investigated. Microstructure is characterized prior and subsequent to mechanical testing using light microscopy and SEM. The manufacturing process yields open-cell foams with relative densities in the range of 14-20%, solid struts being circular in shape and defect-free surfaces. This morphology leads to improved yield strengths compared to open-cell steel foams produced by the powder metallurgical route. Among the manufactured open-cell steel foams, F55 foams with finegrained duplex microstructures show highest yield strength, strain hardening, and energy absorption with a sufficient ductility. Although a martensitic transformation is present in highly deformed struts of soft austenitic stainless steel foams, strain hardening in the plateau region is lower compared to duplex foams.

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“…Lightweight metal structures are widely used in aeronautics, automotive, biomedical [1], energy, and bionics [2] fields. Namely, high strength-to-weight ratio, thermal and acoustic insulation, good properties of energy absorption, and even electromagnetic shielding [3] benefit when metal cellular materials are considered [4].…”

Section: Introductionmentioning

confidence: 99%

“…In particular, layer-by-layer AM building (i.e., two-stage processing) is expected to provide higher accuracy as compared with directed deposition AM (i.e., one-stage processing) [18]. The feasibility of manufacturing similar-to-foam steel components with spherical porosity adopting laser powder bed fusion (LPBF) has been explored [4], but limited research has been devoted to the manufacturing of metal random foam structures, which have some issues that must be addressed. First, interconnected porosity is mandatory in order to allow the extraction of loose powder from cavities.…”

Section: Introductionmentioning

confidence: 99%

Design and Fabrication of Random Metal Foam Structures for Laser Powder Bed Fusion

2019

Self Cite

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With the development of additive manufacturing, the building of new categories of lightweight structures such as random foams have been offered. Nevertheless, given the complexity of the required parts, macroscopic defects may result or the process may even fail. Therefore, proper actions must be taken at the design stage. In this paper, a method of design for additive manufacturing (DfAM) to build metal random foam structures is proposed. Namely, a procedure is suggested to generate a structure that has interconnected porosity. This procedure is based on the aimed fractional density and several technical requirements, and then the geometry is optimized and meshed. To validate the algorithm, a test article consisting of a metal cylinder with spherical random pores ranging from 1 to 6 mm in diameter with a resulting fractional density of 40 ± 2% has been conceived and manufactured by means of laser powder bed fusion (LPBF). On the basis of the outcome of the manufacturing process, crucial information has been gathered to update the algorithm.

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Manufacturing and characterization of similar to foam steel components processed through selective laser melting

Cited by 25 publications

References 26 publications

Mechanical Properties of Optimized Diamond Lattice Structure for Bone Scaffolds Fabricated via Selective Laser Melting

Mechanical Properties of Optimized Diamond Lattice Structure for Bone Scaffolds Fabricated via Selective Laser Melting

Investment Casting and Mechanical Properties of Open‐Cell Steel Foams

Design and Fabrication of Random Metal Foam Structures for Laser Powder Bed Fusion

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