Possibilities and limitations of titanium alloy additive manufacturing

Агаповичев, А. В.; Сотов, А В; Кокарева, В. В.; Смелов, В. Г.

doi:10.1051/matecconf/201822401064

Cited by 28 publications

(7 citation statements)

References 5 publications

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“…When metallic implants are exposed to irradiation, they emit scattering rays that are detrimental to tissues. Economic reasons connected to manufacturing procedures (especially Electron Beam Melting, EBM, which is the most prevalent process for the production of Ti implants) have led researchers to hunt for new implant materials [ 30 ]. Researchers have switched to the examination of potential Ti substitutes in order to address the above-mentioned restrictions and reduce biological issues after implant insertion.…”

Section: Introductionmentioning

confidence: 99%

Adaptive Mechanism for Designing a Personalized Cranial Implant and Its 3D Printing Using PEEK

et al. 2022

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The rehabilitation of the skull’s bones is a difficult process that poses a challenge to the surgical team. Due to the range of design methods and the availability of materials, the main concerns are the implant design and material selection. Mirror-image reconstruction is one of the widely used implant reconstruction techniques, but it is not a feasible option in asymmetrical regions. The ideal design approach and material should result in an implant outcome that is compact, easy to fit, resilient, and provides the perfect aesthetic and functional outcomes irrespective of the location. The design technique for the making of the personalized implant must be easy to use and independent of the defect’s position on the skull. As a result, this article proposes a hybrid system that incorporates computer tomography acquisition, an adaptive design (or modeling) scheme, computational analysis, and accuracy assessment. The newly developed hybrid approach aims to obtain ideal cranial implants that are unique to each patient and defect. Polyetheretherketone (PEEK) is chosen to fabricate the implant because it is a viable alternative to titanium implants for personalized implants, and because it is simpler to use, lighter, and sturdy enough to shield the brain. The aesthetic result or the fitting accuracy is adequate, with a maximum deviation of 0.59 mm in the outside direction. The results of the biomechanical analysis demonstrate that the maximum Von Mises stress (8.15 MPa), Von Mises strain (0.002), and deformation (0.18 mm) are all extremely low, and the factor of safety is reasonably high, highlighting the implant’s load resistance potential and safety under high loading. Moreover, the time it takes to develop an implant model for any cranial defect using the proposed modeling scheme is very fast, at around one hour. This study illustrates that the utilized 3D reconstruction method and PEEK material would minimize time-consuming alterations while also improving the implant’s fit, stability, and strength.

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Section: Introductionmentioning

confidence: 99%

Adaptive Mechanism for Designing a Personalized Cranial Implant and Its 3D Printing Using PEEK

et al. 2022

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“…For example, if the machinability of a given alloy is known, the right tool geometry and Table 1 A general comparison between PBF-LB, PBF-EB, and DED. Adapted from different sources [15][16][17][18]. tool material can be selected, the cutting data can be adjusted for improved productivity, and scrap rates can be reduced.…”

Section: Machinabilitydefinition and Assessment Methodsmentioning

confidence: 99%

Post-processing of additively manufactured metallic alloys – A review

Malakizadi

Mallipeddi

Dadbakhsh

et al. 2022

International Journal of Machine Tools and Manufacture

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“…Various metal AM methods exist which can be used for the manufacture of titanium alloy components. Compared to conventional processes, these methods offer benefits such as greater manufacturing flexibility, the ability to manufacture components with more complex geometries and hollow features, as well as greater control over the material properties [9]. These benefits, as well as the advantage of the reduced requirement for material removal, makes metal AM an attractive option for many applications.…”

Section: Additive Manufacturing Processesmentioning

confidence: 99%

“…There are currently a variety of NNS manufacturing processes available, which can be grouped in to the following families: metal additive manufacturing (AM) and hybrid processing routes. At present, these processes are at different levels of technology readiness, ranging from early developmental stages to being used for niche component manufacture [9]. The authors are currently investigating the potential benefits and challenges of a range of emerging processing routes for the manufacture and finish machining of small scale components, such as the valve train rocker arms shown in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Childerhouse

Jackson

2019

Metals

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Near net shape (NNS) manufacturing offers an alternative to conventional processes for the manufacture of titanium alloy components. Compared to the conventional routes, which typically require extensive material removal of forged billets, NNS methods offer more efficient material usage and can significantly reduce machining requirements. Furthermore, NNS manufacturing processes offer benefits such as greater flexibility and reduced costs compared to conventional methods. Processes such as metal additive manufacturing (AM) have started to be adopted in niche applications, most notably for the manufacture of medical implants, where many conventionally forged components have been replaced by those manufactured by AM processes. However, for more widespread adoption of these emerging processes, an improvement in the confidence in the techniques by manufacturers is necessary. This requires addressing challenges such as the limited mechanical properties of parts in their as-built condition compared to wrought products and the post-process machining requirements of components manufactured by these routes. In this review, processes which use a powder or wire feedstock are evaluated to assess their capabilities for the manufacture of titanium alloy components. These processes include powder bed fusion and direct energy deposition metal additive processes as well as hybrid routes, which combine powder metallurgy with thermomechanical post-processing.

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Possibilities and limitations of titanium alloy additive manufacturing

Cited by 28 publications

References 5 publications

Adaptive Mechanism for Designing a Personalized Cranial Implant and Its 3D Printing Using PEEK

Adaptive Mechanism for Designing a Personalized Cranial Implant and Its 3D Printing Using PEEK

Post-processing of additively manufactured metallic alloys – A review

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

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