Process–Structure–Property Relationships in Selective Laser Melting of Porosity Graded Gyroids

Abstract

Selective laser melting (SLM) can be used to tailor both the geometry and mechanical properties of lattice structures to match bone properties. In this work, a process–structure–property (PSP) relationship for Ti6AL4V porosity graded gyroids (PGGs) structures was developed. A design of experiment approach was used to test the significance and contribution of different process parameters on microstructure, morphology, and mechanical properties. Process maps to predict the morphology errors at specific laser power and scan speed were developed. Moreover, the mechanical properties of radially PGGs with a relative density of 25% are evaluated using different SLM process parameters. The results showed that PGGs with different radial gradation designs have mechanical properties that are compatible with bone implants: apparent compressive modulus of 1.4–5.3 GPa and compressive strength 40–154 MPa.

Effect of Compositional Variation Induced by EBM Processing on Deformation Behavior and Phase Stability of Austenitic Cr-Mn-Ni TRIP Steel

“…Powder bed-based AM technologies, i.e., EBM, as well as L-PBF, allow for the fabrication of components with tailored and spatially varying mechanical properties. This can comprise geometrical grading, e.g., for a modification of the elastic modulus for biomedical applications, [61][62][63][64] as well as modification of microstructure and texture evolution by an appropriate adaption of process parameters. [17][18][19]23,[65][66][67] Moreover, it is basically possible to adjust material deformation behavior by incorporating compositional variations.…”

Computational Analysis of the Mechanical Impedance of the Sandwich Beam with Auxetic Metal Foam Core

“…They are able to create 3D auxetic structures of extremally small sizes. Such lattices and so‐called functionally graded materials (FGM) with auxetic parts can be used in orthopedics for 3D‐printed implants, as shown in a recent review by Mahmoud and Elbestawi . Other innovations include disordered microstructures such as these introduced by Pozniak et al The disorder was achieved with randomization of selected geometry parameter.…”

Challenges on optimization of 3D-printed bone scaffolds

“…In addition to materials and structural optimization, the process parameters should be adjusted and optimized to manufacture scaffolds with desired attributes. Numerous studies investigated the effect of process parameters on different responses such as mechanical properties (strength, elongation, Young's modulus), surface roughness, resolution and dimensional accuracy, and printing quality in different techniques including SLA [221][222][223][224], SLS [225][226][227][228][229][230][231][232][233][234], EBM [235][236][237][238][239][240][241], LENS [242,243], SLM [39,[244][245][246][247][248][249][250], 2PP [251][252][253], FDM [254][255][256], MJ [257,258], AJP [259][260][261][262], and IJP [263]…”

“…In addition to materials and structural optimization, the process parameters should be adjusted and optimized to manufacture scaffolds with desired attributes. Numerous studies investigated the effect of process parameters on different responses such as mechanical properties (strength, elongation, Young’s modulus), surface roughness, resolution and dimensional accuracy, and printing quality in different techniques including SLA [ 221 – 224 ], SLS [ 225 – 234 ], EBM [ 235 – 241 ], LENS [ 242 , 243 ], SLM [ 39 , 244 – 250 ], 2PP [ 251 – 253 ], FDM [ 254 – 256 ], MJ [ 257 , 258 ], AJP [ 259 – 262 ], and IJP [ 263 – 266 ]. There are many parameters in the 3D printing approaches which vary between different techniques as their machine structure, printing mechanisms, and materials used are rather different.…”

“…Among the studies on process parameters, some have used systematical methodologies including DOE and response surface methodology (RSM) such as Taguchi, two-level factorial, Box–Behnken, and central composite designs [ 221 , 222 , 228 , 230 , 234 , 244 , 245 , 247 , 253 – 255 , 260 , 263 , 266 ]. A response surface methodology is an optimization approach and a collection of statistical and mathematical approaches utilized to accomplish the multi-objective optimization procedure in various systems including materials, geometry and process.…”