Pure tantalum manufactured by laser powder bed fusion: Influence of scanning speed on the evolution of microstructure and mechanical properties

Song, Changhui; Deng, Zhengtai; Zou, Zhuang; Li, Lisha; Xu, Kuixue; Yang, Yongqiang

doi:10.1016/j.ijrmhm.2022.105882

Cited by 17 publications

(7 citation statements)

References 30 publications

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“…In a study reported by Khorasani et al (2019), an excessive increase in Vs causes process instability to enhance surface tension, thus the pore formation. Song et al (2022) resulted that the low Vs results in a wider melt pool and vice versa. It was also revealed that the Ed is also linked with the laser material interaction time and the temperature gradient which influence the solidification velocity.…”

Section: Resultsmentioning

confidence: 99%

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

Rehman

Wang

Ishfaq

et al. 2023

RPJ

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Purpose Since the biomedical implants with an improved compressive strength, near bone elastic modulus, controlled porosity, and sufficient surface roughness, can assist in long term implantation. Therefore, the fine process tuning plays its crucial role to develop optimal settings to achieve these desired properties. This paper aims to find applications for fine process tuning in laser powder bed fusion of biomedical Ti alloys for load-bearing implants. Design/methodology/approach In this work, the parametric porosity simulations were initially performed to simulate the process-induced porosity for selective laser-melted Ti6Al4V as per full factorial design. Continually, the experiments were performed to validate the simulation results and perform multiresponse optimization to fine-tune the processing parameters. Three levels of each control variable, namely, laser power – Pl (180, 190, 200) W, scanning speed – Vs (1500, 1600, 1700) mm/s and scan orientation – ϴ{1(0,0), 2(0,67°), 3(0,90°)} were used to investigate the processing performance. The measured properties from this study include compressive yield strength, elastic modulus, process-induced porosity and surface roughness. Finally, confirmatory experiments and comparisons with the already published works were also performed to validate the research results. Findings The results of porosity parametric simulation and experiments in selective laser melting of Ti6Al4V were found close to each other with overall porosity (less than 10%). The fine process tuning was resulted in optimal settings [Pl (200 W), Vs (1500 mm/s), ϴ (0,90°)], [Pl (200 W), Vs (1500 mm/s), ϴ (0,67°)], [Pl (200 W), Vs (1500 mm/s), ϴ (0,0)] and [Pl (200 W), Vs (1500 mm/s), ϴ (0,0)] with higher compressive strength (672.78 MPa), near cortical bone elastic modulus (12.932 GPa), process-induced porosity (0.751%) and minimum surface roughness (2.72 µm). The morphology of the selective laser melted (SLMed) surface indicated that the lack of fusion pores was prominent because of low laser energy density among the laser and powder bed. Confirmatory experimentation revealed that an overall percent improvement of around 15% was found between predicted and the experimental values. Originality/value Since no significant works are available on the collaborative optimization and fine process tuning in laser powder bed fusion of biomedical Ti alloys for different load bearing implants. Therefore, this work involves the comprehensive investigation and multi-objective optimization to determine optimal parametric settings for better mechanical and physical properties. Another novel aspect is the parametric porosity simulation using Ansys Additive to assist in process parameters and their levels selection. As a result, selective laser melted Ti alloys at optimal settings may help in examining the possibility for manufacturing metallic implants for load-bearing applications.

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Section: Resultsmentioning

confidence: 99%

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

Rehman

Wang

Ishfaq

et al. 2023

RPJ

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“…Tantalum has a high melting point of ~2996°C [ 13 ] . With the development of 3D printing technologies, some technologies capable of providing a temperature high enough to melt tantalum, such as electron-beam-melting-based and laser-meltingbased technologies, are being employed to fabricate porous tantalum [ 14 - 16 ] . The fabricated porous tantalum prostheses geometrically match well with the bone defect and result in effective osteointegration and treatment [ 16 ] .…”

Section: Introductionmentioning

confidence: 99%

Design and biomechanical analysis of patient-specific porous tantalum prostheses for knee joint revision surgery

Mao¹,

Yang²,

Wang³

et al. 2024

IJB

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Artificial joint revision surgery, as an increasingly common surgery in orthopedics, often requires patient-specific prostheses to repair the bone defect. Porous tantalum is a good candidate due to its excellent abrasion and corrosion resistance and good osteointegration. Combination of 3D printing technology and numerical simulation is a promising strategy to design and prepare patient-specific porous prostheses. However, clinical design cases have rarely been reported, especially from the viewpoint of biomechanical matching with the patient’s weight and motion and specific bone tissue. This work reports a clinical case on the design and mechanical analysis of 3D-printed porous tantalum prostheses for the knee revision of an 84-year-old male patient. Particularly, standard cylinders of 3D-printed porous tantalum with different pore size and wire diameters were first fabricated and their compressive mechanical properties were measured for following numerical simulation. Subsequently, patient-specific finite element models for the knee prosthesis and the tibia were constructed from the patient’s computed tomography data. The maximum von Mises stress and displacement of the prostheses and tibia and the maximum compressive strain of the tibia were numerically simulated under two loading conditions by using finite element analysis software ABAQUS. Finally, by comparing the simulated data to the biomechanical requirements for the prosthesis and the tibia, a patient-specific porous tantalum knee joint prosthesis with a pore diameter of 600 μm and a wire diameter of 900 μm was determined. The Young’s modulus (5719.32 ± 100.61 MPa) and yield strength (172.71 ± 1.67 MPa) of the prosthesis can produce both sufficient mechanical support and biomechanical stimulation to the tibia. This work provides a useful guidance for designing and evaluating a patient-specific porous tantalum prosthesis.

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“…Scanning speed is an independent process parameter that significantly evaluates microstructure [18][19][20]. Li et al [21] studied the mechanical properties of Ti-45Al-2Cr-5Nb alloy processed through SLM and also discussed the effect of laser scanning speed on the fraction of the α2 (hexagonal close-packed structure based on the DO 19 structure of Ti 3 Al) and β/B2 phases.…”

Section: Introductionmentioning

confidence: 99%

Effect of Scanning Strategies on the Microstructure and Mechanical Properties of Ti-22Al-25Nb Alloy Fabricated through Selective Laser Melting

Lin

Shan

Yang

et al. 2023

Metals

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In this study, Ti-22Al-25Nb intermetallic compound alloys are fabricated through selective laser melting (SLM) at four scanning speeds (600, 700, 800, and 900 mm/s). The microstructure and mechanical properties of the selective laser melting fabricated alloys are systematically evaluated. The results indicate that scanning speed significantly affects microstructure characteristics (e.g., relative density, grain size, texture density, and the precipitation of secondary phases). The variation laws of the relative density, grain size, and texture density are likewise affected by scanning speed. The relative density, grain size, and texture density increase and then decrease with the increase in scanning speed. The alloy fabricated with the lowest scanning speed (600 mm/s) exhibits the maximum relative density, grain size, and texture density. By contrast, the alloy with the highest scanning speed (900 mm/s) exhibits the minimum relative density, grain size, and texture density. Furthermore, the precipitations of the O phase and Ti3Al phase are primarily distributed in regions with a high strain concentration near the pool boundary. The alloy fabricated with a 600 mm/s scanning speed simultaneously achieves the highest strength and elongation, which is closely correlated with the uniform distribution of secondary phases.

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Pure tantalum manufactured by laser powder bed fusion: Influence of scanning speed on the evolution of microstructure and mechanical properties

Cited by 17 publications

References 30 publications

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

Design and biomechanical analysis of patient-specific porous tantalum prostheses for knee joint revision surgery

Effect of Scanning Strategies on the Microstructure and Mechanical Properties of Ti-22Al-25Nb Alloy Fabricated through Selective Laser Melting

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