The influence of laser processing parameters on the densification and surface morphology of pure Fe and Fe-35Mn scaffolds produced by selective laser melting

Carluccio, Danilo; Demir, Ali Gökhan; Caprio, Leonardo; Previtali, Barbara; Bermingham, Michael; Dargusch, Matthew S.

doi:10.1016/j.jmapro.2019.03.018

Cited by 44 publications

(39 citation statements)

References 70 publications

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“…Adding alloy elements into the Fe can also affect its degradation rate. Carluccio et al (2019) prepared Fe and Fe–Mn porous scaffolds. They found that the corrosion rate of Fe–Mn scaffold is much higher than that of pure Fe.…”

Section: The Metal Materials Used In Porous Scaffoldsmentioning

confidence: 99%

Metal Material, Properties and Design Methods of Porous Biomedical Scaffolds for Additive Manufacturing: A Review

Wang

Liu

et al. 2021

Front. Bioeng. Biotechnol.

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Design an implant similar to the human bone is one of the critical problems in bone tissue engineering. Metal porous scaffolds have good prospects in bone tissue replacement due to their matching elastic modulus, better strength, and biocompatibility. However, traditional processing methods are challenging to fabricate scaffolds with a porous structure, limiting the development of porous scaffolds. With the advancement of additive manufacturing (AM) and computer-aided technologies, the development of porous metal scaffolds also ushers in unprecedented opportunities. In recent years, many new metal materials and innovative design methods are used to fabricate porous scaffolds with excellent mechanical properties and biocompatibility. This article reviews the research progress of porous metal scaffolds, and introduces the AM technologies used in porous metal scaffolds. Then the applications of different metal materials in bone scaffolds are summarized, and the advantages and limitations of various scaffold design methods are discussed. Finally, we look forward to the development prospects of AM in porous metal scaffolds.

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Section: The Metal Materials Used In Porous Scaffoldsmentioning

confidence: 99%

Metal Material, Properties and Design Methods of Porous Biomedical Scaffolds for Additive Manufacturing: A Review

Wang

Liu

et al. 2021

Front. Bioeng. Biotechnol.

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“…steep temperature gradient which makes nucleation of equiaxed grains difficult), as well as the requirement for nucleant particles (substrates for heterogeneous nucleation) and alloy solute to generate constitutional supercooling [39]. For pure Fe manufactured via SLM however, the microstructure consists of predominately equiaxed grains with few elongated columnar grains [22,40]. While this may appear at odds to what we know of the solidification process during SLM, especially given that this is pure Fe with no solute to provide constitutional supercooling, it is important to remember that the α-ferrite grains seen in the microstructure are far removed from the initial solidified structure (L → δ → γ → α).…”

Section: A U T H O R M a N U S C R I P T A U T H O R M A N U S C R I P Tmentioning

confidence: 99%

Comparative Study of Pure Iron Manufactured by Selective Laser Melting, Laser Metal Deposition, and Casting Processes

et al. 2019

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“…As was the case with additions of Ag to Zn [294], increasing the Ag content increased the corrosion rate. The SLM processability of Fe-Mn alloys was actually found to be worse than that of pure Fe for solid components, but vice versa for scaffolds [314,315]. This was attributed to the larger melting range of the alloy, which, when using higher energy density typical of solid components, can result in more processing porosity.…”

Section: Selective Laser Melting Of Iron and Alloysmentioning

confidence: 99%

“…The general consensus in literature, however, is that laser energy input combined into one index (the energy density) is one of the best predictors for part quality [303,324]. It is important to note that this is generally true for bulk components [66] but not for scaffolds, where there does not appear to be any direct correlation between the usual quality indicators and the volumetric energy density [315].…”

Section: Process Parametersmentioning

confidence: 99%

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Selective laser melting novel biodegradable iron-based bone scaffolds for load-bearing applications

Carluccio¹

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Autologous bone grafting has long been the "gold standard" for the reconstruction and remodelling of critical maxillofacial bone defects. However, it has several disadvantages, and as such bone scaffolds have become increasingly popular. Ceramic and polymer scaffolds have been extensively researched, but due to their limited mechanical properties, these classes of materials are generally not suited for load bearing applications.Permanent metallic scaffolds have much better mechanical properties, but their permanent nature can result in long term inflammation along and rejection.To overcome these drawbacks biodegradable metallic (BDM) implants are being developed, showing great potential. An ideal BDM would retain its mechanical properties during bone growth and slowly degrade away transferring the stress to the newly formed bone without damaging it; subsequent to full healing, the implant would completely dissolve away leaving behind no residue. Fe has emerged as an enticing candidate for load-bearing scaffold application as it has high mechanical properties, and with the addition of Mn displays excellent MRI compatibility, formability, and an increased corrosion rate compared to pure Fe.Selective laser melting (SLM) can produce highly customisable implants with optimised lattice structures, interconnected porosities and controllable pore sizes, which have been shown to improve bioactivity. Research on the SLM of pure Fe and Fe-based alloys has mostly been focused on maraging steels, tools steels, and other steels used in industry.Until the end of this thesis there had been relatively limited amount of work on the selective laser melting of Fe for biomedical applications.The first part of the thesis aims to understand the SLM processability of Fe-35Mn and how SLM affects the material properties of biodegradable implants by: (i) implementing a design of experiment approach to determine the SLM processing of Fe-35Mn and pure Fe firstly for bulk structures and after for scaffolds; (ii) understanding the effect of SLM processing on the properties of pure Fe by comparing it to other manufacturing methods, specifically for biodegradable implant applications.

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The influence of laser processing parameters on the densification and surface morphology of pure Fe and Fe-35Mn scaffolds produced by selective laser melting

Cited by 44 publications

References 70 publications

Metal Material, Properties and Design Methods of Porous Biomedical Scaffolds for Additive Manufacturing: A Review

Metal Material, Properties and Design Methods of Porous Biomedical Scaffolds for Additive Manufacturing: A Review

Comparative Study of Pure Iron Manufactured by Selective Laser Melting, Laser Metal Deposition, and Casting Processes

Selective laser melting novel biodegradable iron-based bone scaffolds for load-bearing applications

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