Effects of Post-processing on the Surface Finish, Porosity, Residual Stresses, and Fatigue Performance of Additive Manufactured Metals: A Review

Effects of Process Parameters and Process Defects on the Flexural Fatigue Life of Ti-6Al-4V Fabricated by Laser Powder Bed Fusion

The fatigue performance of laser powder bed fusion-fabricated Ti-6Al-4V alloy was investigated using four-point bending testing. Specifically, the effects of keyhole and lack-of-fusion porosities along with various surface roughness parameters, were evaluated in the context of pore circularity and size using 2D optical metallography. Surface roughness of Sa = 15 to 7 microns was examined by SEM, and the corresponding fatigue performance was found to vary by 102 cycles to failure. The S-N curves for the various defects were also correlated with process window examination in laser beam power-velocity (P-V) space. Basquin's stress-life relation was well fitted to the experimental S-N curves for various process parameters except keyhole porosity, indicating reduced importance for LPBF-fabricated Ti-6Al-4V alloy components.

Characterisation of 3D-printed acetabular hip implants

Three-dimensional printing is a rapidly growing manufacturing method for orthopaedic implants and it is currently thriving in several other engineering industries. It enables the variation of implant design and the construction of complex structures which can be exploited in orthopaedics and other medical sectors. In this review, we develop the vocabulary to characterise 3D printing in orthopaedics from terms defined by industries employing 3D printing, and by fully examining a 3D-printed off-the-shelf acetabular cup (Fig. 1). This is a commonly used 3D-printed implant in orthopaedics, and it exhibits a range of prominent features brought about by 3D printing. The key features and defects of the porous and dense regions of the implant are clarified and discussed in depth to determine reliable definitions and a common understanding of characteristics of 3D printing between engineers and medical experts in orthopaedics. Despite the extensive list of terminology derived here, it is clear significant gaps exist in the knowledge of this field. Therefore, it is necessary for continued investigations of unused implants, but perhaps more significantly, examining those in vivo and retrieved to understand their long-term impact on patients and the effects of certain features (e.g. surface-adhered particles). Analyses of this kind will establish an understanding of 3D printing in orthopaedics and additionally it will help to update the regulatory approach to this new technology.

Size effect characteristics and influences on fatigue behavior of laser powder bed fusion of thin wall GRCop-42 copper alloy

Size effects, influencing a material's strength, elongation, fatigue limit, and longevity, depend on the operative and dominant deformation and failure mechanisms. This study explores the size effects in additive manufactured (AM) GRCop-42 (Cu-4at%Cr-2at%Nb) thin wall structures fabricated via laser-powder bed fusion (L-PBF) and their impact on fatigue life. The influence of internal defects and surface topography on the fatigue life of specimens in both as-built and hot isostatic pressed (HIP) conditions across different thicknesses is investigated. Where micro-computed tomography (μCT) was used to quantify the internal porosity of as-built, pristine HIP'd, and fatigued HIP'd specimens, and laser microscopy was employed to quantify the surface topography of specimens prior to fatigue. Additionally, quasi-static tests were used to establish baseline mechanical properties (i.e. yield strength (YS), ultimate tensile strength (UTS), and elongation) to frame fatigue testing conditions. Results indicate a significant enhancement in fatigue life for HIP'd specimens for both thicknesses, with internal defects depicting a greater impact than surface topography. Furthermore, fractographic analysis suggests that thicker specimens exhibit higher resistance to crack propagation during fatigue testing in the absence of substantial porosity. Thus, the size effects observed on the fatigue life of L-PBF GRCop-42 appears to be dominated by internal defects.

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed.

Effect of laser shock peening on microstructure and mechanical properties of laser cladding 30CrMnSiNi2A high-strength steel

The effect of laser shock peening (LSP) on the microhardness and tensile properties of laser cladding (LC) 30CrMnSiNi2A high-strength steel was studied. After LSP, the microhardness of the cladding zone reached approximately 800 HV_0.2, which was 25% higher than that of the substrate, while the cladding zone without LSP had an approximately 18% increase in its microhardness. Two strengthening processes were designed: groove LSP + LC + surface LSP versus LC + surface LSP. The former's tensile strength and yield strength were less than 10% weaker than those of forged materials, which is the best mechanical property recovery found in LC samples. The microstructural characteristics of the LC samples were analysed by scanning electron microscopy (SEM) and electron backscatter diffraction. Under the action of the laser-induced shock wave, the grain size of the LC sample surface was refined, the low-angle grain boundaries on the surface layer increased significantly, and the austenite grain length was reduced from 30-40 μm in the deep layer to 4-8 μm in the surface layer. In addition, LSP modulated the residual stress field, hence preventing the weakening effect of the LC process's thermal stress on the components' mechanical properties.

Functional engineering strategies of 3D printed implants for hard tissue replacement

Three-dimensional printing technology with the rapid development of printing materials are widely recognized as a promising way to fabricate bioartificial bone tissues. In consideration of the disadvantages of bone substitutes, including poor mechanical properties, lack of vascularization and insufficient osteointegration, functional modification strategies can provide multiple functions and desired characteristics of printing materials, enhance their physicochemical and biological properties in bone tissue engineering. Thus, this review focuses on the advances of functional engineering strategies for 3D printed biomaterials in hard tissue replacement. It is structured as introducing 3D printing technologies, properties of printing materials (metals, ceramics and polymers) and typical functional engineering strategies utilized in the application of bone, cartilage and joint regeneration.

Surface Free Energy Dominates the Biological Interactions of Postprocessed Additively Manufactured Ti-6Al-4V

Additive manufacturing (AM) has emerged as a disruptive technique within healthcare because of its ability to provide personalized devices; however, printed metal parts still present surface and microstructural defects, which may compromise mechanical and biological interactions. This has made physical and/or chemical postprocessing techniques essential for metal AM devices, although limited fundamental knowledge is available on how alterations in physicochemical properties influence AM biological outcomes. For this purpose, herein, powder bed fusion Ti-6Al-4V samples were postprocessed with three industrially relevant techniques: polishing, passivation, and vibratory finishing. These surfaces were thoroughly characterized in terms of roughness, chemistry, wettability, surface free energy, and surface ζ-potential. A significant increase in Staphylococcus epidermidis colonization was observed on both polished and passivated samples, which was linked to high surface free energy donor γ^– values in the acid–base, γ^AB component. Early osteoblast attachment and proliferation (24 h) were not influenced by these properties, although increased mineralization was observed for both these samples. In contrast, osteoblast differentiation on stainless steel was driven by a combination of roughness and chemistry. Collectively, this study highlights that surface free energy is a key driver between AM surfaces and cell interactions. In particular, while low acid–base components resulted in a desired reduction in S. epidermidis colonization, this was followed by reduced mineralization. Thus, while surface free energy can be used as a guide to AM device development, optimization of bacterial and mammalian cell interactions should be attained through a combination of different postprocessing techniques.

Analysis of Fatigue Strength of L-PBF AlSi10Mg with Different Surface Post-Processes: Effect of Residual Stresses

Space and aerospace industries has been starting in the recent years the replacement process of parts and components obtained by traditional manufacturing processes with those produced by Additive Manufacturing (AM). The complexity of the obtainable parts makes, in general, challenging the superficial post processing of some zones, making a stringent requirement the investigation of the fatigue performances of components with rough superficial state or machined. The aim of this work is then to analyse and compare the fatigue performances of an additively manufactured (AMed) AlSi10Mg material considering both the effects of the manufacturing defects and residual stresses related to three different superficial states, namely machined, net-shape and sandblasted. The residual stress profiles of the three superficial states were found to play a key role in determining the fatigue properties of the analysed material, while the manufacturing defects at the failure origin were found to be comparable among the three series. To take into account the combined effect of residual stresses and manufacturing defects a fracture mechanics approach was considered for the estimation of the fatigue performances in both infinite and finite life regimes. It was found that by considering the nominal measured residual stress profiles in the fracture mechanics model the estimations were satisfactory compared to the experimental data-point. To increase the accuracy of the fatigue life estimations a series of numerical analyses were performed aimed to investigate the residual stresses relaxation during the cyclic loading. The adoption of the relaxed residual stress profiles in the fracture mechanics model resulted in good estimations respect to the experimental data-points, highlighting the necessity in adopting such developed approaches during the design phase of AM parts and components.