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Um SH, Lee J, Chae M, Paternoster C, Copes F, Chevallier P, Lee DH, Hwang SW, Kim YC, Han HS, Lee KS, Mantovani D, Jeon H. Biomedical Device Surface Treatment by Laser-Driven Hydroxyapatite Penetration-Synthesis Technique for Gapless PEEK-to-Bone Integration. Adv Healthc Mater 2024:e2401260. [PMID: 38953344 DOI: 10.1002/adhm.202401260] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/05/2024] [Revised: 06/19/2024] [Indexed: 07/04/2024]
Abstract
Polyetheretherketone (PEEK), a bioinert polymer known for its mechanical properties similar to bone, is capable of averting stress shielding. Due to these attributes, it finds applications in diverse fields like orthopedics, encompassing cervical disc replacement for the neck and spine, along with dentistry and plastic surgery. However, due to insufficient bonding with bone, various methods such as hydroxyapatite (HA) coating on the surface are attempted. Nonetheless, the interface between the polymer and ceramic, two different materials, tended to delaminate after transplantation, posing challenges in preventing implant escape or dislodgement. This research delves into the laser-driven hydroxyapatite penetration-synthesis technique. Differing from conventional coating methods that bond layers of dissimilar materials like HA and PEEK, this technology focuses on synthesizing and infiltrating ionized HA within the PEEK substrate resulting in an interface-free HA-PEEK surface. Conversely, HA-PEEK with this technology applied achieves complete, gap-free direct bone-implant integration. Our research involved the analysis of various aspects. By means of these, we quantitatively assesed the enhanced bone bonding characteristics of HA-PEEK surfaces treated with this approach and offered and explanation for the mechanism responsible for direct bone integration.
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Affiliation(s)
- Seung-Hoon Um
- Biomaterials Research Center, Biomedical Research Division, Korea Institute of Science and Technology (KIST), Seoul, 02792, Republic of Korea
- Lab Biomaterials and Bioengineering, CRC-I, Department of Mining, Metallurgical and Materials Engineering and CHU de Quebec Research Centre, Regenerative Medicine, Laval University, Quebec City, QC, G1V 0A6, Canada
| | - Jaehong Lee
- Biomaterials Research Center, Biomedical Research Division, Korea Institute of Science and Technology (KIST), Seoul, 02792, Republic of Korea
| | - Minseong Chae
- Biomedical Engineering Research Center, Asan Institute for Life Sciences, Asan Medical Center, College of Medicine, University of Ulsan, Seoul, 05505, Republic of Korea
| | - Carlo Paternoster
- Lab Biomaterials and Bioengineering, CRC-I, Department of Mining, Metallurgical and Materials Engineering and CHU de Quebec Research Centre, Regenerative Medicine, Laval University, Quebec City, QC, G1V 0A6, Canada
| | - Francesco Copes
- Lab Biomaterials and Bioengineering, CRC-I, Department of Mining, Metallurgical and Materials Engineering and CHU de Quebec Research Centre, Regenerative Medicine, Laval University, Quebec City, QC, G1V 0A6, Canada
| | - Pascale Chevallier
- Lab Biomaterials and Bioengineering, CRC-I, Department of Mining, Metallurgical and Materials Engineering and CHU de Quebec Research Centre, Regenerative Medicine, Laval University, Quebec City, QC, G1V 0A6, Canada
| | - Dong-Ho Lee
- Department of Orthopedic Surgery, Asan Medical Center, University of Ulsan College of Medicine, Seoul, 05505, Republic of Korea
| | - Suk-Won Hwang
- KU-KIST Graduate School of Converging Science and Technology, Korea University, Seoul, 02841, Republic of Korea
| | - Yu-Chan Kim
- Biomaterials Research Center, Biomedical Research Division, Korea Institute of Science and Technology (KIST), Seoul, 02792, Republic of Korea
| | - Hyung-Seop Han
- Biomaterials Research Center, Biomedical Research Division, Korea Institute of Science and Technology (KIST), Seoul, 02792, Republic of Korea
| | - Kang-Sik Lee
- Biomedical Engineering Research Center, Asan Institute for Life Sciences, Asan Medical Center, College of Medicine, University of Ulsan, Seoul, 05505, Republic of Korea
| | - Diego Mantovani
- Lab Biomaterials and Bioengineering, CRC-I, Department of Mining, Metallurgical and Materials Engineering and CHU de Quebec Research Centre, Regenerative Medicine, Laval University, Quebec City, QC, G1V 0A6, Canada
| | - Hojeong Jeon
- Biomaterials Research Center, Biomedical Research Division, Korea Institute of Science and Technology (KIST), Seoul, 02792, Republic of Korea
- KU-KIST Graduate School of Converging Science and Technology, Korea University, Seoul, 02841, Republic of Korea
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Tanrikulu AA, Farhang B, Ganesh-Ram A, Hekmatjou H, Durlov SH, Amerinatanzi A. In Situ Microstructure Modification Using a Layerwise Surface-Preheating Laser Scan of Ti-6Al-4V during Laser Powder Bed Fusion. MATERIALS (BASEL, SWITZERLAND) 2024; 17:1929. [PMID: 38673286 PMCID: PMC11052529 DOI: 10.3390/ma17081929] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 02/19/2024] [Revised: 04/11/2024] [Accepted: 04/14/2024] [Indexed: 04/28/2024]
Abstract
An innovative in situ thermal approach in the domain of LPBF for Ti-6Al-4V fabrication has been carried out with results directing towards an improved fatigue life without the need for post-processing. The thermal process involves an additional laser scan with different process parameters to preheat the selected regions of each layer of the powder bed prior to their full melting. This preheating step influences the cooling rate, which in turn affects surface characteristics and subsurface microstructure, both of which are directly correlated with fatigue properties. A thorough analysis has been conducted by comparing the preheated samples with reference samples with no preheating. Without any additional thermal processing, the preheated samples showed a significant improvement over their reference counterparts. The optimized preheated sample showed an improved prior β-grain distribution with a circular morphology and thicker α laths within the even finer prior β-grain boundaries. Also, an overall increment of the c/a ratio of the HCP α has been observed, which yielded lattice strain relaxation in the localized grain structure. Furthermore, a less-profound surface roughness was observed in the preheated sample. The obtained microstructure with all these factors delivered a 10% improvement in its fatigue life with better mechanical strength overall.
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Affiliation(s)
- Ahmet Alptug Tanrikulu
- Materials Science and Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA;
- Turkish Aerospace Industries, Ankara 06980, Türkiye
| | - Behzad Farhang
- Mechanical Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA; (B.F.); (A.G.-R.); (H.H.); (S.H.D.)
- ArcelorMittal North America, East Chicago, IN 46312, USA
| | - Aditya Ganesh-Ram
- Mechanical Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA; (B.F.); (A.G.-R.); (H.H.); (S.H.D.)
| | - Hamidreza Hekmatjou
- Mechanical Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA; (B.F.); (A.G.-R.); (H.H.); (S.H.D.)
| | - Sadman Hafiz Durlov
- Mechanical Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA; (B.F.); (A.G.-R.); (H.H.); (S.H.D.)
| | - Amirhesam Amerinatanzi
- Materials Science and Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA;
- Mechanical Engineering, The University of Texas at Arlington, Arlington, TX 76019, USA; (B.F.); (A.G.-R.); (H.H.); (S.H.D.)
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3
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Mahmud A, Ayers N, Huynh T, Sohn Y. Additive Manufacturing of SS316L/IN718 Bimetallic Structure via Laser Powder Bed Fusion. MATERIALS (BASEL, SWITZERLAND) 2023; 16:6527. [PMID: 37834664 PMCID: PMC10573787 DOI: 10.3390/ma16196527] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/31/2023] [Revised: 09/25/2023] [Accepted: 09/28/2023] [Indexed: 10/15/2023]
Abstract
Laser powder bed fusion (LPBF) is a popular additive manufacturing (AM) technique that has demonstrated the capability to produce sophisticated engineering components. This work reports the crack-free fabrication of an SS316L/IN718 bimetallic structure via LPBF, along with compositional redistribution, phase transformations and microstructural development, and nanohardness variations. Constituent intermixing after LPBF was quantitatively estimated using thermo-kinetic coefficients of mass transport and compared with the diffusivity of Ni in the austenitic Fe-Ni system.
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Affiliation(s)
| | | | | | - Yongho Sohn
- Department of Materials Science and Engineering, University of Central Florida, Orlando, FL 32816, USA; (A.M.); (N.A.); (T.H.)
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Patuelli C, Cestino E, Frulla G, Valente F, Servetti G, Esposito F, Barbero L. FEM Simulation of AlSi10Mg Artifact for Additive Manufacturing Process Calibration with Industrial-Computed Tomography Validation. MATERIALS (BASEL, SWITZERLAND) 2023; 16:4754. [PMID: 37445068 DOI: 10.3390/ma16134754] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/23/2023] [Revised: 06/20/2023] [Accepted: 06/28/2023] [Indexed: 07/15/2023]
Abstract
Dimensional accuracy of selective laser melting (SLM) parts is one of manufacturers' major concerns. The additive manufacturing (AM) process is characterized by high-temperature gradients, consolidation, and thermal expansion, which induce residual stress on the part. These stresses are released by separating the part from the baseplate, leading to plastic deformation. Thermo-mechanical finite elements (FE) simulation can be adopted to determine the effect of process parameters on final geometrical accuracy and minimize non-compliant parts. In this research, a geometry for process parameter calibration is presented. The part has been manufactured and then analyzed with industrial computed tomography (iCT). An FE process simulation has been performed considering material removal during base plate separation, and the computed distortions have been compared with the results of the iCT, revealing good accordance between the final product and its digital twin.
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Affiliation(s)
- Cesare Patuelli
- Department of Mechanical and Aerospace Engineering (DIMEAS), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
| | - Enrico Cestino
- Department of Mechanical and Aerospace Engineering (DIMEAS), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
| | - Giacomo Frulla
- Department of Mechanical and Aerospace Engineering (DIMEAS), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
| | | | | | - Fabio Esposito
- TEC Eurolab S.r.l, Viale Europa, 40, 41011 Campogalliano, Italy
| | - Luca Barbero
- SPEM S.r.l, Via Torino, 307, 10032 Brandizzo, Italy
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Tak M, Gaur B, Ravi B, Mote RG. Electrochemical Dissolution Characteristics and Electrochemical Micromachining of Ti6Al4V Alloy Fabricated by Direct Metal Laser Sintering Method. Electrocatalysis (N Y) 2022. [DOI: 10.1007/s12678-022-00761-3] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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Ti6Al4V-ELI Alloy Manufactured via Laser Powder-Bed Fusion and Heat-Treated below and above the β-Transus: Effects of Sample Thickness and Sandblasting Post-Process. APPLIED SCIENCES-BASEL 2022. [DOI: 10.3390/app12115359] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Ti6Al4V-ELI is the most-used lightweight alloy in the aerospace industrial sector thanks to its high mechanical strength and corrosion resistance. The present paper aims, firstly, to evaluate the effects induced by different heat treatments, which were performed above and below the β-transus temperature on Ti6Al4V-ELI samples manufactured via Laser Powder-Bed Fusion in different orientations (XZ, XY, Z and 45°). The first set of tensile samples and bars were heat-treated at 1050 °C × 1 h, while the second and third set were heat-treated at 704 °C × 120′ following the AMS2801 standard specification, and at 740 °C × 130′. These heat treatments were chosen to improve the as-built mechanical properties according to the ASTM F3001 and also ASTM F2924-14 standard specifications. Optical and SEM measurements reveal primary, secondary and tertiary α-laths below the β-transus, while above this temperature, the microstructure varies in relation to the sample’s thickness. Secondly, this work analyzed the results obtained after a sandblasting process, which was performed on half of all the available heat-treated tensile samples, through XRD and Vickers microhardness measurements. XRD analysis also highlighted the presence of α2-Ti3Al and TiAl3 precipitates and the microstructural change in terms of the α-phase.
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7
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Geometry Effect on Microstructure and Mechanical Properties in Laser Powder Bed Fusion of Ti-6Al-4V. METALS 2022. [DOI: 10.3390/met12030482] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/27/2023]
Abstract
Laser Powder Bed Fusion (LPBF) of Ti-6Al-4V enables the manufacturing of complex parts for lightweight applications. The emerging microstructure in the LPBF process and thus the mechanical properties are defined by the thermal cycles, which are locally variable for complex geometries. Predictions of local mechanical properties by simulation would reduce the development time of new applications drastically but are today not possible on part scale, so new part applications must be qualified experimentally at great effort. In this study, representative geometry sections were transferred into a simplified sample shape to mechanically characterize different geometry-dependent microstructures. In areas exposed to comparatively increased heat input over time, a lamellar α + β microstructure with β fraction up to 20% was measured in contrast to the common martensitic α′ microstructure of LPBF-manufactured Ti-6Al-4V, resulting in reduced tensile strength and fatigue life. For the first time, a correlation was successfully established between ultimate tensile strength of multiple geometries and the corresponding temperature–time cycles. With reduced computational effort by use of simplifying assumptions in the simulation, this correlation model can theoretically be applied to the part level. This work has laid the foundation for the simulation-based prediction of mechanical properties for entire parts manufactured with LPBF.
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8
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Ghio E, Cerri E. Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects. MATERIALS (BASEL, SWITZERLAND) 2022; 15:2047. [PMID: 35329496 PMCID: PMC8953129 DOI: 10.3390/ma15062047] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/03/2022] [Revised: 03/03/2022] [Accepted: 03/04/2022] [Indexed: 12/29/2022]
Abstract
Laser powder bed fusion (L-PBF) is an additive manufacturing technology that is gaining increasing interest in aerospace, automotive and biomedical applications due to the possibility of processing lightweight alloys such as AlSi10Mg and Ti6Al4V. Both these alloys have microstructures and mechanical properties that are strictly related to the type of heat treatment applied after the L-PBF process. The present review aimed to summarize the state of the art in terms of the microstructural morphology and consequent mechanical performance of these materials after different heat treatments. While optimization of the post-process heat treatment is key to obtaining excellent mechanical properties, the first requirement is to manufacture high quality and fully dense samples. Therefore, effects induced by the L-PBF process parameters and build platform temperatures were also summarized. In addition, effects induced by stress relief, annealing, solution, artificial and direct aging, hot isostatic pressing, and mixed heat treatments were reviewed for AlSi10Mg and Ti6AlV samples, highlighting variations in microstructure and corrosion resistance and consequent fracture mechanisms.
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Affiliation(s)
- Emanuele Ghio
- Department of Engineering and Architecture, University of Parma, 43124 Parma, Italy;
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9
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Pantawane MV, Yang T, Jin Y, Joshi SS, Dasari S, Sharma A, Krokhin A, Srinivasan SG, Banerjee R, Neogi A, Dahotre NB. Crystallographic texture dependent bulk anisotropic elastic response of additively manufactured Ti6Al4V. Sci Rep 2021; 11:633. [PMID: 33437003 PMCID: PMC7804281 DOI: 10.1038/s41598-020-80710-6] [Citation(s) in RCA: 10] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/16/2020] [Accepted: 12/21/2020] [Indexed: 11/09/2022] Open
Abstract
Rapid thermokinetics associated with laser-based additive manufacturing produces strong bulk crystallographic texture in the printed component. The present study identifies such a bulk texture effect on elastic anisotropy in laser powder bed fused Ti6Al4V by employing an effective bulk modulus elastography technique coupled with ultrasound shear wave velocity measurement at a frequency of 20 MHz inside the material. The combined technique identified significant attenuation of shear velocity from 3322 ± 20.12 to 3240 ± 21.01 m/s at 45[Formula: see text] and 90[Formula: see text] orientations of shear wave plane with respect to the build plane of printed block of Ti6Al4V. Correspondingly, the reduction in shear modulus from 48.46 ± 0.82 to 46.40 ± 0.88 GPa was obtained at these orientations. Such attenuation is rationalized based on the orientations of [Formula: see text] crystallographic variants within prior columnar [Formula: see text] grains in additively manufactured Ti6Al4V.
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Affiliation(s)
- Mangesh V Pantawane
- Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76207, USA.,Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX, 76207, USA
| | - Teng Yang
- Department of Physics, University of North Texas, Denton, TX, 76203, USA.,Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX, 76207, USA
| | - Yuqi Jin
- Department of Physics, University of North Texas, Denton, TX, 76203, USA
| | - Sameehan S Joshi
- Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76207, USA.,Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX, 76207, USA
| | - Sriswaroop Dasari
- Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76207, USA
| | - Abhishek Sharma
- Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76207, USA
| | - Arkadii Krokhin
- Department of Physics, University of North Texas, Denton, TX, 76203, USA
| | | | - Rajarshi Banerjee
- Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76207, USA.,Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX, 76207, USA
| | - Arup Neogi
- Department of Physics, University of North Texas, Denton, TX, 76203, USA.,Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX, 76207, USA
| | - Narendra B Dahotre
- Department of Materials Science and Engineering, University of North Texas, Denton, TX, 76207, USA. .,Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX, 76207, USA.
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