Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

Exploring the potential of intermetallic alloys as implantable biomaterials: A comprehensive review

This review delves into the utilization of intermetallic alloys (IMAs) as advanced biomaterials for medical implants, scrutinizing their conceptual framework, fabrication challenges, and diverse manufacturing techniques such as casting, powder metallurgy, and additive manufacturing. Manufacturing techniques such as casting, powder metallurgy, additive manufacturing, and injection molding are discussed, with specific emphasis on achieving optimal grain sizes, surface roughness, and mechanical properties. Post-treatment methods aimed at refining surface quality, dimensional precision, and mechanical properties of IMAs are explored, including the use of heat treatments to enhance biocompatibility and corrosion resistance. The review presents an in-depth examination of IMAs-based implantable biomaterials, covering lab-scale developments and commercial-scale implants. Specific IMAs such as Nickel Titanium, Titanium Aluminides, Iron Aluminides, Magnesium-based IMAs, Zirconium-based IMAs, and High-entropy alloys (HEAs) are highlighted, with detailed discussions on their mechanical properties, including strength, elastic modulus, and corrosion resistance. Future directions are outlined, with an emphasis on the anticipated growth in the orthopedic devices market and the role of IMAs in meeting this demand. The potential of porous IMAs in orthopedics is explored, with emphasis on achieving optimal pore sizes and distributions for enhanced osseointegration. The review concludes by highlighting the ongoing need for research and development efforts in IMAs technologies, including advancements in design and fabrication techniques.

Innovative technologies for the fabrication of 3D/4D smart hydrogels and its biomedical applications - A comprehensive review

Repairing and regenerating damaged tissues or organs, and restoring their functioning has been the ultimate aim of medical innovations. 'Reviving healthcare' blends tissue engineering with alternative techniques such as hydrogels, which have emerged as vital tools in modern medicine. Additive manufacturing (AM) is a practical manufacturing revolution that uses building strategies like molding as a viable solution for precise hydrogel manufacturing. Recent advances in this technology have led to the successful manufacturing of hydrogels with enhanced reproducibility, accuracy, precision, and ease of fabrication. Hydrogels continue to metamorphose as the vital compatible bio-ink matrix for AM. AM hydrogels have paved the way for complex 3D/4D hydrogels that can be loaded with drugs or cells. Bio-mimicking 3D cell cultures designed via hydrogel-based AM is a groundbreaking in-vivo assessment tool in biomedical trials. This brief review focuses on preparations and applications of additively manufactured hydrogels in the biomedical spectrum, such as targeted drug delivery, 3D-cell culture, numerous regenerative strategies, biosensing, bioprinting, and cancer therapies. Prevalent AM techniques like extrusion, inkjet, digital light processing, and stereo-lithography have been explored with their setup and methodology to yield functional hydrogels. The perspectives, limitations, and the possible prospects of AM hydrogels have been critically examined in this study.

Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review

Precision manufacturing requirements are the key to ensuring the quality and reliability of biomedical implants. The powder bed fusion (PBF) technique offers a promising solution, enabling the creation of complex, patient-specific implants with a high degree of precision. This technology is revolutionizing the biomedical industry, paving the way for a new era of personalized medicine. This review explores and details powder bed fusion 3D printing and its application in the biomedical field. It begins with an introduction to the powder bed fusion 3D-printing technology and its various classifications. Later, it analyzes the numerous fields in which powder bed fusion 3D printing has been successfully deployed where precision components are required, including the fabrication of personalized implants and scaffolds for tissue engineering. This review also discusses the potential advantages and limitations for using the powder bed fusion 3D-printing technology in terms of precision, customization, and cost effectiveness. In addition, it highlights the current challenges and prospects of the powder bed fusion 3D-printing technology. This work offers valuable insights for researchers engaged in the field, aiming to contribute to the advancement of the powder bed fusion 3D-printing technology in the context of precision manufacturing for biomedical applications.

Advanced Analysis of the Properties of Solid-Wire Electric Contacts Produced by Ultrasonic Welding and Soldering

The current article presents an advanced analysis of the properties of solid-wire electric contacts produced with ultrasonic welding and soldering. Soldering is generally used to join thin, solid copper wires to produce electrical contacts in small-volume production, as ultrasonic welding does not provide acceptable peel force and tensile strength due to the deformation and thinning of the wires. In this article, ultrasonic welding of thin, solid copper wires using a ring before and after a thermal shock test is discussed and compared with the standard soldering technique. The thermal shock test was carried out in the temperature range from -30 to 150 °C. Half of the samples, for both the joining techniques and the wires, were subjected to the thermal shock test; the other half were not. Investigations included electrical resistance tests, optical and SEM microscopy, XRD, microhardness measurements, peel tests, tensile tests, and fractographic analysis. The electrical resistance test, microscopy, microhardness measurements, and fracture examinations showed no differences between the thermal shock-exposed and the non-exposed samples with the same joining process. In mechanical tests, the ultrasonic joint demonstrated superior strength compared to the soldered joint.

Health hazards of particles in additive manufacturing: a cross-disciplinary study on reactivity, toxicity and occupational exposure to two nickel-based alloys

The increasing use of additive manufacturing (AM) techniques (e.g., 3D-printing) offers many advantages but at the same time presents some challenges. One concern is the possible exposure and health risk related to metal containing particles of different sizes. Using the nickel-based alloys Hastelloy X (HX) and Inconel 939 (IN939) as a case, the aim of this cross-disciplinary study was to increase the understanding on possible health hazards and exposure. This was done by performing in-depth characterization of virgin, reused and condensate powders, testing in vitro toxicity (cytotoxicity, genotoxicity, oxidative stress), and measuring occupational airborne exposure. The results showed limited metal release from both HX and IN939, and slightly different surface composition of reused compared to virgin powders. No or small effects on the cultured lung cells were observed when tested up to 100 µg/mL. Particle background levels in the printing facilities were generally low, but high transient peaks were observed in relation to sieving. Furthermore, during post processing with grinding, high levels of nanoparticles (> 100,000 particles/cm3) were noted. Urine metal levels in AM operators did not exceed biomonitoring action limits. Future studies should focus on understanding the toxicity of the nanoparticles formed during printing and post-processing.

Effect of Multiple Reverse Transformation Treatments on Grain Refinement and Mechanical Properties of Biomedical Co-Cr-Mo-N Alloys Fabricated by Electron Beam Melting

We investigated the improvement of mechanical properties of biograde Co-28Cr-6Mo-0.11N alloy prepared by electron beam melting through grain refinement via multiple reverse transformations. While the effects of single and double reverse transformation treatments on the microstructure have been investigated in previous studies, we investigated the effects of multiple reverse transformation heat treatments. The particle size was refined to 1/4, and the yield strength, tensile silence strength, and elongation were enhanced to 655 MPa, 1234 MPa, and 45%, respectively, satisfying ASTM F75 standards. Moreover, a mixed phase of ε and γ was observed to provide higher yield strength than a single γ structure. The dominant behavior in the γ → ε phase transformation at 1073 K was obvious. Grain growth was suppressed by the grain-boundary pinning effect of the Cr2N phase during reverse transformation to the γ phase. Because no fracture was caused by precipitates such as σ, η, and Cr2N phases, the influence of the precipitates on the tensile properties was small.

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM's capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

Green solvents, materials, and lead-free semiconductors for sustainable fabrication of perovskite solar cells

Perovskite materials research has received unprecedented recognition due to its applications in photovoltaics, LEDs, and other large area low-cost electronics. The exceptional improvement in the photovoltaic conversion efficiency of Perovskite solar cells (PSCs) achieved over the last decade has prompted efforts to develop and optimize device fabrication technologies for the industrial and commercial space. However, unstable operation in outdoor environments and toxicity of the employed materials and solvents have hindered this proposition. While their optoelectronic properties are extensively studied, the environmental impacts of the materials and manufacturing methods require further attention. This review summarizes and discusses green and environment-friendly methods for fabricating PSCs, particularly non-toxic solvents, and lead-free alternatives. Greener solvent choices are surveyed for all the solar cell films, (i.e. electron and hole transport, semiconductor, and electrode layers) and their impact on thin film quality, morphology and device performance is explored. We also discuss lead content in perovskites, its environmental impact and sequestration routes, and progress in replacing lead with greener alternatives. This review provides an analysis of sustainable green routes in perovskite solar cell fabrication, discussing the impact of each layer in the device stack, via life cycle analysis.

A Review-Additive Manufacturing of Intermetallic Alloys Based on Orthorhombic Titanium Aluminide Ti2AlNb

Titanium alloys based on orthorhombic titanium aluminide Ti₂AlNb are promising refractory materials for aircraft engine parts in the operating temperature range from 600-700 °C. Parts made of Ti₂AlNb-based alloys by traditional technologies, such as casting and metal forming, have not yet found wide application due to the sensitivity of processability and mechanical properties in chemical composition and microstructure compared with commercial solid-solution-based titanium alloys. In the last three decades, metal additive manufacturing (MAM) has attracted the attention of scientists and engineers for the production of intermetallic alloys based on Ti₂AlNb. This review summarizes the recent achievements in the production of O-phase-based Ti alloys using MAM, including the analysis of the feedstock materials, technological processes, machines, microstructure, phase composition and mechanical properties. Powder bed fusion (PBF) and direct energy deposition (DED) are the most widely employed MAM processes to produce O-phase alloys. MAM provides fully dense, fine-grained material with a superior combination of mechanical properties at room temperature. Further research on MAM for the production of critical parts made of Ti₂AlNb-based alloys can be focused on a detailed study of the influence of post-processing and chemical composition on the formation of the structure and mechanical properties, including cyclic loading, fracture toughness, and creep resistance.

Bonding and Strengthening the PLA Biopolymer in Multi-Material Additive Manufacturing

3D printing is a revolutionary additive manufacturing method that enables rapid prototyping and design flexibility. A variety of thermoplastic polymers can be used in printing. As it is necessary to reduce the consumption of petrochemical resources, alternative solutions are being researched, and the interest in using bioplastics and biocomposites is constantly growing. Often, however, the properties of biopolymers are insufficient and need to be improved to compete with petroleum-based plastics. The paper aims to analyze the available information on elements produced from more than one material, with additive manufacturing resulting from 3D printing using biopolymer Polylactic Acid (PLA). The study notes the possibility of modifying and improving the properties of PLA using layered printing or by modifying PLA filaments. Several modifications improving and changing the properties of PLA were also noted, including printing parameters when combined with other materials: process temperatures, filling, and surface development for various sample geometries.

Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation

Vacuum induction melting gas atomization (VIGA) has evolved as an important production technique of superalloy powders used in additive manufacturing. However, the development of powder preparation techniques is limited because the crushing process of gas-atomized metal melt is difficult to characterize by conventional experimental methods. Herein, we report the application of computational fluid dynamics to simulate the breaking behavior of droplets in the process of preparing nickel-based superalloy powders by VIGA, as well as the results on the effect of gas pressure on the atomization process and powder particle size distribution of metal melt. In the process of primary atomization, the crushing morphology of superalloy melt shows an alternate transformation of umbrella shapes and inverted mushroom cloud shapes, and with the increase in atomization pressure, the disorder of the two-phase flow field increases, which is conducive to sufficient breakage of the melt. Most importantly, in the process of secondary atomization and with the increasing atomization pressure, the particle size distribution becomes narrower, the median particle diameter and average particle size decrease, and the decreasing trend of the particle size increases gradually. The simulation results are compliant with the performed nickel-based superalloy powder preparation tests. This study provides insight into the production and process optimization of superalloy powder prepared by the VIGA method.

Industry 4.0 and Digitalisation in Healthcare

Industry 4.0 in healthcare involves use of a wide range of modern technologies including digitisation, artificial intelligence, user response data (ergonomics), human psychology, the Internet of Things, machine learning, big data mining, and augmented reality to name a few. The healthcare industry is undergoing a paradigm shift thanks to Industry 4.0, which provides better user comfort through proactive intervention in early detection and treatment of various diseases. The sector is now ready to make its next move towards Industry 5.0, but certain aspects that motivated this review paper need further consideration. As a fruitful outcome of this review, we surveyed modern trends in this arena of research and summarised the intricacies of new features to guide and prepare the sector for an Industry 5.0-ready healthcare system.

Study on the Shear Modulus Based Equivalent Homogenization Methods of Multi-Layer BCC Lattice Sandwich

In this paper, the shear modulus based equivalent homogenization methods of multi-layer BCC (body-centered cubic) lattice sandwich structures have been studied using analytical, experimental, and finite element methods. In the analytical approach, the multiple strut-deformation patterns were introduced in the derivations of the shear modulus based on Euler–Bernoulli beam theory and Timoshenko beam theory according to different boundary conditions. The analytical shear modulus of three types of rectangle shaped sandwich BCC lattice structures was derived. Finite element models of the BCC lattice structures by ANSYS were conducted to estimate the analytical solutions. Butterfly style sandwich BCC lattice structures were printed by SLM technology using 304 stainless steel (06Cr19Ni10), and corresponding shear experiments using modified Arcan Rig experimental devices were conducted to validate the analytical and numerical calculations. Good agreements were observed among the analytical, numerical, and experimental results.

A Review on the Processing of Aero-Turbine Blade Using 3D Print Techniques

Additive manufacturing (AM) has proven to be the preferred process over traditional processes in a wide range of industries. This review article focused on the progressive development of aero-turbine blades from conventional manufacturing processes to the additive manufacturing process. AM is known as a 3D printing process involving rapid prototyping and a layer-by-layer construction process that can develop a turbine blade with a wide variety of options to modify the turbine blade design and reduce the cost and weight compared to the conventional production mode. This article describes various AM techniques suitable for manufacturing high-temperature turbine blades such as selective laser melting, selective laser sintering, electron beam melting, laser engineering net shaping, and electron beam free form fabrication. The associated parameters of AM such as particle size and shape, powder bed density, residual stresses, porosity, and roughness are discussed here.

Investigation of Mechanical and Magnetic Properties of Co-Based Amorphous Powders Obtained by Atomization

Properties of Co-based alloys with high Glass Forming Ability (GFA) in the form of powder are still not widely known. However, powders of high GFA alloys are often used for the development of bulk metallic glasses by additive manufacturing. In this work Co_47.6B_21.9Fe_20.4Si_5.1Nb₅% at. and Co₄₂B_26.5Fe₂₀Ta_5.5Si₅Cu₁% at. were developed by gas-atomization. Obtained powders in size 50-80 µm were annealed at T_g and T_x of each alloy. Then SEM observation, EDS analyses, differential thermal analysis, X-ray diffraction, nanoindentation, Mössbauer, and magnetic properties research was carried out for as-atomized and annealed states. The gas atomization method proved to be an efficient method for manufacturing Co-based metallic glasses. The obtained powder particles were spherical and chemically homogeneous. Annealing resulted in an increase of mechanical properties such as hardness and the elastic module of Co_47.6B_21.9Fe_20.4Si_5.1Nb₅% at and Co₄₂B_26.5Fe₂₀Ta_5.5Si₅Cu₁%, which was caused by crystallization. The magnetic study shows that Co_47.6B_21.9Fe_20.4Si_5.1Nb₅ and Co₄₂B_26.5Fe₂₀Ta_5.5Si₅Cu₁ are soft magnetic and semi-hard magnetic materials, respectively.

Powder Reuse Cycles in Electron Beam Powder Bed Fusion-Variation of Powder Characteristics

A path to lowering the economic barrier associated with the high cost of metal additively manufactured components is to reduce the waste via powder reuse (powder cycled back into the process) and recycling (powder chemically, physically, or thermally processed to recover the original properties) strategies. In electron beam powder bed fusion, there is a possibility of reusing 95-98% of the powder that is not melted. However, there is a lack of systematic studies focusing on quantifying the variation of powder properties induced by number of reuse cycles. This work compares the influence of multiple reuse cycles, as well as powder blends created from reused powder, on various powder characteristics such as the morphology, size distribution, flow properties, packing properties, and chemical composition (oxygen and nitrogen content). It was found that there is an increase in measured response in powder size distribution, tapped density, Hausner ratio, Carr index, basic flow energy, specific energy, dynamic angle of repose, oxygen, and nitrogen content, while the bulk density remained largely unchanged.

Texturing and Phase Evolution in Ti-6Al-4V: Effect of Electron Beam Melting Process, Powder Re-Using, and HIP Treatment

The research demonstrates microstructural changes and development of specific texture in Ti-6Al-4V specimens produced by electron beam melting (EBM) under different conditions. The effect of two factors, namely, raw material (powder) recycling and hot isostatic pressing (HIP), on the EBM produced samples structure and properties, has been explored. The as-printed and treated samples were investigated using electron backscattered diffraction (EBSD) analysis. Modification of mechanical properties after the EBM and HIP are explained by the EBSD data on microstructural phenomena and phase transformations. The work is devoted to assessing the possibility of reusing the residual titanium alloy powder for the manufacture of titanium components by the combination of EBM and HIP methods.

Mechanical properties and in vitro cytocompatibility of dense and porous Ti-6Al-4V ELI manufactured by selective laser melting technology for biomedical applications

The Ti-6Al-4V alloy is the most common biomaterial used for bone replacements and reconstructions. Despite its advantages, the Ti-6Al-4V has a high stiffness that can cause stress-shielding. In this work, we demonstrated that the selective laser melting (SLM) technology could be used to fabricate porosity in Ti-6Al-4V extra low interstitial (ELI) to reduce its stiffness while improving cell adhesion and proliferation. With a porosity of 14.04%, the elastic modulus of the porous Ti-6Al-4V ELI was reduced to 80 GPa. The compressive stress and the 3-point-bending flexural tests revealed that the porous Ti-6Al-4V ELI possessed a brittle characteristic. The additional pores within the beams of the lattice structures of porous Ti-6Al-4V ELI increased its surface arithmetic average roughness, R_a = 3.94 μm. The in vitro cytocompatibility test showed that the SLM printing process and the post-processes did not cause any toxicity in the MC3T3-E1 cells. The in vitro cell proliferation test also showed that the porous Ti-6Al-4V ELI increased the proliferation rate of osteogenic induced MC3T3-E1 cells on Day 7. The findings from this study would provide engineers and researchers with both the mechanical information and biological understanding of SLM printed porous Ti-6Al-4V ELI, and SLM printed dense Ti-6Al-4V ELI towards biomedical applications.

Contrasting the Role of Pores on the Stress State Dependent Fracture Behavior of Additively Manufactured Low and High Ductility Metals

This study investigates the disparate impact of internal pores on the fracture behavior of two metal alloys fabricated via laser powder bed fusion (L-PBF) additive manufacturing (AM)—316L stainless steel and Ti-6Al-4V. Data from mechanical tests over a range of stress states for dense samples and those with intentionally introduced penny-shaped pores of various diameters were used to contrast the combined impact of pore size and stress state on the fracture behavior of these two materials. The fracture data were used to calibrate and compare multiple fracture models (Mohr-Coulomb, Hosford-Coulomb, and maximum stress criteria), with results compared in equivalent stress (versus stress triaxiality and Lode angle) space, as well as in their conversions to equivalent strain space. For L-PBF 316L, the strain-based fracture models captured the stress state dependent failure behavior up to the largest pore size studied (2400 µm diameter, 16% cross-sectional area of gauge region), while for L-PBF Ti-6Al-4V, the stress-based fracture models better captured the change in failure behavior with pore size up to the largest pore size studied. This difference can be attributed to the relatively high ductility of 316L stainless steel, for which all samples underwent significant plastic deformation prior to failure, contrasted with the relatively low ductility of Ti-6Al-4V, for which, with increasing pore size, the displacement to failure was dominated by elastic deformation.

Investigation of Microstructure and Mechanical Properties for Ti-6Al-4V Alloy Parts Produced Using Non-Spherical Precursor Powder by Laser Powder Bed Fusion

An unmodified, non-spherical, hydride-dehydride (HDH) Ti-6Al-4V powder having a substantial economic advantage over spherical, atomized Ti-6Al-4V alloy powder was used to fabricate a range of test components and aerospace-related products utilizing laser beam powder-bed fusion processing. The as-built products, utilizing optimized processing parameters, had a Rockwell-C scale (HRC) hardness of 44.6. Following heat treatments which included annealing at 704 °C, HIP at ~926 °C (average), and HIP + anneal, the HRC hardnesses were observed to be 43.9, 40.7, and 40.4, respectively. The corresponding tensile yield stress, UTS, and elongation for these heat treatments averaged 1.19 GPa, 1.22 GPa, 8.7%; 1.03 GPa, 1.08 GPa, 16.7%; 1.04 GPa, 1.09 GPa, 16.1%, respectively. The HIP yield strength and elongation of 1.03 GPa and 16.7% are comparable to the best commercial, wrought Ti-6Al-4V products. The corresponding HIP component microstructures consisted of elongated small grains (~125 microns diameter) containing fine, alpha/beta lamellae.

Critical Raw Materials Saving by Protective Coatings under Extreme Conditions: A Review of Last Trends in Alloys and Coatings for Aerospace Engine Applications

Several applications, where extreme conditions occur, require the use of alloys often containing many critical elements. Due to the ever increasing prices of critical raw materials (CRMs) linked to their high supply risk, and because of their fundamental and large utilization in high tech products and applications, it is extremely important to find viable solutions to save CRMs usage. Apart from increasing processes’ efficiency, substitution, and recycling, one of the alternatives to preserve an alloy and increase its operating lifetime, thus saving the CRMs needed for its manufacturing, is to protect it by a suitable coating or a surface treatment. This review presents the most recent trends in coatings for application in high temperature alloys for aerospace engines. CRMs’ current and future saving scenarios in the alloys and coatings for the aerospace engine are also discussed. The overarching aim of this paper is to raise awareness on the CRMs issue related to the alloys and coating for aerospace, suggesting some mitigation measures without having the ambition nor to give a complete overview of the topic nor a turnkey solution.

Complex Concentrated Alloys for Substitution of Critical Raw Materials in Applications for Extreme Conditions

The paper is proposing a mini-review on the capability of the new complex concentrated alloys (CCAs) to substitute or reduce the use of critical raw materials in applications for extreme conditions. Aspects regarding the regulations and expectations formulated by the European Union in the most recent reports on the critical raw materials were presented concisely. A general evaluation was performed on the CCAs concept and the research directions. The advantages of using critical metals for particular applications were presented to acknowledge the difficulty in the substitution of such elements with other materials. In order to establish the level of involvement of CCAs in the reduction of critical metal in extreme environment applications, a presentation was made of the previous achievements in the field and the potential for the reduction of critical metal content through the use of multi-component compositions.