From microstructural design to surface engineering: A tailored approach for improving fatigue life of additively manufactured meta-biomaterials

Ahmadi, S.M.; Kumar, Rakesh; Борисов, Е. В.; Petrov, Roumen; Leeflang, M.A.; Li, Yageng; Tümer, N.; Huizenga, R. M.; Ayas, Can; Zadpoor, Amir A.; Popovich, Vera

doi:10.1016/j.actbio.2018.10.043

Cited by 95 publications

(37 citation statements)

References 69 publications

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“…Moreover, machining cannot be applied on complex lattice parts or for thin internal features such as thin channels [28]. Other post-processing solutions have been investigated, such as chemical or electrochemical polishing [29,30], shot peening [31], and sand blasting [32].…”

Section: Introductionmentioning

confidence: 99%

A competition between the contour and hatching zones on the high cycle fatigue behaviour of a 316L stainless steel: Analyzed using X-ray computed tomography

Andreau

Pessard

Koutiri

et al. 2019

Materials Science and Engineering: A

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Metal powder bed fusion techniques can be used to build parts with complex internal and external geometries. Process parameters are optimized in order to obtain parts with low surface roughness and porosity, while maintaining a high productivity rate. The goal of this work is to quantify the sensitivity to internal and surface defects on the fatigue endurance of additively manufactured metallic parts. 316L Stainless Steel samples were fabricated through powder bed fusion using identical contour parameters, but three different hatching strategies were applied by varying the scanning speeds in the internal portions of the parts. Samples were subsequently mirror-polished to smooth the rough as-built surface. X-ray computed tomography analysis revealed several defect populations in samples from all three parametric sets due to lack of fusion in the bulk, with a nearly fully dense external "shell". High cycle fatigue tests at R = 0.1 were then performed on the specimens and combined with the X-ray computed tomography scans, helping to identify the largest and the critical defect size at which crack initiation occurred. Most fatigue failures initiated within the external contour zone for small (< 100 μm) defects, even when larger (> 200 μm) lack of fusion defects were widely present below the surface. It was determined that the high porosity (1% in volume or above 5% in area at some fabricated layers) observed in the bulk of parts manufactured with high scanning speeds had little impact on the fatigue limit of the material.

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Section: Introductionmentioning

confidence: 99%

A competition between the contour and hatching zones on the high cycle fatigue behaviour of a 316L stainless steel: Analyzed using X-ray computed tomography

Andreau

Pessard

Koutiri

et al. 2019

Materials Science and Engineering: A

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“…160,161 For example, in the case of the titanium alloy Ti-6Al-4V processed with SLM, a very brittle phase (i.e., a 0 ) is often formed, which reduces the fatigue life of the resulting material. 162 Heat treatments alone 76,158,[163][164][165][166][167][168][169][170] as well as in combination with high pressures (e.g., in hot isostatic pressing 157,162,171 ) and surface treatments 162 could be used to both reduce the level of the residual stresses and to improve the microstructural features of the materials processed with EBM and SLM.…”

Section: Additive Manufacturing Techniquesmentioning

confidence: 99%

“…49,76,158,163,165,166,168,170 Combining high temperatures with high levels of pressure could be also used in a process called hot isostatic pressing (HIP) to close the pores (i.e., manufacturing defects) created by the AM process, thereby increasing the mechanical properties of the resulting lattice structures. 49,157,162,171 The surface properties of the struts constituting the lattice structures could be also improved through surface treatments such as sand blasting and chemical etching aimed at removing the unmolten powder particles and smoothening the surface of AM porous structures. 49,162 It is important to realize that these types of surface treatments are different both in protocol and purpose from those used for bio-functionalization of AM porous biomaterials (Section 6).…”

Section: Post-am Heat and Surface Treatmentsmentioning

confidence: 99%

“…49,157,162,171 The surface properties of the struts constituting the lattice structures could be also improved through surface treatments such as sand blasting and chemical etching aimed at removing the unmolten powder particles and smoothening the surface of AM porous structures. 49,162 It is important to realize that these types of surface treatments are different both in protocol and purpose from those used for bio-functionalization of AM porous biomaterials (Section 6). Improving the smoothness of the surface of the struts could, for example, help in reducing the notches that act as crack initiation sites and may lead to premature fatigue failure under repetitive mechanical loading.…”

Section: Post-am Heat and Surface Treatmentsmentioning

confidence: 99%

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Additively manufactured porous metallic biomaterials

Zadpoor

2019

J. Mater. Chem. B

169

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“…Ahmadi et al. 24 studied the effects of heat treatments, hot isostatic pressing (HIP), sand blasting, and chemical etching on the microstructure, surface morphology, strength, and fatigue resistance of selective laser melted titanium meta-biomaterials. The results showed the profound effect of post-processing process on the fatigue behavior of Ti6Al4V structures.…”

Section: Introductionmentioning

confidence: 99%

Multiobjective optimization of a newly developed additively manufactured functionally graded anisotropic porous lattice structure

Mahbod

Asgari

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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In this paper, the elastic behavior of uniform and functionally graded porous lattice structures made by a double pyramid dodecahedron unit cell is investigated. Analytical solutions are derived in order to estimate the elastic moduli of the proposed structures in two directions. The analytical solution is validated by finite element simulations and experimental tests while the results show good agreement in general. The average difference between the numerical and analytical values of elastic modulus is under 14.44%, while the average error of experimental test and analytical solution is 15.69%. A comprehensive optimization is performed by considering elastic moduli in two different directions as objective functions. Various uniform lattice structures with different relative densities are optimized using NSGA-II algorithm as well as lattice structures with graded distribution of porosity. A variety of optimal designs are achieved by multiobjective optimization algorithm and the best point of the Pareto front is selected by the TOPSIS method. Furthermore, the functionally graded lattice structures are optimized by considering desirable relative densities in each layer and applying constructive constraints. Different distribution patterns of relative density are considered in layers in order to present the flexible design capability of the developed structure. The obtained results show that the elastic modulus is significantly dependent on the relative density of each layer as well as cell configuration. Also, different lattice structures could be achieved by applying desirable prescribed distribution of properties. A comparison between optimized and base model indicated that elastic moduli was considerably improved in optimized models. In optimization of uniform models, [Formula: see text] was increased by 115%, 89%, and 69% in optimized structures for relative densities of 10%, 30%, and 50%, respectively. Moreover, [Formula: see text] was improved in optimized models by 27%, 24%, and 18% for relative densities of 10%, 30%, and 50%, respectively.

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From microstructural design to surface engineering: A tailored approach for improving fatigue life of additively manufactured meta-biomaterials

Cited by 95 publications

References 69 publications

A competition between the contour and hatching zones on the high cycle fatigue behaviour of a 316L stainless steel: Analyzed using X-ray computed tomography

A competition between the contour and hatching zones on the high cycle fatigue behaviour of a 316L stainless steel: Analyzed using X-ray computed tomography

Additively manufactured porous metallic biomaterials

Multiobjective optimization of a newly developed additively manufactured functionally graded anisotropic porous lattice structure

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