Abstract:Nickel–Titanium (NiTi)-based shape-memory alloys (SMA) are utilized in automotive, biomedical, microsystem applications because of their excellent shape memory effect, biocompatibility and super elastic properties. These alloys are considered difficult to cut—especially with conventional technologies because of the work hardening and residual stresses. Laser-machining is one of the most effective tools for processing of these alloys especially for microsystem applications. In this work, a thorough inve… Show more
“…The lower extreme in the solution space projects the optimal solution. 12.5 and 30.8 µm were the minimized optimal taper values and spattered, respectively [ 196 ]. Fig.…”
Section: Surface Modification Of Metallic Implant Biomaterialsmentioning
There is a tremendous increase in the demand for converting biomaterials into high-quality industrially manufactured human body parts, also known as medical implants. Drug delivery systems, bone plates, screws, cranial, and dental devices are the popular examples of these implants - the potential alternatives for human life survival. However, the processing techniques of an engineered implant largely determine its preciseness, surface characteristics, and interactive ability with the adjacent tissue(s) in a particular biological environment. Moreover, the high cost-effective manufacturing of an implant under tight tolerances remains a challenge. In this regard, several subtractive or additive manufacturing techniques are employed to manufacture patient-specific implants, depending primarily on the required biocompatibility, bioactivity, surface integrity, and fatigue strength. The present paper reviews numerous non-degradable and degradable metallic implant biomaterials such as stainless steel (SS), titanium (Ti)-based, cobalt (Co)-based, nickel-titanium (NiTi), and magnesium (Mg)-based alloys, followed by their processing via traditional turning, drilling, and milling including the high-speed multi-axis CNC machining, and non-traditional abrasive water jet machining (AWJM), laser beam machining (LBM), ultrasonic machining (USM), and electric discharge machining (EDM) types of subtractive manufacturing techniques. However, the review further funnels down its primary focus on Mg, NiTi, and Ti-based alloys on the basis of the increasing trend of their implant applications in the last decade due to some of their outstanding properties. In the recent years, the incorporation of cryogenic coolant-assisted traditional subtraction of biomaterials has gained researchers’ attention due to its sustainability, environment-friendly nature, performance, and superior biocompatible and functional outcomes fitting for medical applications. However, some of the latest studies reported that the medical implant manufacturing requirements could be more remarkably met using the non-traditional subtractive manufacturing approaches. Altogether, cryogenic machining among the traditional routes and EDM among the non-traditional means along with their variants, were identified as some of the most effective subtractive manufacturing techniques for achieving the dimensionally accurate and biocompatible metallic medical implants with significantly modified surfaces.
“…The lower extreme in the solution space projects the optimal solution. 12.5 and 30.8 µm were the minimized optimal taper values and spattered, respectively [ 196 ]. Fig.…”
Section: Surface Modification Of Metallic Implant Biomaterialsmentioning
There is a tremendous increase in the demand for converting biomaterials into high-quality industrially manufactured human body parts, also known as medical implants. Drug delivery systems, bone plates, screws, cranial, and dental devices are the popular examples of these implants - the potential alternatives for human life survival. However, the processing techniques of an engineered implant largely determine its preciseness, surface characteristics, and interactive ability with the adjacent tissue(s) in a particular biological environment. Moreover, the high cost-effective manufacturing of an implant under tight tolerances remains a challenge. In this regard, several subtractive or additive manufacturing techniques are employed to manufacture patient-specific implants, depending primarily on the required biocompatibility, bioactivity, surface integrity, and fatigue strength. The present paper reviews numerous non-degradable and degradable metallic implant biomaterials such as stainless steel (SS), titanium (Ti)-based, cobalt (Co)-based, nickel-titanium (NiTi), and magnesium (Mg)-based alloys, followed by their processing via traditional turning, drilling, and milling including the high-speed multi-axis CNC machining, and non-traditional abrasive water jet machining (AWJM), laser beam machining (LBM), ultrasonic machining (USM), and electric discharge machining (EDM) types of subtractive manufacturing techniques. However, the review further funnels down its primary focus on Mg, NiTi, and Ti-based alloys on the basis of the increasing trend of their implant applications in the last decade due to some of their outstanding properties. In the recent years, the incorporation of cryogenic coolant-assisted traditional subtraction of biomaterials has gained researchers’ attention due to its sustainability, environment-friendly nature, performance, and superior biocompatible and functional outcomes fitting for medical applications. However, some of the latest studies reported that the medical implant manufacturing requirements could be more remarkably met using the non-traditional subtractive manufacturing approaches. Altogether, cryogenic machining among the traditional routes and EDM among the non-traditional means along with their variants, were identified as some of the most effective subtractive manufacturing techniques for achieving the dimensionally accurate and biocompatible metallic medical implants with significantly modified surfaces.
“…The machinability of titanium alloy Ti6Al4V with laser milling has been investigated in the work of Ahmed et al [12], with the MRR and the surface roughness being considered as representative indexes of the alloy's machinability. The MRR and the dimensional accuracy in fabrication of microchannels with Nd:YAG laser on alumina was studied by Mohammed et al [13], while the machining quality of microchannels on Nickel-Titanium (NiTi) based shape-memory alloys was discussed in the work of Mohammed et al [14]. From the literature review, the importance and interest on studying the surface quality after laser machining and engraving for different materials and alloys is clearly deduced.…”
Abstract. Laser engraving process is widely used for various industrial applications, such as the creation of small and complex geometries with ultra-high precision. As surface topography can affect the functionality of produced surfaces in various ways, it is required to carry out comprehensive experimental work in order to correlate the laser engraving process parameters with surface topography characteristics. In the current paper, the surface topography of SAE304 stainless steel specimens in respect to laser power, scanning speed and pulse repetition rate is studied through microscope observations. The findings indicate that the scanning speed is the most dominant parameter regarding surface roughness and from the viewpoint of surface quality, it is suggested that higher scanning speed, lower power and pulse repetition rate values should be employed.
“…23 Laser machining, due to its advantages such as high material removal rate, ability to machine a wide range of machining, and precision, is a good choice for machining micro-channels, especially in difficult-to-cut materials. 24 The high-quality surfaces that may be achieved with laser machining, in particular, reduce liquid flow turbulence and prevent the formation of micro cavities, which are crucial for bacteria multiplication, is an added advantage in bio-medical device fabrications. 25 However, laser machining has its challenges also, such as more heat-affected zone.…”
Laser processing of materials finds application in micro-nano devices mainly because of its accuracy, flexibility, and ability to machine almost any material. Although it offers numerous advantages, it is a complex process involving a large number of factors. The quality of machining often depends on the appropriate selection of parameters. Moreover, the output responses in machining processes have conflicting nature; some are to be minimized, and others have to be maximized. This work uses grey relationship analysis coupled with principal component analysis for multi-response optimization of conflicting responses during laser machining of micro-channels. Micro-channels with a cross-sectional size of 200 × 100 µm were created using Nd:YAG laser beam micro-milling in steel alloy (AISI 1045). The scan speed, layer thickness, and scan strategy were found to have a significant effect on the dimensional accuracy of the microchannel. At the same time, the material removal rate was mostly influenced by layer thickness. Multi-response optimization results suggest low pulse frequency, high scan speed, low layer thickness, and S3 scan strategy for accurately fabricating micro-channels.
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