Additive manufacturing of metals

Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following a...

/pdf/review-of-selective-laser-melting-materials-and-applications-2gpgz4zp60.pdf

Review of selective laser melting : materials and applications

https://onlinelibrary.wiley.com/doi/pdf/10.1002/jor.23075

Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs.

A Review on Biomedical Titanium Alloys: Recent Progress and Prospect

Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review

Nowadays, the research on prosthetic solutions is focused on minimising patients' trauma. In the case of joint pathologies (Lindqvist et al. 1992; Westermark et al. 2006), this can be achieved thro...

Measurement and interpretation of viscous interactions during contact between bone and prosthetic materials

The design of reliable prosthetic solutions requires wide knowledge of the contact interactions existing inside human joints. Biotribology is of major interest to understand the various mechanisms encountered during this type of contact. The aim of the present work is to propose a new method of experiments and interpretation of the contact existing between bone and a prosthetic material. Firstly, a new tribometer is developed to reproduce this type of contact in vitro, under conditions similar to physiological ones. The experimental tests enabled to quantify bone wear and to determine global interaction forces. Secondly, a rheological model is proposed to identify the frictional and viscous parts of this global interaction force. An example of measurement is detailed in this paper in order to illustrate the fitting of the simulated results to the experimental ones. The values of the rheological parameters corresponding to the best fitting are provided. Thanks to this approach, several conclusions are drawn, allowing to deepen the comprehension of this type of interaction. Kljuþne reþi • modeliranje interakcija • koeficijent trenja • viskoznost • trosenje kostiju Izvod

MEASUREMENT AND INTERPRETATION OF VISCOUS INTERACTIONS DURING CONTACT BETWEEN BONE AND PROSTHETIC MATERIALS MERENJE I INTERPRETACIJA VISKOZNIH INTERAKCIJA PRI MEĈUSOB NOM KONTAKTU KOSTI I PROTETIýKIH MATERIJALA

Because of its biocompatibility and high mechanical properties, the commercially pure grade 2 titanium (CPG2Ti) is largely used for fabrication of patient specific implants or hard tissue substitutes with complex shape. To avoid the stress-shielding and help their colonization by bone, prostheses with a controlled porosity are designed. The selective laser melting (SLM) is well adapted to manufacture such geometrically complicated structures constituted by struts with rough surfaces and relatively small diameters. Few studies were dedicated to characterize the fatigue properties of SLM processed samples and bulk parts. They followed conventional or standard protocols. The fatigue behavior of standard samples is very different from the one of porous raw structures. In this study, the SLM made "as built" (AB) and "heat treated" (HT) tubular samples were tested in fatigue. Wohler curves were determined in both cases. The obtained endurance limits were equal to σD(AB)=74.5MPa and σD(HT)=65.7MPa, respectively. The heat treatment worsened the endurance limit by relaxation of negative residual stresses measured on the external surface of the samples. Modified Goodman diagram was established for raw specimens. Porous samples, based on the pattern developed by Barbas et al. (2012), were manufactured by SLM. Fatigue tests and finite element simulations performed on these samples enabled the determination of a simple rule of fatigue assessment. The method based on the stress gradient appeared as the best approach to take into account the notch influence on the fatigue life of CPG2Ti structures with a controlled porosity. The direction dependent apparent fatigue strength was found. A criterion based on the effective, or global, nominal stress was proposed taking into account the anisotropy of the porous structures. Thanks to this criterion, the usual calculation methods can be used to design bone substitutes, without a precise modelling of their internal fine porosity.

Fatigue behavior of thin-walled grade 2 titanium samples processed by selective laser melting. Application to life prediction of porous titanium implants.

Commercially Pure Porous Titanium (CPPTi) can be used for surgical implants to avoid the stress shielding effect due to the mismatch between the mechanical properties of titanium and bone. Most researchers in this area deal with randomly distributed pores or simple architectures in titanium alloys. The control of porosity, pore size and distribution is necessary to obtain implants with mechanical properties close to those of bone and to ensure their osseointegration. The aim of the present work was therefore to develop and characterize such a specific porous structure. First of all, the properties of titanium made by Selective Laser Melting (SLM) were characterized through experimental testing on bulk specimens. An elementary pattern of the porous structure was then designed to mimic the orthotropic properties of the human bone following several mechanical and geometrical criteria. Finite Element Analysis (FEA) was used to optimize the pattern. A porosity of 53% and pore sizes in the range of 860 to 1500 μm were finally adopted. Tensile tests on porous samples were then carried out to validate the properties obtained numerically and identif the failure modes of the samples. Finally, FE elastoplastic analyses were performed on the porous samples in order to propose a failure criterion for the design of porous substitutes.

https://hal.archives-ouvertes.fr/hal-00959501/document

Development and mechanical characterization of porous titanium bone substitutes

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Measurement and interpretation of viscous interactions during contact between bone and prosthetic materials

MEASUREMENT AND INTERPRETATION OF VISCOUS INTERACTIONS DURING CONTACT BETWEEN BONE AND PROSTHETIC MATERIALS MERENJE I INTERPRETACIJA VISKOZNIH INTERAKCIJA PRI MEĈUSOB NOM KONTAKTU KOSTI I PROTETIýKIH MATERIJALA

Fatigue behavior of thin-walled grade 2 titanium samples processed by selective laser melting. Application to life prediction of porous titanium implants.

Development and mechanical characterization of porous titanium bone substitutes