In this work, we employ a combination of high-speed imaging and schlieren imaging, as well as multiphysics modelling, to elucidate the effects of the interaction between the laser beam and the powder bed. The formation of denuded areas where the powder was removed during single line and island scans over several layers were imaged for the first time. The inclination of the laser plume was shifted from forwards to backwards by changing power and scan speed, resulting in different denudation regimes with implications to the heat, mass and momentum transfer of the process. As the build progressed, denudation became less severe than for a single powder layer, but the occurrence of sintered and fused powder agglomerates, which were affected by the plume, increased. Schlieren imaging enabled the visualisation of the Ar gas flow, which takes place in the atmosphere above the bed due to the plume, in addition to its interaction with affected particles. Numerical modelling was used to understand and quantify the observed flow behaviour, through the hydrodynamic treatment of the laser plume as a multi-component Ar-Fe plasma. These results promote the characterisation of fluid dynamic phenomena during the laser powder-bed fusion (LPBF) process, which constitutes a key factor in the prevention of defects in additively manufactured parts.
This study explores cardiovascular stents fabricated using laser powder bed fusion (LPBF); an emerging method to offer patient-specific customisable parts. Here, the shape memory alloy NiTi, in a near equiatomic composition, was investigated to deconvolve the material response from macroscopic component effects. Specifically, stress-geometry interactions were revealed, in-situ, for a minaturised cardiovascular stent subjected to an externally applied cylindrical stress whilst acquiring synchrotron X-ray imaging and diffraction data. The approach enabled the collection of spatially resolved micromechanical deformation data; the formation of stress-induced martensite and R-phase was evident, occurring in locations near junctions between stent ligaments where stress concentrations exist. In the as-fabricated condition, hardness maps were obtained through nanoindentation, demonstrating that the localised deformation and deformation patterning is further controlled by porosity and microstructural heterogeneity. Electron backscatter diffraction (EBSD) supported these observations, showing a finer grain structure near stent junctions with higher associated lattice curvature. These features, combined with stress concentrations when loaded will initiate localised phase transformations. If the stent was subjected to repeated loading, representing in-vivo conditions, these regions would be susceptible to cyclic damage through transformation memory loss, leading to premature component failure. This study highlights the challenges that must be addressed for the post-processing treatment of LABF-processed stents for healthcare-related applications.
A 3-D printed narrowband bandpass filter based on spherical dual-mode resonators is presented in this article. It is designed for output multiplexers (OMUXs) using high-$Q$ spherical dual-mode resonators. Realization is by laser powder bed fusion (L-PBF) technology of Invar alloy chosen for its low coefficient of thermal expansion (CTE). Using PBF circumvents the alloy’s manufacturability issues associated with its hardness in machining and free forming. Compared with polymer-based vat photopolymerization technology, PBF allows for direct metal manufacture of complex monolithic microwave components with better thermal-mechanical properties and higher power-handling capability. Using Invar can further help achieve high temperature stability of the filter in high-power operation. To demonstrate the proposed solution, detailed thermal-RF test at different temperatures was carried out. The experimental results of a 0.47% fourth-order silver-plated Invar filter with two transmission zeros verify the design and manufacturing. An insertion loss of 1 dB and an effective temperature coefficient of less than 2 ppm/K were achieved.
The optimisation of processing parameters to produce high densification AlSi10Mg parts by laser powder bed fusion (LPBF) has received considerable attention in recent years. Nonetheless, it is important to consider the potential presence of as-built large pores in real world applications, e.g. due to limitations of the available LPBF system, time and cost constraints associated with producing near-perfect density and so on. In this work, recycled powder was used to fabricate AlSi10Mg specimens with sub-optimal densification by LPBF and an experimental investigation into the evolution of specimen porosity occurring under increasing tensile load was performed. A combination of high-resolution X-ray micro computed tomography (XμCT) and an in-situ micro-testing stage was employed to acquire 3D images at different loading stages. Specimens were tested in the as-built condition and following hot isostatic pressing (HIPping) or HIPping with T6. As-built porosity did not change markedly in the lead-up to brittle-like fracture. Pores within ductile HIPped specimens were uniformly elongated up to the onset of damage propagation and pore coalescence. Pore shape change occurred largely without volume change at small extension. HIPping plus T6 produced a compromise between as-built and HIPped conditions in terms of the extent of pore modification observed prior to failure.
Additive manufacturing (AM) of customised vascular or peripheral stents is of great potential for surgeons and patients, enabling the patients to have customised stents and achieving better outcomes from stenting procedures, with further advantages of having a resource efficient manufacturing process. In this study, the potential for AM of superelastic NiTi-based shape memory alloy (Nitinol) stents was investigated. Two stent designs, which are used for the treatment of complex peripheral artery stenosis in the lower limbs, were studied. Laser Powder Bed Fusion (LPBF) of two stent designs was studied to investigate the impact of the process parameters on the stent geometry, strut size, structural integrity and the phase transformations. The study demonstrated the successful manufacture of Nitinol stents via LPBF, with strut sizes in the range between 250 µm and ≈ 560 µm. The elastic modulus of the stents was between 56 and 73 GPa, which matches well with the elastic modulus of standard austenitic Nitinol. Chemical etching was used to reduce the strut diameter and to remove the partially melted particles. It was shown that the laser energy input has a vital role in controlling the Ni-evaporation and the subsequent changes in the transformation temperatures, as well as the morphology of the stents. The lower energy input results in a reduced Ni-evaporation, maintaining the austenite finish temperature at the expected range, in addition to generating a good build morphology.
'%3e%3cpath fill='%23012169' d='M0 0v30h60V0z'/%3e%3cpath stroke='%23fff' stroke-width='6' d='m0 0 60 30m0-30L0 30'/%3e%3cpath stroke='%23C8102E' stroke-width='4' d='m0 0 60 30m0-30L0 30' clip-path='url(%23b)'/%3e%3cpath stroke='%23fff' stroke-width='10' d='M30 0v30M0 15h60'/%3e%3cpath stroke='%23C8102E' stroke-width='6' d='M30 0v30M0 15h60'/%3e%3c/g%3e%3c/svg%3e)
'/%3e%3cuse xlink:href='%23a' transform='rotate(23.036 .093 25.536)'/%3e%3cuse xlink:href='%23a' transform='rotate(45.87 1.273 16.18)'/%3e%3cuse xlink:href='%23a' transform='rotate(69.945 .996 12.078)'/%3e%3cuse xlink:href='%23a' transform='rotate(20.66 -19.689 31.932)'/%3e%3c/svg%3e)
