The Study on Resolution Factors of LPBF Technology for Manufacturing Superelastic NiTi Endodontic Files.

Laser Powder Bed Fusion (LPBF) technology is a new trend in manufacturing complex geometric structures from metals. This technology allows producing topologically optimized parts for aerospace, medical and industrial sectors where a high performance-to-weight ratio is required. Commonly the feature size for such applications is higher than 300-400 microns. However, for several possible applications of LPBF technology, for example, microfluidic devices, stents for coronary vessels, porous filters, dentistry, etc., a significant increase in the resolution is required. This work is aimed to study the resolution factors of LPBF technology for the manufacturing of superelastic instruments for endodontic treatment, namely Self-Adjusting Files (SAF). Samples of thin walls with different incline angles and SAF samples were manufactured from Nickel-Titanium pre-alloyed powder with a 15-45 µm fraction. The printing procedure was done using an LPBF set-up equipped with a conventional ytterbium fiber laser with a nominal laser spot diameter of 55 microns. The results reveal physical, apparatus, and software factors limiting the resolution of the LPBF technology. Additionally, XRD and DSC tests were done to study the effect of single track based scanning mode manufacturing on the phase composition and phase transformation temperatures. Found combination of optimal process parameters including laser power of 100 W, scanning speed of 850 mm/s, and layer thickness of 20 µm was suitable for manufacturing SAF files with the required resolution. The results will be helpful for the production of NiTi micro objects based on periodic structures both by the LPBF and µLPBF methods.

Selective Laser Melting of Pre-Alloyed NiTi Powder: Single-Track Study and FE Modeling with Heat Source Calibration.

Unique functional properties such as the low stiffness, superelasticity, and biocompatibility of nickel-titanium shape-memory alloys provide many applications for such materials. Selective laser melting of NiTi enables low-cost customization of devices and the manufacturing of highly complex geometries without subsequent machining. However, the technology requires optimization of process parameters in order to guarantee high mass density and to avoid deterioration of functional properties. In this work, the melt pool geometry, surface morphology, formation mode, and thermal behavior were studied. Multiple combinations of laser power and scanning speed were used for single-track preparation from pre-alloyed NiTi powder on a nitinol substrate. The experimental results show the influence of laser power and scanning speed on the depth, width, and depth-to-width aspect ratio. Additionally, a transient 3D FE model was employed to predict thermal behavior in the melt pool for different regimes. In this paper, the coefficients for a volumetric double-ellipsoid heat source were calibrated with bound optimization by a quadratic approximation algorithm, the design of experiments technique, and experimentally obtained data. The results of the simulation reveal the necessary conditions of transition from conduction to keyhole mode welding. Finally, by combining experimental and FE modeling results, the optimal SLM process parameters were evaluated as P = 77 W, V = 400 mm/s, h = 70 µm, and t = 50 µm, without printing of 3D samples.

Laser Powder Bed Fusion of Chromium Bronze Using Recycled Powder.

Laser powder bed fusion (LPBF) of Cu-0.5Cr was carried out using recycled powder taken out from the LPBF machine after previous printing. Various volumetric defects characterized the powder wherein particle size distribution was the same as virgin powder. Using recycled powder resulted in extra spherical pore formation after the LPBF process. Despite that, a relative density of 99.2% was achieved by LPBF parameters optimization. Solidified microstructure with a small volume of defects consisted of an oversaturated dendritic Cu matrix and nano-sized Cr precipitations providing strengthening mechanism occurrence. The possibility of a satisfactory level of mechanical properties with σ0.2 = 136.8 MPa, UTS = 187.4 MPa, along with 15.5% of elongation achieving, was shown.

Selective Laser Melting of Al-Based Matrix Composites with Al2O3 Reinforcement: Features and Advantages.

Aluminum matrix composites (AMC) are of great interest and importance as high-performance materials with enhanced mechanical properties. Al2O3 is a commonly used reinforcement in AMCs fabricated by means of various technological methods, including casting and sintering. Selective laser melting (SLM) is a suitable modern method of the fabrication of net-shape fully dense parts from AMC with alumina. The main results, achievements, and difficulties of SLM applied to AMCs with alumina are discussed in this review and compared with conventional methods. It was shown that the initial powder preparation, namely the particle size distribution, sphericity, and thorough mixing, affected the final microstructure and properties of SLMed materials drastically. The distribution of reinforcing particles tends to consolidate the near-melting pool-edges process because of pushing by the liquid-solid interface during the solidification process that is a common problem of various fabrication methods. The achievement of an homogeneous distribution was shown to be possible through both the thorough mixing of the initial powders and the precise optimization of SLM parameters. The strength of the AMCs fabricated by the SLM method was relatively low compared with materials produced by conventional methods, while for superior relative densities of more than 99%, hardness and tribological properties were obtained, making SLM a promising method for the Al-based matrix composites with Al2O3.