Assessment of Residual Stresses in Laser Powder Bed Fusion Manufactured IN 625.

Residual stresses pose significant challenges in the powder bed fusion of metals using a laser (PBF-LB/M), impacting both the dimensional accuracy and mechanical properties. This study quantitatively analyzes deformation and residual stresses in additively manufactured Inconel 625. Investigating both as-built and stress-relieved states with varied scanning strategies (90°, 67°, strip, and 90° chessboard) in PBF-LB/M/IN625, distortion is evaluated using the bridge curvature method. Quantitative measurements are obtained through 3D laser surface scanning on pairs of bridge specimens-one measured before and after detachment from the build plate, and the other undergoing stress-relieving heat treatment at 870 °C for 1 h. The findings reveal that, among as-built specimens, the 90° and 90° strip strategies induce the least distortion, followed by the 67° and chessboard 90° strategies. Furthermore, stress-relief treatment significantly reduces residual stress levels. After post-treatment, the deformation in X-axis samples with 90° and 90° strip strategies decreases by 39% and 42%. In contrast, the samples with the 67° and 90° checkerboard strategies exhibit more pronounced reductions of 44% and 63%, respectively. These quantitative results contribute useful insights for optimizing PBF-LB/M/IN625 processes in additive manufacturing.

A Study on Long-Term Oxidation and Thermal Shock Performance of Nanostructured YSZ/NiCrAlY TBC with a Less Dense Bond Coat.

This paper focused on studying the performance of a nanostructured thermal barrier coating (TBC) system deposited by APS, which had a bond coat with inter-lamellar porosities that resulted during the manufacturing process. The higher porosity level of the bond coat was studied as a possible way to keep the thickness of the TGO under control, as it is distributed on a higher surface, thereby reducing the chance of top-coat (TC) spallation during long-term oxidation and high-temperature thermal shock. The TBC system consisted of nanostructured yttria partially stabilized zirconia (YSZ) as a top coat and a conventional NiCrAlY bond coat. Inter-lamellar porosities ensured the development of a TGO distributed on a higher surface without affecting the overall coating performance. Based on long-term isothermal oxidation tests performed at 1150 °C, the inter-lamellar pores do not affect the high resistance of nanostructured TBCs in case of long-term iso-thermal oxidation at 1150 °C. The ceramic layer withstands the high-temperature exposure for 800 h of maintaining without showing major exfoliation. Fine cracks were discovered in the ceramic coating after 400 h of isothermal oxidation, and larger cracks were found after 800 h of exposure. An increase in both ceramic and bond-coat compaction was observed after prolonged high-temperature exposure, and this was sustained by the higher adhesion strength. Moreover, in extreme conditions, under high-temperature thermal shock cycles, the TBC withstands for 1242 cycles at 1200 °C and 555 cycles at 1250 °C.

Assessment of Additive Manufactured IN 625's Tensile Strength Based on Nonstandard Specimens.

The study aimed to evaluate the tensile strength of additively manufactured (AMed) IN 625 using sub-sized test pieces and compare them to standard specimens. Cylindrical round coupons of varying diameters were manufactured along the Z-axis using the laser powder bed fusion technique and subjected to heat treatment. The simulation of the alloy solidification predicted the formation of several intermetallics and carbides under equilibrium conditions (slow cooling), apart from the γ phase (FCC). Sub-sized tensile specimens with different gauge diameters were machined from the coupons and tensile tested at ambient temperature. The results showed that sub-sized specimens exhibited lower tensile and yield strengths compared to standard specimens, but still higher than the minimum requirements of the relevant ASTM standard for AMed IN 625. The lower strength was attributed to the "size effect" of the test specimens. Fracture surfaces of the sub-sized test specimens exhibit a mixed character, combining cleavage and microvoid coalescence, with improved ductility compared to standard test pieces. The study highlights the importance of adapting characterization methods to the particularities of manufactured parts, including reduced thicknesses that make sampling standard-size specimens impractical. It concludes that sub-sized specimens are valuable for quality control and verifying compliance with requirements of AMed IN 625 tensile properties.

A Study on Mechanical Properties of Low-Cost Thermoplastic-Based Materials for Material Extrusion Additive Manufacturing.

The present research focused on studying the mechanical properties of three commercially available thermoplastic-based materials used for the additive manufacturing (AM) fused filament deposition (FFD) method. The scientific motivation for the study was the limited information available in the literature regarding the materials' properties, the inconsistencies that were recorded by other scientists between the materials' properties and the technical datasheets and the anisotropic behavior of additively manufactured materials. Thereby, it was considered of great importance to perform an extensive study on several materials' mechanical properties, such as tensile properties and flexural properties. Three materials were tested, Tough PLA, nGen CF10 and UltraFuse PAHT CF15. The tests consisted of monotonic tensile tests, open-hole tensile tests and three-point bending tests. The tests were assisted also with the use of microscopical investigations. Framed specimens' configurations with two different raster orientations (90°/0° and -45°/+45°) were manufactured using an in-house-developed 3D printing equipment. The best mechanical performances were recorded for UltraFuse PAHT CF15. The 90°/0° raster orientations ensured the highest tensile, open-hole tensile and flexural strength, regardless of the material type, while the -45°/+45° raster orientations ensured the highest elongation values. The analysis showed the importance of the experimental validation of materials for AM.

Laser Powder Bed Fusion Process Parameters' Optimization for Fabrication of Dense IN 625.

This paper presents an experimental study on the influence of the main Laser Powder Bed Fusion (PBF-LB) process parameters on the density and surface quality of the IN 625 superalloy manufactured using the Lasertec 30 SLM machine. Parameters' influence was investigated within a workspace defined by the laser power (150-400 W), scanning speed (500-900 m/s), scanning strategy (90° and 67°), layer thickness (30-70 µm), and hatch distance (0.09-0.12 µm). Experimental results showed that laser power and scanning speed play a determining role in producing a relative density higher than 99.5% of the material's theoretical density. A basic set of process parameters was selected for generating high-density material: laser power 250 W, laser speed 750 mm/s, layer thickness 40 µm, and hatch distance 0.11 mm. The 67° scanning strategy ensures higher roughness surfaces than the 90° scanning strategy, roughness that increases as the laser power increases and the laser speed decreases.

A Microvascular System Self-Healing Approach on Polymeric Composite Materials.

The paper addresses the synthesis of a nano-fibre network by coaxial electrospinning, embedding the healing agent dicyclopentadiene (DCPD) in polyacrylonitrile (PAN) fibres. Compared to other encapsulation methods, the use of nano-fibres filled with healing agent have no effect on the mechanical properties of the matrix and can address a larger healing area. Additionally, carbon nanotubes were added as nanofillers to enhance the reactivity between DCPD and the epoxydic matrix. The self-healing capability of the nano-fibre network was carried out by flexural tests, at epoxy resin level and composite level. Results obtained from Fourier transform infrared (FTIR) spectrometry, thermogravimetric analysis (TGA) and scanning electron microscopy (SEM) confirmed the successful encapsulation of DCPD healing agent in PAN fibres. Flexural tests indicate that after 48 h, the epoxy resin has recovered 84% of its flexural strength while the composite material recovered 93%.

Assessment of Hot Corrosion in Molten Na2SO4 and V2O5 of Inconel 625 Fabricated by Selective Laser Melting versus Conventional Technology.

Inconel 625 samples, obtained by Selective Laser Melting (SLM) and conventional technology, were tested for hot corrosion resistance against a molten mixture of Na2SO4 and V2O5. The assessments were performed in air, at 900 °C with exposure time of up to 96 h, and at 1000 °C for 8 h. Weight gain was higher for samples obtained by SLM, with 37.4% after 8 h, 3.98% after 24 h, 4.46% after 48 h, and 5.8% after 96 h at 900 °C (22.6% at 1000 °C, 8 h). Three stages of corrosion were observed, the first and last with a high corrosion rate, while the second one showed a slower corrosion rate. Corrosion behaviour depends on the morphology of the grain boundary, which can influence the infiltration of corrosive salts, and on the formation of Cr2NiO4 compound, which acts as a temporary barrier.

Investigation of Scanning Strategies and Laser Remelting Effects on Top Surface Deformation of Additively Manufactured IN 625.

The main drawbacks of the Laser Powder Bed Fusion (LPBF) process are the surface quality and dimensional accuracy of manufactured parts due to the edge and corner effects. These effects can be diminished by using an appropriate balance of the process parameters and scanning strategies. This paper focuses on the assessment of reducing the edge and corner effects that occur in additively manufactured IN 625 alloy via the LPBF technique by varying the hatch angle rotation (by 45°, 67°, and 90°) and volumetric energy density (VED), and using the laser top surface remelting technique (LSR). The edge and corner effects of the cubic samples were quantitatively evaluated on the top surface by 3D laser surface scanning. It was found that the edge and corner effects became more pronounced in the cases of samples built with no contour and hatch angles of 45° and 67°, while the smallest deformations were obtained when the hatch angle was rotated by 90°. Moreover, the heights of both the edge and corner ridges increase as the number of remeltings passing the top layer increases. Conversely, when a lower VED was used for melting the top layer(s) of the samples, the edge and corner ridges were slightly reduced.

Manufacturing of Closed Impeller for Mechanically Pump Fluid Loop Systems Using Selective Laser Melting Additive Manufacturing Technology.

In the space industry, the market demand for high-pressure mechanically pumped fluid loop (MPFL) systems has increased the interest for integrating advanced technologies in the manufacturing process of critical components with complex geometries. The conventional manufacturing process of a closed impeller encounters different technical challenges, but using additive manufacturing (AM) technology, the small component is printed, fulfilling the quality requirements. This paper presents the Laser Powder Bed Fusion (LPBF) process of a closed impeller designed for a centrifugal pump integrated in an MPFL system with the objective of defining a complete manufacturing process. A set of three closed impellers was manufactured, and each closed impeller was subjected to dimensional accuracy analysis, before and after applying an iterative finishing process for the internal surface area. One of the impellers was validated through non-destructive testing (NDT) activities, and finally, a preliminary balancing was performed for the G2.5 class. The process setup (building orientation and support structure) defined in the current study for a pre-existing geometry of the closed impeller takes full advantages of LPBF technology and represents an important step in the development of complex structural components, increasing the technological readiness level of the AM process for space applications.

Durotaxis of Passive Nanoparticles on Elastic Membranes.

The transport of macromolecules and nanoscopic particles to a target cellular site is a crucial aspect in many physiological processes. This directional motion is generally controlled via active mechanical and chemical processes. Here we show, by means of molecular dynamics simulations and an analytical theory, that completely passive nanoparticles can exhibit directional motion when embedded in nonuniform mechanical environments. Specifically, we study the motion of a passive nanoparticle adhering to a mechanically nonuniform elastic membrane. We observe a nonmonotonic affinity of the particle to the membrane as a function of the membrane's rigidity, which results in the particle transport. This transport can be both up or down the rigidity gradient, depending on the absolute values of the rigidities that the gradient spans across. We conclude that rigidity gradients can be used to direct average motion of passive macromolecules and nanoparticles on deformable membranes, resulting in the preferential accumulation of the macromolecules in regions of certain mechanical properties.

The Influence of Laser Defocusing in Selective Laser Melted IN 625.

Laser defocusing was investigated to assess the influence on the surface quality, melt pool shape, tensile properties, and densification of selective laser melted (SLMed) IN 625. Negative (-0.5 mm, -0.3 mm), positive (+0.3 mm, +0.5 mm), and 0 mm defocusing distances were used to produce specimens, while the other process parameters remained unchanged. The scanning electron microscopy (SEM) images of the melt pools generated by different defocusing amounts were used to assess the influence on the morphology and melt pool size. The mechanical properties were evaluated by tensile testing, and the bulk density of the parts was measured by Archimedes' method. It was observed that the melt pool morphology and melting mode are directly related to the defocusing distances. The melting height increases while the melting depth decreases from positive to negative defocusing. The use of negative defocusing distances generates the conduction melting mode of the SLMed IN 625, and the alloy (as-built) has the maximum density and ultimate tensile strength. Conversely, the use of positive distances generates keyhole mode melting accompanied by a decrease of density and mechanical strength due to the increase in porosity and is therefore not suitable for the SLM process.

In-Depth Comparative Assessment of Different Metallic Biomaterials in Simulated Body Fluid.

Invitro experiments have been conducted on metallic biomaterials used for orthopedic implants in order to determine their behavior when immersed in simulated body fluid (SBF). Thus, 3Ti-based metallic biomaterial samples already available on the marked were purchased and immersed in simulated blood plasma, and kept at 37 °C for 4 months. In-depth characterization consisted of a wide series of structural characterizations of both the samples and SBF. Sample analysis consisted of the following: optical (OM) and scanning electron microscopy (SEM) in order to establish the surface and deep corrosion, mass gain/loss assessment for determining the metallic ions loss and/or protective layer formation, and X-ray diffraction in order to establish if and what kind of layers are formed. SBF analysis consisted of using inductively coupled plasma mass spectroscopy (ICP-MS) in order to establish if and/or how many metallic ions have dissociated from the metallic samples into the SBF, and measurements of pH and electrical conductivity. The key findings of the research are as follows: during the four months while kept in SBF, the samples show surface corrosion degradation and protective layer generation. Also, the amount of metallic ions dissociated into the SBF is making them suitable for use. Taking into account that it is highly improbable for such a large area of metal as the one considered within this work to be exposed to real body fluids and that all the samples have developed protective oxide films, the overall conclusion is that they are appropriate for implant use.

Evaluation of Dispersion Methods and Mechanical Behaviour of Glass Fibre Composites with Embedded Self-Healing Systems.

The present paper is focused on evaluating the most suitable dispersion method in the epoxy matrix of two self-healing systems containing dicyclopentadiene (DCPD) and 5-ethylidene-2-norbornene (ENB) monomers encapsulated in a urea-formaldehyde (UF) shell, prior to integration, fabrication and impact testing of specimens. Both microstructural analysis and three-point bending tests were performed to evaluate and assess the optimum dispersion method. It was found that ultrasonication damages the microcapsules of both healing systems, thus magnetic stirring was used for the dispersion of both healing systems in the epoxy matrix. Using magnetic dispersion, 5%, 7%, 10%, 12% and 15% volumes of microcapsules were embedded in glass fibre composites. Some of the samples were subjected to thermal cycling between -20 °C and +100 °C for 8 h, to evaluate the behaviour of both healing systems after temperature variation. Impact test results showed that the mechanical behaviour decreases with increasing microcapsule volume, while for specimens subjected to thermal cycling, the impact strength increases with microcapsule volume up to 10%, after which a severe drop in impact strength follows. Retesting after 48 h shows a major drop in mechanical properties in specimens containing 15% MUF-ENB microcapsules, up to total penetration of the specimen.

A Study on Using the Additive Manufacturing Process for the Development of a Closed Pump Impeller for Mechanically Pumped Fluid Loop Systems.

The efficiency of a centrifugal pump for mechanical pump fluid loops, apart from the design, relies on the performance of the closed impeller which is linked to the manufacturing process in terms of dimensional accuracy and the surface quality. Therefore, the activities of this paper were focused on defining the manufacturing process of a closed impeller using the additive manufacturing technology for mechanically pumped fluid loop (MPFL) systems in space applications. Different building orientations were studied to fabricate three closed impellers using selective laser melting technology and were subjected to dimensional accuracy and surface quality evaluations in order to identify the optimal building orientation. The material used for the closed impeller is Inconel 625. The results showed that both geometrical stability and roughness were improved as the building orientation increased, however, the blade thickness presented small deviations, close to imposed values. Finishing processes for inaccessible areas presented significant results in terms of roughness, nevertheless, the process can be further improved. Abrasive flow machining (AFM) post-processing operations have been considered and the results show major improvements in surface quality. Thus, important steps were made towards the development of complex structural components, consequently increasing the technological readiness level of the additive manufacturing process for space applications.

Influence of membrane-cortex linkers on the extrusion of membrane tubes.

The cell membrane is an inhomogeneous system composed of phospholipids, sterols, carbohydrates, and proteins that can be directly attached to underlying cytoskeleton. The protein linkers between the membrane and the cytoskeleton are believed to have a profound effect on the mechanical properties of the cell membrane and its ability to reshape. Here, we investigate the role of membrane-cortex linkers on the extrusion of membrane tubes using computer simulations and experiments. In simulations, we find that the force for tube extrusion has a nonlinear dependence on the density of membrane-cortex attachments: at a range of low and intermediate linker densities, the force is not significantly influenced by the presence of the membrane-cortex attachments and resembles that of the bare membrane. For large concentrations of linkers, however, the force substantially increases compared with the bare membrane. In both cases, the linkers provided membrane tubes with increased stability against coalescence. We then pulled tubes from HEK cells using optical tweezers for varying expression levels of the membrane-cortex attachment protein Ezrin. In line with simulations, we observed that overexpression of Ezrin led to an increased extrusion force, while Ezrin depletion had a negligible effect on the force. Our results shed light on the importance of local protein rearrangements for membrane reshaping at nanoscopic scales.

Tensile Notch Sensitivity of Additively Manufactured IN 625 Superalloy.

The notch sensitivity of additively manufactured IN 625 superalloy produces by laser powder bed fusion (LPBF) has been investigated by tensile testing of cylindrical test pieces. Smooth and V-notched test pieces with four different radii were tested both in as-built state and after a stress relief heat treatment for 1 h at 900 °C. Regardless of the notch root radius, the investigated alloy exhibits notch strength ratios higher than unity in both as-built and in stress-relieved states, showing that the additive manufactured IN 625 alloy is not prone to brittleness induced by the presence of V-notches. Higher values of notch strength ratios were recorded for the as-built material as a result of the higher internal stress level induced by the manufacturing process. Due to the higher triaxiality of stresses induced by notches, for both as-built and stress-relieved states, the proof strength of the notched test pieces is even higher than the tensile strength of the smooth test pieces tested in the same conditions. SEM fractographic analysis revealed a mixed mode of ductile and brittle fracture morphology of the V-notched specimens regardless the notch root radius. A more dominant ductile mode of fracture was encountered for stress-relieved test pieces than in the case of the as-built state. However, future research is needed to better understand the influence of notches on additive manufactured IN 625 alloy behaviour under more complex stresses.

Microstructural and Tensile Properties Anisotropy of Selective Laser Melting Manufactured IN 625.

The present study was focused on the assessment of microstructural anisotropy of IN 625 manufactured by selective laser melting (SLM) and its influence on the material's room temperature tensile properties. Microstructural anisotropy was assessed based on computational and experimental investigations. Tensile specimens were manufactured using four building orientations (along Z, X, Y-axis, and tilted at 45° in the XZ plane) and three different scanning strategies (90°, 67°, and 45°). The simulation of microstructure development in specimens built along the Z-axis, applying all three scanning strategies, showed that the as-built microstructure is strongly textured and is influenced by the scanning strategy. The 45° scanning strategy induced the highest microstructural texture from all scanning strategies used. The monotonic tensile test results highlighted that the material exhibits significant anisotropic properties, depending on both the specimen orientation and the scanning strategy. Regardless of the scanning strategy used, the lowest mechanical performances of IN 625, in terms of strength values, were recorded for specimens built in the vertical position, as compared with all the other orientations.

Dynamic Clustering Regulates Activity of Mechanosensitive Membrane Channels.

Experiments have suggested that bacterial mechanosensitive channels separate into 2D clusters, the role of which is unclear. By developing a coarse-grained computer model we find that clustering promotes the channel closure, which is highly dependent on the channel concentration and membrane stress. This behaviour yields a tightly regulated gating system, whereby at high tensions channels gate individually, and at lower tensions the channels spontaneously aggregate and inactivate. We implement this positive feedback into the model for cell volume regulation, and find that the channel clustering protects the cell against excessive loss of cytoplasmic content.