A Pragmatic Approach for Rapid, Non-Destructive Assessment of Defect Types in Laser Powder Bed Fusion Based on Melt Pool Monitoring Data.

Process monitoring systems, e.g., systems based on photodiodes, could be used in laser-based powder bed fusion (PBF-LB/M) to measure various process parameters and process signatures to eventually allow for a local, detailed analysis of the produced parts. Here, simple statements only concerning the occurrence of defects in parts are sufficient in many cases, especially with respect to industrial application. Therefore, a pragmatic approach to rapidly infer the occurrence of defects and their types based on in situ data obtained by commercially available process monitoring systems is introduced. In this approach, a color distribution in form of a histogram is determined for each produced part using layer-wise screenshots of the visualized data provided by the monitoring software. Assessment of the histograms of AlSi10Mg samples, which were processed with different parameter combinations, revealed characteristics depending on the prevailing defect types. These characteristics enable the prediction of the occurring defect types without the necessity to apply conventional downstream testing methods, and thus, a straightforward separation of parts with good quality from defective components. Since the approach presented uses the data visualization of the monitoring software, it can be used even when direct access to the raw data is not provided by the machine manufacturer.

Pathways toward the Use of Non-Destructive Micromagnetic Analysis for Porosity Assessment and Process Parameter Optimization in Additive Manufacturing of 42CrMo4 (AISI 4140).

Laser-based powder bed fusion of metals (PBF-LB/M) is a widely applied additive manufacturing technique. Thus, PBF-LB/M represents a potential candidate for the processing of quenched and tempered (Q&T) steels such as 42CrMo4 (AISI 4140), as these steels are often considered as the material of choice for complex components, e.g., in the toolmaking industry. However, due to the presence of process-induced defects, achieving a high quality of the resulting parts remains challenging in PBF-LB/M. Therefore, an extensive quality inspection, e.g., using process monitoring systems or downstream by destructive or non-destructive testing (NDT) methods, is essential. Since conventionally used downstream methods, e.g., X-ray computed tomography, are time-consuming and cost-intensive, micromagnetic NDT measurements represent an alternative for ferromagnetic materials such as 42CrMo4. In this context, 42CrMo4 samples were manufactured by PBF-LB/M with different process parameters and analyzed using a widely established micromagnetic measurement system in order to investigate potential relations between micromagnetic properties and porosity. Using multiple regression modeling, relations between the PBF-LB/M process parameters and six selected micromagnetic variables and relations between the process parameters and the porosity were assessed. The results presented reveal first insights into the use of micromagnetic NDT measurements for porosity assessment and process parameter optimization in PBF-LB/M-processed components.

Micromechanical Modeling of AlSi10Mg Processed by Laser-Based Additive Manufacturing: From as-Built to Heat-Treated Microstructures.

The unique microstructure of the alloy AlSi10Mg produced by the laser-based powder bed fusion of metals (PBF-LB/M) provides high-strength and high-strain-hardening capabilities of the material. The microstructure and mechanical properties of 3D-printed, i.e., additively manufactured, AlSi10Mg are significantly altered by post-building heat-treatment processes applied in order to tailor the final properties of the parts. Using an accurate computational model to predict and improve the mechanical performance of 3D-printed samples considering their microstructural features can accelerate their employment in envisaged applications. The present study aims to investigate the correlation between microstructural features and the mechanical behavior of as-built, direct-aged, and T6 heat-treated samples of PBF-LB/M AlSi10Mg under tensile loading using experiment and microstructure-sensitive modeling approaches. Nanoindentation tests are used to calibrate the parameters of the constitutive models for the Al and Si-rich phases. The experimental investigations revealed that heat treatment significantly changes the sub-grain morphology of the Si-rich phase, and this can have a considerable effect on the mechanical behavior of the components. The effect of the modeling of the Si-rich phase in the representative volume elements on the prediction of mechanical behavior is investigated using the J2 plasticity model. The combination of the crystal plasticity model for Al and the J2 plasticity model for the Si-rich phase is used to predict the tensile properties of the as-built and heat-treated states. The predicted results are in good agreement with the experimental results. This approach can be used to understand the microstructure-property relationship of PBF-LB/M AlSi10Mg and eventually tailor heat treatment for PBF-LB/M AlSi10Mg based on the requirement of the application.

Damage tolerant design of additively manufactured metallic components subjected to cyclic loading: State of the art and challenges.

Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the workshop discussions. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: Criteria for damage tolerant component design;Criteria for the determination of fatigue and fracture properties;Strategies for the determination of the fatigue life in dependence of different manufacturing conditions;Methods for the quantitative characterization of microstructure and defects;Methods for the determination of residual stresses;Effect of the defects and the residual stresses on the fatigue life and behaviour. We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. FEM) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.

High resolution bioprinting of multi-component hydrogels.

Materials capable of directing cell fate by providing spatially-graded mechanical and biomolecular cues are critically important in the reconstitution of living matter. Herein, we report a multi-component inkjet bioprinting method that allows for spatially varying composition and network properties in cell-instructive glycosaminoglycan (GAG)-based biohybrid and pure poly(ethylene glycol) hydrogels with unprecedented (50 µm) resolution. The principle relies on the covalent crosslinking of different polymeric precursors through a very rapid bio-orthogonal Michael type addition scheme adjusted in ways to occur during the fusion of bio-ink droplets prior to and upon contact with the target. Exemplary data show that chemotactic molecular gradients produced by this approach within printed GAG-gels of defined zonal architecture can effectively direct migratory activity and morphogenesis of embedded human bone-marrow derived mesenchymal stem cells. The introduced methodology is expected to enable a new, holistic level of control over reductionistic tissue and organoid models.

Thermoresponsive Microgel Coatings as Versatile Functional Compounds for Novel Cell Manipulation Tools.

For the effective use of live cells in biomedicine as in vitro test systems or in biotechnology, non-invasive cell processing and characterisation are key elements. Thermoresponsive polymer coatings have been demonstrated to be highly beneficial for controlling the interaction of adherent cells through their cultivation support. However, the widespread application of these coatings is hampered by limitations in their adaptability to different cell types and because the full range of applications has not yet been fully explored. In the work presented here, we address these issues by focusing on three different aspects. With regard to the first aspect, by using well-defined laminar flow in a microchannel, a highly controllable and reproducible shear force can be applied to adherent cells. Employing this tool, we demonstrate that cells can be non-invasively detached from a support using a defined shear flow. The second aspect relates to the recent development of simple methods for patterning thermoresponsive coatings. Here, we show how such patterned coatings can be used for improving the handling and reliability of a wound-healing assay. Two pattern geometries are tested using mouse fibroblasts and CHO cells. In terms of the third aspect, the adhesiveness of cells depends on the cell type. Standard thermoresponsive coatings are not functional for all types of cells. By coadsorbing charged nanoparticles and thermoresponsive microgels, it is demonstrated that the adhesion and detachment behaviour of cells on such coatings can be modulated.

Patterned Thermoresponsive Microgel Coatings for Noninvasive Processing of Adherent Cells.

Cultivation of adherently growing cells in artificial environments is of utmost importance in medicine and biotechnology to accomplish in vitro drug screening or to investigate disease mechanisms. Precise cell manipulation, like localized control over adhesion, is required to expand cells, to establish cell models for novel therapies and to perform noninvasive cell experiments. To this end, we developed a method of gentle, local lift-off of mammalian cells using polymer surfaces, which are reversibly and repeatedly switchable between a cell-attractive and a cell-repellent state. This property was introduced through micropatterned thermoresponsive polymer coatings formed from colloidal microgels. Patterning was obtained through automated nanodispensing or microcontact printing, making use of unspecific electrostatic interactions between microgels and substrates. This process is much more robust against ambient conditions than covalent coupling, thus lending itself to up-scaling. As an example, wound healing assays were accomplished at 37 °C with highly increased precision in microfluidic environments.