Microstructural characterization and mechanical properties of functionally graded PA12/HDPE parts by selective laser sintering

The use of selective laser sintering in the production of functional gradient materials offers advantages, as freeform construction and localized control of the composition and process parameters, compared to other rapid manufacturing processes. In this work, selective laser sintering was used for manufacturing three-dimensional parts in functionally graded polymer blends based on polyamide 12 and high-density polyethylene with gradient composition in two directions (Y and Z). Test specimens were prepared in PA12/HDPE ratios of 0/100, 20/80, 50/50, 80/20 and 100/0 (w/w). These specimens were assessed in terms of density, microstructure by scanning electron microscopy and polarized light microscopy and mechanical performance by DMA. The sintered binary blend systems with composition gradient showed microstructure and properties variation as function of the blend compositions. The results demonstrated the potential of selective laser sintering to manufacture advanced polymeric functional gradient material parts.     

Towards selective laser sintering of objects with customized mechanical properties based on ANFIS predictions

Recently, the adaptive network-based fuzzy inference system (ANFIS) has been used extensively in modeling of manufacturing processes to save both optimization time and manufacturing costs. ANFIS is a powerful iterative tool for optimizing non-linear and multivariable manufacturing operations. In the present study, ANFIS is used to predict the optimum manufacturing parameters in selective laser sintering (SLS) of cement-filled polyamide 12 (PA12) composite. For this purpose, a set of cement-filled PA12 test specimens is manufactured by SLS technique with 8 different values of laser power (4.5–8 Watt) and 8 different weight fractions of white cement (5 %–40 %). Mechanical characterization of cement-filled PA12 is carried out to evaluate the ultimate tensile strength (UTS), compressive strength, and flexural properties. The experimental data are then divided into two groups; one group for training the ANFIS model and the other group for checking the validity of the identified model. The built ANFIS model was validated experimentally and comparison with experimental results revealed mean relative errors of 2.92 %, 3.84 %, 4.75 %, and 3.31 % in the predictions of UTS, compressive strength, flexural modulus, and flexural yield strength, respectively.

     

激光选区烧结超高分子量聚乙烯工艺及性能

研究了激光选区烧结(SLS)成型工艺中不同工艺参数以及后续热处理工艺对超高分子量聚乙烯(UHMWPE)材料成型性能的影响。通过调整扫描间距、激光功率、扫描速度等不同工艺参数,描述了SLS成型UHMWPE零件的致密度、拉伸强度以及断裂伸长率,并对热处理前后的SLS成型UHMWPE零件的力学性能进行了比较。结果显示,致密度、拉伸强度、断裂伸长率总体上与激光功率呈正相关关系,与扫描间距、扫描速度呈负相关关系。经热处理后,SLS成型UHMWPE零件的力学性能有明显提高,致密度达到95.12%,抗拉强度达到24.08 MPa,断裂伸长率达到334.82 MPa。实验结果表明:SLS成型UHMWPE零件与模塑成型UHMWPE零件性能尚有差距,仅优化成型工艺不足以得到理想性能,但经热处理后,零件性能基本满足使用要求。     

Process optimization for PA12/MWCNT nanocomposite manufacturing by selective laser sintering

Nanocomposites produced through the addition of carbon nanotubes to a polymeric matrix can improve the material properties. The mobility of the polymer chains is usually affected, and this is also related to the properties. Parts produced with the free-form fabrication process using the selective laser sintering (SLS) technique can be used in different high-performance applications as they do not require expensive tools for their manufacture. A specific field of interest is the aerospace industry which is characterized by a low production volume and the need for materials with a high performance to weight ratio. In this study, the free-form fabrication by SLS of parts made from nanocomposites comprised of polyamide 12 and multiwalled carbon nanotubes (MWCNTs) was investigated. Specimens were manufactured by SLS to identify the appropriate processing parameters to achieve high mechanical properties for aerospace applications. Laser energy density was adjusted to improve the material density, flexural modulus, and stress at 10 % elongation. Design of experiments was used to identify and quantify the effects of various factors on the mechanical properties. The results obtained showed that there was a limit to the amount of MWCNTs which could be mixed with the polyamide powder to improve the mechanical properties since a higher content affected the laser sintering process.     

Performance of sinking EDM electrodes made by selective laser sintering technique

Electrical discharge machining (EDM) is a nonconventional machining process widely applied for the manufacture of intricate shapes in hard materials which are not easily machined by conventional machining processes. The production of geometrically complex EDM electrodes is difficult, time consuming, and it can account for about 50 % of the total process costs. Selective laser sintering (SLS) can be an alternative technique to produce EDM electrodes in a faster way. This work conducted an experimental study on the performance of EDM electrodes made by SLS using pure copper, bronze–nickel alloy, copper/bronze–nickel alloy, and steel alloy powders. Important EDM performance measures such as material removal rate and volumetric relative wear were investigated and discussed for finishing, semifinish, and roughing regimes. This work contributes with an insight into the production of EDM electrodes via selective laser sintering, as an alternative technique to conventional machining processes, as well as to evaluate the performance of the electrodes, and also provide directions for future research on this field.     

陶瓷粉末选择性激光烧结及聚合物纳米复合材料的研究现状及前景

介绍选择性激光烧结技术(SLS)的原理、特点。评述国内外选择性激光烧结普通陶瓷粉末、纳米陶瓷粉末及聚合物纳米复合材料的研究进展,并对以后的研究方向提出建议。     

Rough-cut fast numerical investigation of temperature fields in selective laser sintering/melting

The surface micro/nano-topographical modifications have been widely used in improving the biocompatibility of biomedical implants. In this paper, the feasibility of the micro-milling process for construction of micro-grooves without burrs on titanium alloy materials was investigated. Low melting point alloy was selected as supporting material to extend the boundary of the workpiece, so the burrs produced on the surface of supporting material. A novel hierarchical micro/nano-topography with micro-grooves and TiO₂ nanotubes was fabricated on titanium alloy surface combining micro-milling and anodic oxidation. The scanning electron microscope, energy-dispersive spectroscopy, laser scanning microscope, and contact angle tester were used in characterizing surface features of machined workpieces. Results showed that the micro-grooves with dimension of 40 μm in depth were machined using V-shaped cutting tool, and the TiO₂ nanotubes with dimension of 70 nm in diameter were superimposed on the surfaces of micro-grooves by anodic oxidation. In addition, the hydrophilicity of micro/nano-structured surface was significantly enhanced with the water contact angle decreasing from 114.8° to 60.3°. It is concluded that this hybrid method combining micro-milling technology and anodic oxidation can be used in improving the biological activity of biomedical implants through changing surface topographies.     

Fabrication of macroscopic solid models of three-dimensional microscopic data by selective laser sintering

We discuss and give examples of the use of selective laser sintering to fabricate solid macroscopic models of microscopic specimens that have been imaged with a confocal microscope. The digital image processing necessary to create structurally sound models of both translucent and opaque specimens is presented. The fabricated models offer the ultimate in data visualization since they can be physically handled and manipulated to investigate the shape and features of the specimen. Such a powerful visualization tool is useful in both research and educational environments.     

Effect of post-heat treatment on the microstructure and mechanical properties of laser metal deposition Inconel 718

Journal of Mechanical Science and Technology - The microstructure, hardness, and fracture strength of Inconel 718 fabricated with laser metal deposition are investigated. The solution treatment...     

Differences in microstructure and properties between selective laser melting and traditional manufacturing for fabrication of metal parts: A review

Selective laser melting (SLM), as one of the additive manufacturing technologies, is widely investigated to fabricate metal parts. In SLM, parts are manufactured directly from powders in a layer-by-layer fashion; SLM also provides several advantages, such as production of complex parts with high three-dimensional accuracy, compared with other additive manufacturing technologies. Therefore, SLM can be applied in aeronautics, astronautics, medicine, and die and mould industry. However, this technique differs from traditional methods, such as casting and forging; for instance, the former greatly differs in terms of microstructure and properties of products. This paper summarizes relevant studies on metal material fabrication through SLM. Based on a work completed in Huazhong Univ. Sci Tech., Rapid Manuf. Center (HUST-RMC) and compared with characteristics described in other reported studies, microstructure, properties, dimensional accuracy, and application of SLM are presented.     

316L不锈钢多孔结构的选区激光烧结成型工艺研究

研究了一种新型的制备金属多孔结构技术-选区激光烧结,着重说明该技术的基本原理和工艺过程,并利用此制备技术对316L不锈钢粉末进行了激光烧结制备多孔材料的实验研究.利用SEM分析了316L不锈钢多孔试样的微观孔隙特征,并测定其孔隙率.结果表明,在较高的扫描速率下可获得孔径分布均匀、孔隙贯通性良好的多孔结构;随扫描速率逐渐提高,试样孔隙率和弹性模量呈上升趋势.     

The effects of laser energy density and particle size in the selective laser sintering of polycaprolactone/progesterone specimens: morphology and drug release

The goals of this work were to fabricate specimens of different powder particle sizes and laser energy density of polycaprolactone and progesterone by selective laser sintering and evaluate the morphology by scanning electron microscopy and the mechanism of drug release in vitro. The results showed that the specimens maintained morphological uniformity, coalescence of particles, and interconnected pores distributed in the sintered structure. The drug release mechanism of all specimens studied followed a zero-order kinetics, and drug release rates were dependent on sintering degree and, consequently, on matrix erosion.     

选择性激光烧结激光能量密度与温度补偿规律研究

选择性激光烧结（SLS）成型预热温度从成型缸中间到缸壁呈降低趋势,由于预热温度不均匀,导致SLS成型件密度不均匀。针对这一问题,通过增加激光能量密度对预热温度不足进行了补偿。通过试验建立了激光能量密度差△E与预热温差△T的经验公式,并比较了温度补偿前后烧结件的机械强度。实验结果表明,通过增加激光能量密度对预热温度不足进行补偿,提高了产品机械强度。     

激光选区烧结成型材料的研究和应用现状

介绍激光快速成型的原理及SLS对材料性能的要求,概括激光选取烧结成形技术中各种材料的研究和应用现状,分析SLS技术产业化存在的问题及可能解决的途径。     

Selective laser sintering of hydroxyapatite reinforced polyethylene composites for bioactive implants and tissue scaffold development

Selective laser sintering (SLS) has been investigated for the production of bioactive implants and tissue scaffolds using composites of high-density polyethylene (HDPE) reinforced with hydroxyapatite (HA) with the aim of achieving the rapid manufacturing of customized implants. Single-layer and multilayer block specimens made of HA-HDPE composites with 30 and 40 vol % HA were sintered successfully using a CO2 laser sintering system. Laser power and scanning speed had a significant effect on the sintering behaviour. The degree of particle fusion and porosity were influenced by the laser processing parameters, hence control can be attained by varying these parameters. Moreover, the SLS processing allowed exposure of HA particles on the surface of the composites and thereby should provide bioactive products. Pores existed in the SLS-fabricated composite parts and at certain processing parameters a significant fraction of the pores were within the optimal sizes for tissue regeneration. The results indicate that the SLS technique has the potential not only to fabricate HA-HDPE composite products but also to produce appropriate features for their application as bioactive implants and tissue scaffolds.     

变能量激光选区熔化IN718镍基超合金的成形工艺及高温机械性能

开展了基于激光选区熔化技术对IN718镍基超合金直接激光熔化成形的研究。将零件分为心部与轮廓区,通过改变激光线输入量进行选区熔化研究。首先,建立熔池内烧结的数值模型,改变激光线输入量,获得了激光线输入量对零件致密度的影响规律并观察了成形体中的组织生长。然后,增加轮廓部位扫描,改变激光线输入量与扫描顺序,获得其对零件表面质量的影响规律。最后,通过优化热处理工艺提高零件高温拉伸强度和高温持久性能。试验结果表明,在激光线输入量为300J/m时,成形体致密度最高,为98.9%,成形体沿层间方向组织为树枝晶加等轴晶,在层内方向组织为等轴晶。采用心部+后轮廓扫描的方式,轮廓激光线输入量为100J/m时表面质量最优,粗糙度为3.1μm。对成形体采用1 065℃固溶+双时效的热处理可以获得最佳高温性能组合,高温拉伸强度为1 356MPa,高温持久时间为34h。结果显示,通过激光选区熔化制作IN718镍基超合金可以满足航空结构件对致密度、表面质量和高温性能要求。     

Tribological and mechanical properties of carbon nitride thin coating prepared by ion-beam-assisted deposition

Carbon nitride thin films may become good competitors for diamond-like carbon, due to their high hardness, high wear resistance, and low friction coefficient. At present, there are only a few studies of the effect of CN _x coating hardness and internal stress on its tribological properties, such as coating life and frictional behaviour. This work deals with tribological and mechanical properties of a carbon nitride coating prepared by ion-beam-assisted deposition (IBAD). Friction coefficients in the range of 0.10–0.12 were observed for the best CN _x coatings sliding against silicon nitride under ambient conditions. A nonlinear correlation between coating life and its internal stress and hardness was found.     

Investigation into the selective laser sintering of styrene–acrylonitrile copolymer and postprocessing

The amorphous polymer of polystyrene (PS) has been widely used in the selective laser sintering (SLS) process. However, PS is not suitable to make parts with thin-wall or delicate structures because of the poor mechanical properties of its SLS parts. Therefore, styrene–acrylonitrile copolymer (SAN), another kind of amorphous polymers, was investigated as an SLS material. The effects of laser energy density on the relative density, mechanical properties, and dimensional accuracy of the SLS parts were studied, and the properties of PS and SAN SLS parts were compared. The postprocessing method of infiltrating with epoxy resin was used to reinforce the green SAN SLS parts. The results show that there is little difference in the relative density between the SAN and PS SLS parts, while the flexural strength of the SAN SLS specimens is obviously higher than that of the PS SLS specimens at the same energy density. After the postprocessing, the flexural strength, flexural modulus, and impact strength of the SAN SLS specimens increase by 133%, 4394%, and 254%, respectively, and the SLS parts maintain relatively high-dimensional accuracy although slight shrinkage occurs due to epoxy resin cure. SAN can be used to fabricate SLS parts with more complex and delicate structures.     

Effects of heat input on microstructure and mechanical property of Al/Ti joints by rectangular spot laser welding-brazing method

A rectangular spot laser welding–brazing method was developed to join butted Ti/Al dissimilar alloys. In order to evaluate effects of heat input on mechanical property of the joints, microstructure of the joints were characterized. TiAl₃ intermetallic compounds (IMCs) were found at the joint interface in the case of low-heat input and TiAl₃, TiAl, Ti₅Si₃, and Ti₃Al IMCs were observed at high-heat input. Results of tensile test showed that the joints fracture in the fusion zone under the condition of low-heat input and in the interfacial reaction layer or the fusion zone with a mass of porosities at high-heat input. In addition, tensile strength of specimens broken at the fusion zone is higher obviously than that at the interface or the fusion zone with a mass of porosities, and tensile strength of the joints is up to 290 MPa.