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Fojtík F, Potrok R, Hajnyš J, Ma QP, Kudrna L, Měsíček J. Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser-Powder Bed Fusion Additive Manufacturing Technology. Materials (Basel) 2023; 16:5766. [PMID: 37687459 PMCID: PMC10488369 DOI: 10.3390/ma16175766] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/03/2023] [Revised: 08/11/2023] [Accepted: 08/21/2023] [Indexed: 09/10/2023]
Abstract
This study focuses on the experimental verification of residual stress (RS) in a 3D-printed braking pedal using the Powder Bed Fusion (PBF) method with SS316L material. The RS was measured at two representative locations using the hole drilling method (HDM) and the dividing method, which are semi-destructive and destructive methods of RS measurement, respectively. The finite element method (FEM) was used with Ansys Workbench 2020R2 and Simufact Additive 2021 software to determine the magnitude of RS. The results provide insights into how RS is incorporated into metal 3D-printed components and the available tools for predicting RS. This information is essential for experts to improve the accuracy and functionality of SLM parts when post-subtractive or additive manufacturing processes are used. Overall, this study contributes to the advancement of knowledge on the effects of RS on 3D-printed metal components, which can inform future research and development in this area.
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Affiliation(s)
- František Fojtík
- Department of Applied Mechanics, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic
| | - Roman Potrok
- Department of Applied Mechanics, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic
| | - Jiří Hajnyš
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic; (J.H.)
| | - Quoc-Phu Ma
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic; (J.H.)
| | - Lukáš Kudrna
- Department of Machine and Industrial Design, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic
| | - Jakub Měsíček
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic; (J.H.)
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Chepiga T, Zhilyaev P, Ryabov A, Simonov AP, Dubinin ON, Firsov DG, Kuzminova YO, Evlashin SA. Process Parameter Selection for Production of Stainless Steel 316L Using Efficient Multi-Objective Bayesian Optimization Algorithm. Materials (Basel) 2023; 16:1050. [PMID: 36770057 PMCID: PMC9919176 DOI: 10.3390/ma16031050] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 12/18/2022] [Revised: 01/13/2023] [Accepted: 01/20/2023] [Indexed: 06/18/2023]
Abstract
Additive manufacturing is a modern technique to produce parts with a complex geometry. However, the choice of the printing parameters is a time-consuming and costly process. In this study, the parameter optimization for the laser powder bed fusion process was investigated. Using state-of-the art multi-objective Bayesian optimization, the set of the most-promising process parameters (laser power, scanning speed, hatch distance, etc.), which would yield parts with the desired hardness and porosity, was established. The Gaussian process surrogate model was built on 57 empirical data points, and through efficient sampling in the design space, we were able to obtain three points in the Pareto front in just over six iterations. The produced parts had a hardness ranging from 224-235 HV and a porosity in the range of 0.2-0.37%. The trained model recommended using the following parameters for high-quality parts: 58 W, 257 mm/s, 45 µm, with a scan rotation angle of 131 degrees. The proposed methodology greatly reduces the number of experiments, thus saving time and resources. The candidate process parameters prescribed by the model were experimentally validated and tested.
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Affiliation(s)
- Timur Chepiga
- Skolkovo Institute of Science and Technology, 121205 Moscow, Russia
| | - Petr Zhilyaev
- Skolkovo Institute of Science and Technology, 121205 Moscow, Russia
| | - Alexander Ryabov
- Skolkovo Institute of Science and Technology, 121205 Moscow, Russia
| | | | - Oleg N. Dubinin
- Skolkovo Institute of Science and Technology, 121205 Moscow, Russia
- World-Class Research Center, State Marine Technical University, 190121 Saint Petersburg, Russia
| | - Denis G. Firsov
- Skolkovo Institute of Science and Technology, 121205 Moscow, Russia
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Kudrna L, Ma QP, Hajnys J, Mesicek J, Halama R, Fojtik F, Hornacek L. Restoration and Possible Upgrade of a Historical Motorcycle Part Using Powder Bed Fusion. Materials (Basel) 2022; 15:ma15041460. [PMID: 35207999 PMCID: PMC8879024 DOI: 10.3390/ma15041460] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 01/03/2022] [Revised: 02/10/2022] [Accepted: 02/14/2022] [Indexed: 02/01/2023]
Abstract
Reverse engineering is the process of creating a digital version of an existing part without any knowledge in advance about the design intent. Due to 3D printing, the reconstructed part can be rapidly fabricated for prototyping or even for practical usage. To showcase this combination, this study presents a workflow on how to restore a motorcycle braking pedal from material SS316L with the Powder Bed Fusion (PBF) technology. Firstly, the CAD model of the original braking pedal was created. Before the actual PBF printing, the braking pedal printing process was simulated to identify the possible imperfections. The printed braking pedal was then subjected to quality control in terms of the shape distortion from its CAD counterpart and strength assessments, conducted both numerically and physically. As a result, the exterior shape of the braking pedal was restored. Additionally, by means of material assessments and physical tests, it was able to prove that the restored pedal was fully functional. Finally, an approach was proposed to optimize the braking pedal with a lattice structure to utilize the advantages the PBF technology offers.
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Affiliation(s)
- Lukas Kudrna
- Department of Machine and Industrial Design, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic;
| | - Quoc-Phu Ma
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic; (J.H.); (J.M.)
- Correspondence: ; Tel.: +420-607-326-979
| | - Jiri Hajnys
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic; (J.H.); (J.M.)
| | - Jakub Mesicek
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic; (J.H.); (J.M.)
| | - Radim Halama
- Department of Applied Mechanics, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic; (R.H.); (F.F.)
| | - Frantisek Fojtik
- Department of Applied Mechanics, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic; (R.H.); (F.F.)
| | - Lukas Hornacek
- HORIBA Czech Olomouc Factory, Zeleznicni 512/7, 772 00 Olomouc, Czech Republic;
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Ur Rehman A, Pitir F, Salamci MU. Full-Field Mapping and Flow Quantification of Melt Pool Dynamics in Laser Powder Bed Fusion of SS316L. Materials (Basel) 2021; 14:6264. [PMID: 34771790 DOI: 10.3390/ma14216264] [Citation(s) in RCA: 10] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/01/2021] [Revised: 10/07/2021] [Accepted: 10/13/2021] [Indexed: 11/26/2022]
Abstract
Laser powder bed fusion (LPBF) has a wide range of uses in high-tech industries, including the aerospace and biomedical fields. For LPBF, the flow of molten metal is crucial; until now, however, the flow in the melt pool has not been described thoroughly in 3D. Here, we provide full-field mapping and flow measurement of melt pool dynamics in laser powder bed fusion, through a high-fidelity numerical model using the finite volume method. The influence of Marangoni flow, evaporation, as well as recoil pressure have been included in the model. Single-track experiments were conducted for validation. The temperature profiles at different power and speed parameters were simulated, and results were compared with experimental temperature recordings. The flow dynamics in a single track were exposed. The numerical and experimental findings revealed that even in the same melting track, the melt pool’s height and width can vary due to the strong Marangoni force. The model showed that the variation in density and volume for the same melting track was one of the critical reasons for defects. The acquired findings shed important light on laser additive manufacturing processes and pave the way for the development of robust, computational models with a high degree of reliability.
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Hossain U, Ghouse S, Nai K, Jeffers JR. Mechanical and morphological properties of additively manufactured SS316L and Ti6Al4V micro-struts as a function of build angle. Addit Manuf 2021; 46:None. [PMID: 34603974 PMCID: PMC8448581 DOI: 10.1016/j.addma.2021.102050] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/26/2020] [Revised: 05/05/2021] [Accepted: 05/10/2021] [Indexed: 06/13/2023]
Abstract
Additive manufacturing methods such as laser powder bed fusion (PBF) can produce micro-lattice structures which consist of 'micro-struts', which have properties that differ from the bulk metal and that can vary depending on the orientation of the strut to the build direction (the strut build angle). Characterizing these mechanical and morphological changes would help explain macro-scale lattice behavior. Individual stainless steel (SS316L) and titanium alloy (Ti6Al4V) laser PBF struts were built at 20°, 40°, 70° and 90° to the build platform, with 3 designed diameters and tested in uniaxial tension (n = 5). Micro-CT was used to quantify changes in surface roughness, eccentricity and cross-section. Average elastic modulus was 61.5 GPa and 37.5 GPa for SS316L and Ti6Al4V respectively, less than the bulk material. Yield strength was uniform over build angle for SS316L, but for Ti6Al4V varied from 40% to 98% of the bulk value from 20° to 90° build angles. All lower angle struts had worse morphology, with higher roughness and less circular cross-sections. These data should help inform micro-lattice design, especially in safety critical applications where lower mechanical performance must be compensated for.
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Affiliation(s)
- Umar Hossain
- Department of Mechanical Engineering, Imperial College London, South Kensington, London SW7 2AZ, UK
| | - Shaaz Ghouse
- Department of Mechanical Engineering, Imperial College London, South Kensington, London SW7 2AZ, UK
| | - Kenneth Nai
- Renishaw PLC, New Mills, Wotton-under-Edge, Gloucestershire GL12 8JR, UK
| | - Jonathan R.T. Jeffers
- Department of Mechanical Engineering, Imperial College London, South Kensington, London SW7 2AZ, UK
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Branquinho MV, Ferreira SO, Alvites RD, Magueta AF, Ivanov M, Sousa AC, Amorim I, Faria F, Fernandes MHV, Vilarinho PM, Maurício AC. In Vitro and In Vivo Characterization of PLLA-316L Stainless Steel Electromechanical Devices for Bone Tissue Engineering-A Preliminary Study. Int J Mol Sci 2021; 22:7655. [PMID: 34299274 DOI: 10.3390/ijms22147655] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/27/2021] [Revised: 07/13/2021] [Accepted: 07/14/2021] [Indexed: 12/22/2022] Open
Abstract
Bone injuries represent a major social and financial impairment, commonly requiring surgical intervention due to a limited healing capacity of the tissue, particularly regarding critical-sized defects and non-union fractures. Regenerative medicine with the application of bone implants has been developing in the past decades towards the manufacturing of appropriate devices. This work intended to evaluate medical 316L stainless steel (SS)-based devices covered by a polymer poly (L-lactic acid) (PLLA) coating for bone lesion mechanical and functional support. SS316L devices were subjected to a previously described silanization process, following a three-layer PLLA film coating. Devices were further characterized and evaluated towards their cytocompatibility and osteogenic potential using human dental pulp stem cells, and biocompatibility via subcutaneous implantation in a rat animal model. Results demonstrated PLLA-SS316L devices to present superior in vitro and in vivo outcomes and suggested the PLLA coating to provide osteo-inductive properties to the device. Overall, this work represents a preliminary study on PLLA-SS316L devices' potential towards bone tissue regenerative techniques, showing promising outcomes for bone lesion support.
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Mohammadtaheri M, Li Y, Yang Q. Hard Cr 2O 3 coatings on SS316L substrates prepared by reactive magnetron sputtering technique: a potential candidate for orthopedic implants. Environ Sci Pollut Res Int 2021; 28:25146-25154. [PMID: 31001781 DOI: 10.1007/s11356-019-05006-3] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/22/2018] [Accepted: 03/26/2019] [Indexed: 06/09/2023]
Abstract
316L stainless steel (SS) implants suffer from tribological and biocompatibility problems which limit their service lifetime. In order to improve the surface properties of 316L SS for orthopedic implant applications, hard chromium oxide coatings were applied on 316L SS substrates using a reactive magnetron sputtering technique. The morphological, structural, and phase compositional analyses were conducted on the deposited coatings by scanning electron microscopy, X-ray diffraction, Raman spectroscopy, and X-ray photoelectron spectroscopy. The Rockwell-C indentation tests were performed on the coated substrates to qualitatively evaluate the adhesion of coatings on the steel substrates. The surface characteristics of coatings were measured by using an optical profilometer. The mechanical properties of coatings were reported by measuring the Hardness and Young's modulus. The corrosion resistance of coated and uncoated SS substrates was compared using potentiodynamic polarization tests. An inductively coupled plasma optical emission spectrometry (ICP-OES) was employed to analyze the biocompatibility of the samples by measuring the amount of toxic Cr ions released after the immersion test. The results show that the coatings are adherent and composed of a single Cr2O3 phase with a hardness of 25 to 29 GPa. The corrosion resistance of the SS has been improved by applying a chromium oxide coating. The coated SS samples have also demonstrated better wear resistance and lower friction coefficient compared to bare SS samples under a reciprocating sliding condition in saline solution. The biocompatibility of the SS has been enhanced by the Cr2O3 coating as much less Cr ions were released after immersion tests. These results indicate that the hard Cr2O3 coatings can be considered as a candidate for extending the lifetime of SS implants.
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Affiliation(s)
- Masoud Mohammadtaheri
- Department of Mechanical Engineering, University of Saskatchewan, 57 Campus Drive, Saskatoon, SK, S7H 5A9, Canada
| | - Yuanshi Li
- Department of Mechanical Engineering, University of Saskatchewan, 57 Campus Drive, Saskatoon, SK, S7H 5A9, Canada
| | - Qiaoqin Yang
- Department of Mechanical Engineering, University of Saskatchewan, 57 Campus Drive, Saskatoon, SK, S7H 5A9, Canada.
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