TENSILE BEHAVIOUR OF TI6AL4V LATTICE STRUCTURES PRODUCED BY LASER POWDER BED FUSION AND DESIGN CRITERIA

Öz

Although additive manufacturing (AM) technology has many advantages in manufacturing complex geometries, it is not always possible to have desired results and performance due to its inherent limitations. This situation becomes crucial in manufacturing of lattice structures that are commonly used in aerospace, biomedical, etc. areas. The lattice structure design is easier with AM technologies, therefore process and lattice parameters must be carefully reviewed especially on biomedical properties. Titanium alloys are widely used for additive manufacturing of those implants with laser powder bed fusion (LPBF) technology. By doing so, we are able to achieve porous, lightweight and durable bone implants that aim to reflect bone properties. Due to these benefits of lattice structures and their ease of design, many studies focus on lattice structures, but their design, manufacturing and implementation features have not been completely deduced. As such, lattice topology and design may affect mechanical properties of the parts and manufacturing quality. In this aspect, three different strut-based lattice topologies (octahedron, dodecahedron and star), as potential bone implant structures were selected and tensile test specimens accommodating these topologies were manufactured with Ti6Al4V powder using laser powder bed fusion (LPBF). All the manufactured specimens were subjected to tensile tests and the results were reported.

Anahtar Kelimeler

• Additive Manufacturing
• Lattice Structures
• Laser Powder Bed Fusion
• Ti6Al4V
• Tensile Test
• Orthopedic Bone Implants

Kaynakça

1. 1. Distefano, F., Pasta, S., Epasto, G., “Titanium Lattice Structures Produced via Additive Manufacturing for a Bone Scaffold: A Review”, Journal of Functional Biomaterials, Vol. 14, Issue 3, Pages 125, 2023. 2. McGaffey, M., Zur Linden, A., Bachynski, N., Oblak, M., James, F., Weese, JS., “Manual polishing of 3D printed metals produced by laser powder bed fusion reduces biofilm formation”, PloS one, Vol. 14, Issue 2 Pages e0212995, 2019.
2. 3. Gao, M., He, D., Wu, X., Tan, Z., Guo, X., “Design, Preparation, and Mechanical Property Investigation of Ti–Ta 3D‐Auxetic Structure by Laser Powder Bed Fusion”, Advanced Engineering Materials, Vol. 25, Issue 16, Pages 2300242, 2023.
3. 4. Zhang, Y., Aiyiti, W., Du, S., Jia, R., Jiang, H., “Design and mechanical behaviours of a novel tantalum lattice structure fabricated by SLM”, Virtual and Physical Prototyping, Vol. 18, Issue 1, Pages e2192702, 2023.
4. 5. Gan, M., Wu, Q., Long, L., “Prediction of Residual Deformation and Stress of Laser Powder Bed Fusion Manufactured Ti-6Al-4V Lattice Structures Based on Inherent Strain Method”, Materials Research, Vol. 26, Pages e20220516, 2023.
5. 6. Pugliese, R., Graziosi, S., “Biomimetic scaffolds using triply periodic minimal surface-based porous structures for biomedical applications”, SLAS technology, Vol. 28, Issue 3, Pages 165-182, 2023.
6. 7. Maconachie, T., Leary, M., Lozanovski, Z., Zhang, X., Qian, M., Faruque, O., Brandt, M., “SLM lattice structures: Properties, performance, applications and challenges”, Materials & Design, Vol. 183, Pages 108137., 2019.
7. 8. Korkmaz, ME., Gupta, MK., Robak, G., Moj, K., Krolczyk, GM., Kuntoğlu, M., “Development of lattice structure with selective laser melting process: A state of the art on properties, future trends and challenges”, Journal of Manufacturing Processes, Vol. 81, Pages 1040-1063, 2019.
8. 9. Zargarian, A., Esfahanian, M., Kadkhodapour, J., Ziaei-Rad, S., Zamani, D., “On the fatigue behavior of additive manufactured lattice structures”, Theoretical and Applied Fracture Mechanics, Vol. 100, Pages 225-232, 2019.

9. 10. Nalli, F., Cortese, L., Concli, F., “Ductile damage assessment of Ti6Al4V, 17-4PH and AlSi10Mg for additive manufacturing”, Engineering Fracture Mechanics, Vol. 241, Pages 107395, 2021. 11. Manvendra, T., Kumar, P., “Fracture Performance Evaluation of Additively Manufactured Titanium Alloy”, Advanced Materials for Biomechanical Applications, Pages 215-227, CRC Press, UK, 2022.
10. 12. Naghavi, SA., Tamaddon, M., Garcia-Souto, P., Moazen, M., Taylor, S., Hua, J., Liu, C., “A novel hybrid design and modelling of a customised graded Ti-6Al-4V porous hip implant to reduce stress-shielding: An experimental and numerical analysis”, Frontiers in Bioengineering and Biotechnology, Vol. 11, Pages 1092361, 2023.
11. 13. Khorasani, A., Gibson, I., Awan, US., Ghaderi, A., “The effect of SLM process parameters on density, hardness, tensile strength and surface quality of Ti-6Al-4V”, Additive manufacturing, Vol. 25, pages 176-186.
12. 14. Khorasani, AM., Gibson, I., Ghaderi, A., Mohammed, MI., “Investigation on the effect of heat treatment and process parameters on the tensile behaviour of SLM Ti-6Al-4V parts”, The International Journal of Advanced Manufacturing Technology, Vol. 101, Pages 3183-3197, 2019.
13. 15. Liu, F., Zhou, T., Zhang, T., Xie, H., Tang, Y., Zhang, P., “Shell offset enhances mechanical and energy absorption properties of SLM-made lattices with controllable separated voids”, Materials & Design Vol. 217, Pages 110630, 2022.
14. 16. Fry, AT., Crocker, LE., Lodeiro, MJ., Poole, M., Woolliams, P., Koko, A., et al., “Tensile property measurement of lattice structures”, NPL Report Mat., Pages 119, 2023.
15. 17. Tekerek, E., Perumal, V., Jacquemetton, L., Beckett, D., Halliday, HS., Wisner, B., Kontsos, A., “On the process of designing material qualification type specimens manufactured using laser powder bed fusion”. Materials & Design Vol. 229, Pages 111893, 2023.
16. 18. Dingye, Y., Weixing, Z., Yuli, M., Bo, H., “Numerical Prediction and Experimental Analysis of the Anisotropy of Laser Powder Bed Fusion Produced Ti-6Al-4V Body-Centered Cubic Lattice Structure”, Journal of Materials Engineering and Performance, Vol. 32, Issue 7, Pages 2963-2972, 2023.
17. 19. Ananda, V., Saravana, KG., Jayaganthan, R., Srinivasan, B., “Distortion Prediction in Inconel-718 Part Fabricated through LPBF by Using Homogenized Support Properties from Experiments and Numerical Simulation”, Materials, Vol. 15, Issue 17, Pages 5909, 2023.
18. 20. Yang, X., Ma, W., Gu, W., Zhang, Z., Wang, B., Wang, Y., Liu, S., “Multi-scale microstructure high-strength titanium alloy lattice structure manufactured via selective laser melting” RSC advances Vol. 11, Issue 37, Pages 22734-22743, 2021.
19. 21. Asherloo, M., Wu, Z., Delpazir, MH., Ghebreiesus, E., Fryzlewicz, S., Jiang, R., et al., “Laser-beam powder bed fusion of cost-effective non-spherical hydride-dehydride Ti-6Al-4V alloy”, Additive Manufacturing, Vol. 56, Pages 102875, 2022.
20. 22. EOS Gmbh, EOS Titanium Ti64 data sheet. http://www.eos.info/. Accessed 7 August 2023.
21. 23. Zhang, S., Chertmanova, S., Chou, K., “Surrogate Pore Generations in L-PBF Ti64 and Effects on Mechanical Behavior”, International Manufacturing Science and Engineering Conference, Pages 84256, Cincinnati, 2020.
22. 24. Rauniyar, SK., Chou, K., “Porosity analysis and pore tracking of metal AM tensile specimen by Micro-CT”, 2019 International Solid Freeform Fabrication Symposium, Austin, 2019.
23. 25. Zhang, S., Rauniyar, S., Shrestha, S., Ward, A., Chou, K., “An experimental study of tensile property variability in selective laser meltin”, Journal of Manufacturing Processes, Vol. 43, Pages 26-35, 2019.
24. 26. Jiang, J., Xu, X., Stringer, J., “Support structures for additive manufacturing: a review”, Journal of Manufacturing and Materials Processing, Vol. 2, Issue 4, Pages 64, 2018.
25. 27. Wang, Z., Tang, SY., Scudino, S., Ivanov, YP., Qu, RT., Wang, D., et al., “Additive manufacturing of a martensitic Co–Cr–Mo alloy: Towards circumventing the strength–ductility trade-off”, Additive Manufacturing, Vol. 37, Pages 101725, 2020.
26. 28. Luo, JP., Huang, YJ., Xu, JY., Sun, JF., Dargusch, MS., Hou, CH., et al., “Additively manufactured biomedical Ti-Nb-Ta-Zr lattices with tunable Young's modulus: mechanical property, biocompatibility, and proteomics analysis”, Materials Science and Engineering: C, Vol. 114, Pages 110903, 2020.
27. 29. Mutlu, B., “Tensile testing of square structure built with electron beam melting”, Revista de Metalurgia, Vol. 57, Issue 3, Pages e200, 2021.
28. 30. Soro, N., Brodie, EG., Abdal-hay, A., Alali, AQ., Kent, D., Dargusch, MS., “Additive manufacturing of biomimetic Titanium-Tantalum lattices for biomedical implant applications”, Materials & Design, Vol. 218, Pages 110688, 2022.
29. 31. Milazzo, M., Contessi Negrini, N., Scialla, S., Marelli, B., Farè, S., Danti, S., Buehler, M. J. “Additive manufacturing approaches for hydroxyapatite‐reinforced composites”, Advanced Functional Materials, Vol. 29, Issue 35, 1903055, 2019.
30. 32. Li, Z., Wu, H., Liu, B., Wen, H., Li, H., Shi, J., Tang, X., “Interfacial microstructure and mechanical properties of forging and SLM hybrid manufacturing Ti-6Al-4V parts”, Materials Letters Vol. 339, Pages 134101., 2023. 33. Xu, S., Liu, H., Zhang, J., Cai, X., Si, C., “Effect of Heat Treatment Temperature and Cooling Rate on Microstructure and Tensile Properties of Selective Laser Melted Ti-6al-4v Alloy”, Available at SSRN 4493087, 2023.
31. 34. Ge, J., Huang, Q., Wang, Y., Zhang, C., Liu, Q., Lu, Z., Yin, S., “Microstructural optimization and mechanical enhancement of SLM Ti6Al4V TPMS scaffolds through vacuum annealing treatment”, Journal of Alloys and Compounds, Vol. 934, Pages 167524,2022.