Mechanical and Catalytic Degradation Properties of Porous FeMnCoCr High-Entropy Alloy Structures Fabricated by Selective Laser Melting Additive Manufacturing.

This work investigated the mechanical and catalytic degradation properties of FeMnCoCr-based high-entropy alloys (HEAs) with diverse compositions and porous structures fabricated via selective laser melting (SLM) additive manufacturing for wastewater treatment applications. The effects of Mn content (0, 30 at%, and 50 at%) and topological structures (gyroid, diamond, and sea urchin-inspired shell) on the compression properties and catalytic efficiency of the FeMnCoCr HEAs were discussed. The results indicated that an increase in the Mn content led to a phase structure transition that optimized mechanical properties and catalytic activities.

Recent Progress on 3D Printing of Lightweight Metal Thin-Walled Structures.

Metal thin-walled structures are ubiquitous in various industrial applications and fabricating them through additive manufacturing (AM) enables intricate thin-wall geometries with no assembly required. However, additively manufactured metal thin walls suffer from increased heat accumulation and reduced structural stability, making it difficult to print geometrically accurate thin walls with minimal distortion and defects. Thin-walled structures also experience different thermal histories and solidification conditions compared to bulk structures, leading to drastic differences in the microstructure and mechanical properties.

Manipulating Stacking Fault Energy to Achieve Crack Inhibition and Superior Strength-Ductility Synergy in an Additively Manufactured High-Entropy Alloy.

Additive manufacturing (AM) is a revolutionary technology that heralds a new era in metal processing, yet the quality of AM-produced parts is inevitably compromised by cracking induced by severe residual stress. In this study, a novel approach is presented to inhibit cracks and enhance the mechanical performances of AM-produced alloys by manipulating stacking fault energy (SFE). A high-entropy alloy (HEA) based on an equimolar FeCoCrNi composition is selected as the prototype material due to the presence of microcracks during laser powder bed fusion (LPBF) AM process.

The Printability, Microstructure, and Mechanical Properties of FeMnCoCr High-Entropy Alloys Fabricated by Laser Powder Bed Fusion Additive Manufacturing.

This work investigated the effect of Fe/Mn ratio on the microstructure and mechanical properties of non-equimolar FeMnCoCr ( = 30% and 50%) high-entropy alloys (HEAs) fabricated by laser powder bed fusion (LPBF) additive manufacturing. Process optimization was conducted to achieve fully dense FeMnCoCr and FeMnCoCr HEAs using a volumetric energy density of 105.82 J·mm.

Process Optimization and Tailored Mechanical Properties of a Nuclear Zr-4 Alloy Fabricated via Laser Powder Bed Fusion.

A nuclear Zr-4 alloy with a near full density was fabricated via laser powder bed fusion (LPBF). The influences of process parameters on the printability, surface roughness, and mechanical properties of the LPBF-printed Zr-4 alloy were investigated. The results showed that the relative density of the Zr-4 alloy samples was greater than 99.

Corrosion fatigue behavior and anti-fatigue mechanisms of an additively manufactured biodegradable zinc-magnesium gyroid scaffold.

Additively manufactured biodegradable zinc (Zn) alloy scaffolds constitute an important branch in orthopedic implants because of their moderate degradation behavior and bone-mimicking mechanical properties. This work investigated the corrosion fatigue response of a zinc-magnesium (Zn-Mg) alloy gyroid scaffold fabricated via laser-powder-bed-fusion additive manufacturing at the first time. The high-cycle compression-compression fatigue testing of the printed Zn-Mg scaffold was conducted in simulated body fluid, showing its favorable fatigue strength, structural reliability, and anti-fatigue capability.

Microstructure and Superior Corrosion Resistance of an In-Situ Synthesized NiTi-Based Intermetallic Coating via Laser Melting Deposition.

A nickel-titanium (NiTi)-based intermetallic coating was in-situ synthesized on a Ti-6Al-4V (TC4) substrate via laser melting deposition (LMD) using Ni-20Cr and TC4 powders. Scanning electron microscopy, X-ray diffraction, a digital microhardness tester and an electrochemical analyzer were used to evaluate the microstructure, Vicker's microhardness and electrochemical corrosion resistance of the intermetallic coating. Results indicate that the microstructure of the intermetallic coating is composed of NiTi, NiTi and NiTi.

Densification, Tailored Microstructure, and Mechanical Properties of Selective Laser Melted Ti-6Al-4V Alloy via Annealing Heat Treatment.

This work investigated the influence of process parameters on the densification, microstructure, and mechanical properties of a Ti-6Al-4V alloy printed by selective laser melting (SLM), followed by annealing heat treatment. In particular, the evolution mechanisms of the microstructure and mechanical properties of the printed alloy with respect to the annealing temperature near the β phase transition temperature were investigated. The process parameter optimization of SLM can lead to the densification of the printed Ti-6Al-4V alloy with a relative density of 99.

Insights into unit cell size effect on mechanical responses and energy absorption capability of titanium graded porous structures manufactured by laser powder bed fusion.

Schwartz diamond graded porous structures (SDGPSs), constructed by a triply-periodic-minimal-surface diamond unit cell topology, were developed with various unit cell sizes and printed by laser powder bed fusion (LPBF) from a commercially pure titanium powder for bone implant applications. The effect of unit cell size on the printability, strut dimensions, stress and strain distributions, mechanical properties and energy absorption capability of SDGPSs was investigated. The results indicate the good printability of SDGPSs via LPBF with multiple unit cell sizes from 3.

Recent Advances on High-Entropy Alloys for 3D Printing.

Boosted by the success of high-entropy alloys (HEAs) manufactured by conventional processes in various applications, the development of HEAs for 3D printing has been advancing rapidly in recent years. 3D printing of HEAs gives rise to a great potential for manufacturing geometrically complex HEA products with desirable performances, thereby inspiring their increased appearance in industrial applications. Herein, a comprehensive review of the recent achievements of 3D printing of HEAs is provided, in the aspects of their powder development, printing processes, microstructures, properties, and potential applications.

In situ fabrication of a titanium-niobium alloy with tailored microstructures, enhanced mechanical properties and biocompatibility by using selective laser melting.

A titanium-niobium (Ti-Nb) alloy with tailored microstructures, enhanced mechanical properties and biocompatibility was in situ fabricated by selective laser melting (SLM) using a blended powder with 25 wt.% Nb content. The effect of laser energy density from 70 J/mm to 110 J/mm on the phase transformation, microstructure, and mechanical properties of the SLM-printed Ti-25Nb alloy was investigated.

Effect of pore geometry on the fatigue properties and cell affinity of porous titanium scaffolds fabricated by selective laser melting.

Porous titanium scaffolds with different unit cell type (tetrahedron and octahedron) and pore size (500 µm and 1000 µm) were fabricated by selective laser melting (SLM), and the effects of unit cell type and pore size on their fatigue properties and cell affinity were studied. The fatigue properties were performed by static and dynamic mechanical testing, while the cell affinity was evaluated in vitro with mouse osteoblast cells. It was found that octahedron scaffolds exhibited superior static mechanical properties, longer fatigue lives and higher fatigue strength in comparison to those of tetrahedron ones.

Continuous functionally graded porous titanium scaffolds manufactured by selective laser melting for bone implants.

A significant requirement for a bone implant is to replicate the functional gradient across the bone to mimic the localization change in stiffness. In this work, continuous functionally graded porous scaffolds (FGPSs) based on the Schwartz diamond unit cell with a wide range of graded volume fraction were manufactured by selective laser melting (SLM). The micro-topology, strut dimension characterization and effect of graded volume fraction on the mechanical properties of SLM-processed FGPSs were systematically investigated.

Electrophoretic Deposition of Gentamicin-Loaded Silk Fibroin Coatings on 3D-Printed Porous Cobalt-Chromium-Molybdenum Bone Substitutes to Prevent Orthopedic Implant Infections.

In addition to customizing shapes of metal bone substitutes for patients, the 3D printing technique can reduce the modulus of the substitutes through the design and manufacture of interconnected porous structures, achieving the modulus match between substitute and surrounding bone to improve implant longevity. However, the porous bone substitutes take more risks of postoperative infection due to its much larger surface area compared with the traditional casting solid bone substitute. Here, we prepared of gentamicin-loaded silk fibroin coatings on 3D-printed porous cobalt-chromium-molybdenum (CoCrMo) bone substitutes via electrophoretic deposition technique.

Microstructure and property evolutions of titanium/nano-hydroxyapatite composites in-situ prepared by selective laser melting.

Titanium (Ti)-hydroxyapatite (HA) composites have the potential for orthopedic applications due to their favorable mechanical properties, excellent biocompatibility and bioactivity. In this work, the pure Ti and nano-scale HA (Ti-nHA) composites were in-situ prepared by selective laser melting (SLM) for the first time. The phase, microstructure, surface characteristic and mechanical properties of the SLM-processed Ti-nHA composites were studied by X-ray diffraction, transmission electron microscope, atomic force microscope and tensile tests, respectively.

Electrophoretic deposition of chitosan/gelatin coatings with controlled porous surface topography to enhance initial osteoblast adhesive responses.

Electrophoretically deposited (EPD) coatings have often been employed recently for the addition of different new chemical compositions to classic chitosan coatings to improve the biocompatibility and therapeutic potential of coated implants. However, little attention has been paid to enhance the cell response to EPD coatings via integrating the effects of chemical components and surface topography. Here, we fabricated EPD chitosan/gelatin (CS/G) coatings with controlled porous surface topography by controlling bubble generation in the EPD process via changing the gelatin content in solution from 0, 0.

Porous niobium coatings fabricated with selective laser melting on titanium substrates: Preparation, characterization, and cell behavior.

Nb, an expensive and refractory element with good wear resistance and biocompatibility, is gaining more attention as a new metallic biomaterial. However, the high price of the raw material, as well as the high manufacturing costs because of Nb's strong oxygen affinity and high melting point have limited the widespread use of Nb and its compounds. To overcome these disadvantages, porous Nb coatings of various thicknesses were fabricated on Ti substrate via selective laser melting (SLM), which is a 3D printing technique that uses computer-controlled high-power laser to melt the metal.