Designing high-temperature oxidation-resistant titanium matrix composites via directed energy deposition-based additive manufacturing.

Composite material development via laser-based additive manufacturing offers many exciting advantages to manufacturers; however, a significant challenge exists in our understanding of process-property relationships for these novel materials. Herein we investigate the effect of input processing parameters towards designing an oxidation-resistant titanium matrix composite. By adjusting the linear input energy density, a composite feedstock of titanium-boron carbide-boron nitride (5 wt% overall reinforcement) resulted in a highly reinforced microstructure composed of borides and carbides and nitrides, with variable properties depending on the overall input energy.

Nature-inspired materials and structures using 3D Printing.

Emulating the unique combination of structural, compositional, and functional gradation in natural materials is exceptionally challenging. Many natural structures have proved too complex or expensive to imitate using traditional processing techniques despite recent advances. Recent innovations within the field of additive manufacturing (AM) or 3D Printing (3DP) have shown the ability to create structures that have variations in material composition, structure, and performance, providing a new design-for-manufacturing platform for the imitation of natural materials.

Understanding wear behavior of 3D-Printed calcium phosphate-reinforced CoCrMo in biologically relevant media.

Recent advances in the processing of wear-resistant calcium-phosphate reinforced CoCrMo composites for articulating surface applications has necessitated further investigation of performance in biological conditions relevant to patient applications. To this end, CoCrMo composites containing calcium phosphate in the form of hydroxyapatite (HA) were manufactured to study the influence of the reinforcing phase on the tribofilm formation in biologically-relevant conditions. The CoCrMo-HA composites were processed using a laser engineered net shaping (LENS™) additive manufacturing (AM) system with three distinctive compositions: CoCrMo-0%HA, CoCrMo-1%HA, and CoCrMo-3%HA.

Mechanical properties of additively manufactured variable lattice structures of Ti6Al4V.

Engineered micro- and macro-structures via additive manufacturing (AM) or 3D-Printing can create structurally varying properties in part, which is difficult via traditional manufacturing methods. Herein we have utilized powder bed fusion-based selective laser melting (SLM) to fabricate variable lattice structures of Ti6Al4V with uniquely designed unit cell configurations to alter the mechanical performance. Five different configurations were designed based on two natural crystal structures - hexagonal closed packed (HCP) and body-centered cubic (BCC).

Diamond-reinforced cutting tools using laser-based additive manufacturing.

Production-volume and cost requirements currently limit machine tool manufacturers' ability to produce application-specific tooling with traditional methods, motivating the development of innovative manufacturing technologies. To this end, we detail a manufacturing framework for the design and production of application-specific cutting tools based on industry standard tungsten carbide-cobalt (WC-Co)-based "carbide" cutting materials using additive manufacturing (AM). Herein, novel diamond-reinforced carbide structures were designed and manufactured via AM and subsequently tested in comparison to current commercial products that are traditionally-processed.

Influence of in situ ceramic reinforcement towards tailoring titanium matrix composites using laser-based additive manufacturing.

Increasing performance requirements of advanced components demands versatile fabrication techniques to meet application-specific needs. Composite material processing via laser-based additive manufacturing offers high processing-flexibility and limited tooling requirements to meet this need, but limited information exists on the processing-property relationships for these materials as well as how to exploit it for application-specific needs. In this study, Ti/BC+BN composites are developed for high-temperature applications by designed-incorporation of ceramic reinforcement (5 wt% total) into commercially-pure titanium to form combined particle and reinforcing phases.

Influence of deposition orientation on fatigue response of LENS™ processed Ti6Al4V.

Understanding processing-property relationships for directed-energy-deposition (DED) parts remains a major roadblock to widespread process implementation. Herein we investigate the effect of scanning-strategy and testing-orientation on the fatigue response of as-printed Ti6Al4V components. At ~10 cycles, samples tested in the build-direction exhibited ~ 45% decrease in fatigue strength relative to the horizontally-tested samples, owing to higher overall porosity and the testing orientation relative to residual pores.

Naturally architected microstructures in structural materials via additive manufacturing.

Despite recent advances in our understanding of the unique mechanical behavior of natural structural materials such as nacre and human bone, traditional manufacturing strategies limit our ability to mimic such nature-inspired structures using existing structural materials and manufacturing processes. To this end, we introduce a customizable single-step approach for additively fabricating geometrically-free metallic-based structural composites showing directionally-tailored, location-specific properties. To exemplify this capability, we present a layered metal-ceramic composite not previously reported exhibiting significant directional and site-specific dependence of properties along with crack arrest ability difficult to achieve using traditional manufacturing approaches.

Clinical significance of three-dimensional printed biomaterials and biomedical devices.

Three-dimensional printing (3DP) is becoming a standard manufacturing practice for a variety of biomaterials and biomedical devices. This layer-by-layer methodology provides the ability to fabricate parts from computer-aided design files without the need for part-specific tooling. Three-dimensional printed medical components have transformed the field of medicine through on-demand patient care with specialized treatment such as local, strategically timed drug delivery, and replacement of once-functioning body parts.

Invited Review Article: Metal-additive manufacturing - Modeling strategies for application-optimized designs.

Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge-limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques.