Metal components with applications across a range of industrial sectors can be manufactured by selective laser melting (SLM). A particular strength of SLM is its ability to manufacture components incorporating periodic lattice structures not realisable by conventional manufacturing processes. This enables the production of advanced, functionally graded, components. However, for these designs to be successful, the relationships between lattice geometry and performance must be established. We do so here by examining the mechanical behaviour of uniform and graded density SLM Al-Si10-Mg lattices under quasistatic loading. As-built lattices underwent brittle collapse and non-ideal deformation behaviour. The application of a microstructure-altering thermal treatment drastically improved their behaviour and their capability for energy absorption. Heat-treated graded lattices exhibited progressive layer collapse and incremental strengthening. Graded and uniform structures absorbed almost the same amount of energy prior to densification, 6.3±0.26.3±0.2 MJ/m3 and 5.7±0.25.7±0.2 MJ/m3, respectively, but densification occurred at around 7% lower strain for the graded structures. Several characteristic properties of SLM aluminium lattices, including their effective elastic modulus and Gibson-Ashby coefficients, C1 and α, were determined; these can form the basis of new design methodologies for superior components in the future.

/pdf/a-mechanical-property-evaluation-of-graded-density-al-si10-2t3mb2ihpx.pdf

A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting

This work gives an overview of the production, properties and industrial applications of metal foams. First, it classifies the most relevant manufacturing routes and methods. Then, it reviews the most important properties, with special interest in the mechanical and functional aspects, but also taking into account costs and feasibility considerations. These properties are the motivation and basis of related applications. Finally, a summary of the most relevant applications showing a large number of actual examples is presented. Concluding, we can forecast a slow, but continuous growth of this industrial sector.

Commercial Applications of Metal Foams: Their Properties and Production

Ultrahigh-strength titanium gyroid scaffolds manufactured by selective laser melting (SLM) for bone implant applications

Titanium implants are widely used in the orthopedic and dentistry fields for many decades, for joint arthroplasties, spinal and maxillofacial reconstructions, and dental prostheses. However, despite the quite satisfactory survival rates failures still exist. New Ti-alloys and surface treatments have been developed, in an attempt to overcome those failures. This review provides information about new Ti-alloys that provide better mechanical properties to the implants, such as superelasticity, mechanical strength, and corrosion resistance. Furthermore, in vitro and in vivo studies, which investigate the biocompatibility and cytotoxicity of these new biomaterials, are introduced. In addition, data regarding the bioactivity of new surface treatments and surface topographies on Ti-implants is provided. The aim of this paper is to discuss the current trends, advantages, and disadvantages of new titanium-based biomaterials, fabricated to enhance the quality of life of many patients around the world.

/pdf/new-ti-alloys-and-surface-modifications-to-improve-the-1sxt5d5kyt.pdf

New Ti-Alloys and Surface Modifications to Improve the Mechanical Properties and the Biological Response to Orthopedic and Dental Implants: A Review.

The mechanical properties and biocompatibility of titanium alloy medical devices and implants produced by additive manufacturing (AM) technologies - in particular, selective laser melting (SLM), electron beam melting (EBM) and laser metal deposition (LMD) - have been investigated by several researchers demonstrating how these innovative processes are able to fulfil medical requirements for clinical applications. This work reviews the advantages given by these technologies, which include the possibility to create porous complex structures to improve osseointegration and mechanical properties (best match with the modulus of elasticity of local bone), to lower processing costs, to produce custom-made implants according to the data for the patient acquired via computed tomography and to reduce waste.

https://journals.sagepub.com/doi/pdf/10.5301/jabfm.5000371

Additive manufacturing of titanium alloys in the biomedical field: processes, properties and applications:

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Metal Foams A Design Guide