Failure modes in high strength and stiffness to weight scaffolds produced by Selective Laser Melting

Materials and Design

Volumn 67, Issue , 2015, Pages 501-508

  Sercombe, Timothy B ^a   Xu, Xiaoxue ^a,e   Challis, V J ^b   Green, Richard ^c   Yue, Sheng ^c   Zhang, Ziyu ^d   Lee, Peter D ^c  

^a UNIVERSITY OF WESTERN AUSTRALIA   (Australia)

^b UNIVERSITY OF QUEENSLAND   (Australia)

^c UNIVERSITY OF MANCHESTER   (United Kingdom)

^d IMPERIAL COLLEGE LONDON   (United Kingdom)

^e MACQUARIE UNIVERSITY   (Australia)

Author keywords

Finite element analysis; Porous material; Selective laser melting; Titanium alloys; X ray computed tomography

Indexed keywords

3D PRINTERS; COMPRESSION TESTING; COMPUTERIZED TOMOGRAPHY; FUNCTIONALLY GRADED MATERIALS; MELTING; POROUS MATERIALS; SCAFFOLDS (BIOLOGY); TITANIUM ALLOYS; TOMOGRAPHY; TOPOLOGY;

ADDITIVE MANUFACTURING; DEFORMATION AND FAILURES; FAILURE MECHANISM; SCAFFOLD STRUCTURES; SELECTIVE LASER MELTING; TOPOLOGY OPTIMISATION; X-RAY COMPUTED TOMOGRAPHY; X-RAY MICRO TOMOGRAPHIES;

FINITE ELEMENT METHOD;

EID: 84920622249     PISSN: 02613069     EISSN: 18734197     Source Type: Journal    
DOI: 10.1016/j.matdes.2014.10.063     Document Type: Article

References (48)

1. Challis V.J., Roberts A.P., Grotowski J.F., Zhang L.-C., Sercombe T.B. Prototypes for bone implant scaffolds designed via topology optimization and manufactured by solid freeform fabrication. Adv Eng Mater 2010, 12:1106-1110.
2. Challis V.J., Xu X., Zhang L.C., Roberts A.P., Grotowski J.F., Sercombe T.B. High specific strength and stiffness structures produced using selective laser melting. Mater Des 2014, 63:783-788.
3. Robertson D.M., Pierre L.St., Chahal R. Preliminary observations of bone ingrowth into porous materials. J Biomed Mater Res 1976, 10(3):335-344.
4. Niinomi M. Recent metallic materials for biomedical applications. Metall Mater Trans A 2002, 33(3):477-486.
5. Wang K. The use of titanium for medical applications in the USA. Int Symp Metall Technol Ti Alloys 1996, 213(1-2):134-137.
6. Head W.C., Baulk D.J., Emersom R.H. Titanium as the material of choice for cementless femoral components in total hip arthroplasty. Clin Orthop Relat Res 1995, 311:85.
7. Hulbert S.F., Morrison S.J., Klawitter J.J. Tissue reaction to three ceramics of porous and non-porous structures. J Biomed Mater Res 1972, 6(5):347-374.
8. Holy C.E., Shoichet M.S., Davies J.E. Engineering three-dimensional bone tissue in vitro using biodegradable scaffolds: investigating initial cell-seeding density and culture period. J Biomed Mater Res 2000, 51(3):376-382.
9. Yang L., Harrysson O., West H., Cormier D. Compressive properties of Ti-6Al-4V auxetic mesh structures made by electron beam melting. Acta Mater 2012, 60:3370-3379.
10. Yue S., Lee P.D., Poologasundarampillai G., Jones J.R. Evaluation of 3-D bioactive glass scaffolds dissolution in a perfusion flow system with X-ray microtomography. Acta Biomater 2011, 7:2637-2643.
11. Murphy C.M., O'Brien F.J. Understanding the effect of mean pore size on cell activity in collagen-glycosaminoglycan scaffolds. Cell Adhes Migr 2010, 4(3):377-381.
12. Singh R., Lee P.D., Dashwood R.J., Lindley T.C. Titanium foams for biomedical applications: a review. Mater Technol 2010, 25:127-136.
13. Dunand D.C. Processing of titanium foams. Adv Eng Mater 2004, 6(6):369-376.
14. Ryan G., Pandit A., Apatsidis D.P. Fabrication methods of porous metals for use in orthopaedic applications. Biomaterials 2006, 27(13):2651-2670.
15. Davies G.J., Zhen S. Metallic foams: their production, properties and applications. J Mater Sci 1983, 18(7):1899-1911.
16. Gibson L.J., Ashby M.F. Cellular solids: structure and properties 1999, Cambridge University Press.
17. Zaoui A. Continuum micromechanics: survey. J Eng Mech 2002, 128(8):808-816.
18. Crawford R.P., Cann C.E., Keaveny T.M. Finite element models predict in vitro vertebral body compressive strength better than quantitative computed tomography. Bone 2003, 33(4):744-750.
19. Shen H., Brinson L.C. Finite element modeling of porous titanium. Int J Solids Struct 2007, 44(1):320-335.
20. Thelen S., Barthelat F., Brinson L.C. Mechanics considerations for microporous titanium as an orthopedic implant material. J Biomed Mater Res - Part A 2004, 69(4):601-610.
21. Singh R., Lee P.D., Lindley T.C., Kohlhauser C., Hellmich C., Bram M., et al. Characterization of the deformation behavior of intermediate porosity interconnected Ti foams using micro-computed tomography and direct finite element modeling. Acta Biomater 2010, 6:2342-2351.
22. Bart-Smith H., Bastawros A.F., Mumm D.R., Evans A.G., Sypeck D.J., Wadley H.N.G. Compressive deformation and yielding mechanisms in cellular Al alloys determined using X-ray tomography and surface strain mapping. Acta Mater 1998, 46:3583-3592.
23. Ohgaki T., Toda H., Kobayashi M., Uesugi K., Kobayashi T., Niinomi M., et al. In-situ high-resolution X-ray CT observation of compressive and damage behaviour of aluminium foams by local tomography technique. Adv Eng Mater 2006, 8:473-475.
24. Toda H., Ohgaki T., Uesugi K., Kobayashi M., Kuroda N., Kobayashi T., et al. Quantitative assessment of microstructure and its effects on compression behavior of aluminum foams via high-resolution synchrotron X-ray tomography. Metall Mater Trans A 2006, 37:1211-1219.
25. Watson I.G., Lee P.D., Dashwood R.J., Young P. Simulation of the mechanical properties of an aluminum matrix composite using X-ray microtomography. Metall Mater Trans A 2006, 37:551-558.
26. Zhang Q., Lee P.D., Singh R., Wu G., Lindley T.C. Micro-CT characterization of structural features and deformation behavior of fly ash/aluminum syntactic foam. Acta Mater 2009, 57:3003-3011.
27. Jones J.R., Lee P.D., Hench L.L. Hierarchical porous materials for tissue engineering. Philos Trans Royal Soc A 1838, 2006(364):263-281.
28. Hangai Y., Takahashi K., Yamaguchi R., Utsunomiya T., Kitahara S., Kuwazuru O., et al. Nondestructive observation of pore structure deformation behavior of functionally graded aluminum foam by X-ray computed tomography. Mater Sci Eng, A 2012, 556:678-684.
29. Michailidis N., Stergioudi F., Omar H., Papadopoulos D., Tsipas D.N. Experimental and FEM analysis of the material response of porous metals imposed to mechanical loading. Colloids Surf A 2011, 382:124-131.
30. Hangai Y., Kato H., Utsunomiyav T., Kitahara S., Kuwazuru O., Yoshikawa N. Effects of porosity and pore structure on compression properties of blowing-agent-free aluminum foams fabricated from aluminum alloy die castings. Mater Trans 2012, 53:1515-1520.
31. Zhang Z., Jones D., Yue S., Lee P.D., Jones J.R., Sutcliffe C.J., et al. Hierarchical tailoring of strut architecture to control permeability of additive manufactured titanium implants. Mater Sci Eng C 2013, 33:4055-4062.
32. Zhang Z., Yuan L., Lee P.D., Jones E., Jones J.R. Modeling of time dependent localized flow shear stress and its impact on cellular growth within additive manufactured titanium implants. J Biomed Mater Res - Part B 2014, 102:1689-1699.
33. Challis V.J., Roberts A.P., Wilkins A.H. Design of three dimensional isotropic microstructures for maximized stiffness and conductivity. Int J Solids Struct 2008, 45(14-15):4130-4146.
34. Standard Test Methods for Metal Powders and Powder Metallurgy Products. Princeton, New Jersey USA: Metal Powder Industries Federation; 2009.
35. Yadroitsev I., Bertrand P., Smurov I. Parametric analysis of the selective laser melting process. Appl Surf Sci 2007, 253(19):8064-8069.
36. Gu D.D., Meiners W., Wissenbach K., Poprawe R. Laser additive manufacturing of metallic components: materials, processes and mechanisms. Int Mater Rev 2012, 57:133-164.
37. Lee P.D., Quested P.N., McLean M. Modelling of Marangoni effects in electron beam melting. Philos. Trans. Royal Soc. Lond. A 1998, 356(1739):1027-1043.
38. Rombouts M., Kruth J.P., Froyen L., Mercelis P. Fundamentals of Selective Laser Melting of alloyed steel powders. CIRP Annals - Manuf Technol 2006, 55:187-192.
39. Gusarov A.V., Yadroitsev I., Bertrand P., Smurov I. Heat transfer modelling and stability analysis of selective laser melting. Appl Surf Sci 2007, 254:975-979.
40. Childs T.H.C., Hauser C., Badrossamay M. Mapping and modelling single scan track formation in direct metal selective laser melting. CIRP Annals - Manuf Technol 2004, 53(1):191-194.
41. Ciurana J., Hernandez L., Delgado J. Energy density analysis on single tracks formed by selective laser melting with CoCrMo powder material. Inter J Adv Manuf Technol 2013, 1-8.
42. Raj R.E., Daniel B.S.S. Structural and compressive property correlation of closed-cell aluminum foam. J Alloy Compd 2009, 467(1-2):550-556.
43. Ashby M.F. Plastic deformation of cellular materials. Encyclopedia of materials: science and technology 2001, 7068-7071. Elsevier, Oxford. 2nd ed. KHJB, W.C. Robert, C.F. Merton, I. Bernard, J.K. Edward, M. Subhash (Eds.).
44. Heinl P., Körner C., Singer R.F. Selective Electron Beam Melting Of Cellular Titanium: Mechanical Properties. Adv Eng Mater 2008, 10(9):882-888.
45. Smith M., Guan Z., Cantwell W.J. Finite element modelling of the compressive response of lattice structures manufactured using the selective laser melting technique. Inter J Mech Sci 2013, 67:28-41.
46. Gorny B., Niendorf T., Lackmann J., Thoene M., Troester T., Maier H.J. In situ characterization of the deformation and failure behavior of non-stochastic porous structures processed by selective laser melting. Mater Sci Eng, A 2011, 528:7962-7967.
47. Cheng X.Y., Li S.J., Murr L.E., Zhang Z.B., Hao Y.L., Yang R., et al. Compression deformation behavior of Ti-6Al-4V alloy with cellular structures fabricated by electron beam melting. J Mech Behav Biomed Mater 2012, 16:153-162.
48. Li S.J., Murr L.E., Cheng X.Y., Zhang Z.B., Hao Y.L., Yang R., et al. Compression fatigue behavior of Ti-6Al-4V mesh arrays fabricated by electron beam melting. Acta Mater 2012, 60:793-802.