Micro-Scale Deformation Aspects of Additively Fabricated Stainless Steel 316L under Compression.

The deformation aspects associated with the micro-mechanical properties of the powder laser bed fusion (P-LBF) additively manufactured stainless steel 316L were investigated in the present work. Toward that, micro-pillars were fabricated on different planes of the stainless steel 316L specimen with respect to build direction, and an in situ compression was carried out inside the chamber of the scanning electron microscope (SEM). The results were compared against the compositionally similar stainless steel 316L, which was fabricated by a conventional method, that is, casting. The post-deformed micro-pillars on the both materials were examined by electron microscopy. The P-LBF processed steel exhibits equiaxed as well as elongated grains of different orientation with the characteristics of the melt-pool type arrangements. In contrast, the cast alloy shows typical circular-type grains in the presence of micro-twins. The yield stress and ultimate compressive stress of P-LBF fabricated steel were about 431.02 ± 15.51 - 474.44 ± 23.49 MPa and 547.78 ± 29.58 - 682.59 ± 21.59 MPa, respectively. Whereas for the cast alloy, it was about 322.38 ± 19.78 MPa and 477.11 ± 25.31 MPa, respectively. Thus, the outcome of this study signifies that the AM-processed samples possess higher mechanical properties than conventionally processed alloy of similar composition. Irrespective of the processing method, both specimens exhibit ductile-type deformation, which is typical for metallic alloys.

Heat Treatment's Vital Role: Elevating Orthodontic Mini-Implants for Superior Performance and Longevity-Pilot Study.

Orthodontic mini-implants are devices used for anchorage in various orthodontic treatments. We conducted a pilot study which aimed to observe preliminary trends regarding the impact of heat treatment on the elastic modulus of Ti6Al4V alloy and stainless steel 316L mini-implants. The initial phase involved testing the impact of heat treatment on the mechanical properties of Ti6Al4V alloy and stainless steel 316L mini-implants. MATERIAL AND METHODS: Ten self-drilling mini-implants sourced from two distinct manufacturers (Jeil Medical Corporation® and Leone®) with dimensions of 2.0 mm diameter and 10 mm length were tested. They were separated into two material groups: Ti6Al4V and 316L. Using the CETRUMT-2 microtribometer equipment, indentation testing was conducted employing a diamond-tipped Rockwell penetrator at a constant force of 4.5 N. RESULTS: Slight differences were observed in the elastic modulus of the Ti6Al4V alloy (103.99 GPa) and stainless steel 316L (203.20 GPa) compared to natural bone. The higher elastic moduli of these materials indicate that they are stiffer, which could potentially lead to stress-shielding phenomena and bone resorption. Heat treatment resulted in significant changes in mechanical properties, including elastic modulus reductions of approximately 26.14% for Ti6Al4V and 24.82% for 316L, impacting their performance in orthodontic applications. CONCLUSION: Understanding the effects of heat treatment on these alloys is crucial for optimizing their biomechanical compatibility and longevity in orthodontic treatment. To fully evaluate the effects of heat treatment on mini-implants and to refine their design and efficacy in clinical practice, further research is needed.

On the effect of loading and printing parameters that influence the fatigue behavior of laser powder-bed fusion additively manufactured steels.

The aim of this paper is to investigate the factors (build orientation, sample conditions, and R-ratio) that affect the cyclic response of laser powder-bed fusion stainless steel 316L and 17-4 PH parts. Initially, the data set was analyzed to confirm the normality assumption. The significant and insignificant factors that affect the fatigue life were identified using analysis of variance (ANOVA). Main effects for different sample conditions were also analyzed. Process and reproducibility assessment were performed to study the effect of process factors. Combining fatigue data sets was recommended as the best approach to accurately predict the fatigue behavior of LPBF 316L and 17-4 PH parts. Finally, the effect of sample conditions on fatigue life was quantified. The highest fatigue life was achieved with Machined-Polished surfaces.

Morphological, mechanical and antibacterial properties of Ti-Cu-N thin films deposited by sputtering DC.

The problems associated with Stainless Steel 316 L (SS 316 L) orthopedic implants, when implanted in the human body, are infection, local inflammation, and the possibility of bacterial growth. In this study, SS 316 L was coated with copper-doped Titanium Nitride (Ti-Cu-N) using the DC Sputtering technique. This Ti-Cu-N film improved the antibacterial performance and mechanical properties of SS 316 L. The Ti-Cu-N films were deposited using reactive DC sputtering with an 80%:20% argon to nitrogen ratio. The source voltage and current were kept constant at 10 kV and 10 mA, respectively. X-Ray Diffraction (XRD) showed that the phases formed were TiN and Cu with FCC crystal structure. Results show that the surfaces of samples containing 44.34 wt% and 54.97 wt% Cu had antibacterial effectiveness against Staphylococcus aureus (S. Aureus). The highest hardness value of a Ti-Cu-N layer was 212.032 Vickers Hardness Number (VHN), which was an improvement of 36.63% on the raw material (155.18 VHN). Surface morphology analysis using SEM-EDS was performed on the samples before and after the antibacterial test to investigate the antibacterial mechanism of the surfaces of SS 316 L containing Ti-Cu-N against S. Aureus.

Indirect Induction Sintering of Metal Parts Produced through Material Extrusion Additive Manufacturing.

Avoiding loose powders and resins, material extrusion additive manufacturing is a powerful technique to produce near-net shape parts, being a cheap and safe alternative for developing complex industrial-grade products. Filaments embedded with a high packing density of metallic or ceramic granules are being increasingly used, resulting in almost fully dense parts, whereby geometries are shaped, debinded and sintered sequentially until the completion of the part. Traditionally, "brown" debinded geometries are transported to conventional furnaces to densify the powder compacts, requiring careful tailoring of the heating profiles and sintering environment. This approach is decoupled and often involves time-consuming post-processing, whereby after the completion of the shaping and debinding steps, the parts need to be transported to a sintering furnace. Here, it is shown that sintering via indirect induction heating of a highly filled commercially available filament embedded with stainless steel 316L powder can be an effective route to densify Fused Filament Fabricated (FFF) parts. The results show that densities of 99.8% can be reached with very short soaking times, representing a significant improvement compared to prior methods. A hybrid machine is proposed, whereby a custom-built machine is integrated with an induction heater to combine FFF with local indirect induction sintering. Sintering in situ, without the need for part transportation, simplifies the processing of metal parts produced through material extrusion additive manufacturing.

Microstructural and Nanoindentation Investigation on the Laser Powder Bed Fusion Stainless Steel 316L.

Additive manufacturing (AM) of stainless steel is more difficult than other metallic materials, as the major alloying elements of the stainless steel are prone to oxidation during the fabrication process. In the current work, specimens of the stainless steel 316L were made by the powder laser bed fusion (P-LBF) additive manufacturing process. These specimens were investigated by electron microscopy and micro-/nano-indentation techniques to investigate the microstructural aspects and the mechanical properties, respectively. Compositionally, a similar wrought stainless steel was subjected to identical investigation, and used as a benchmark material. The microstructure of the P-LBF-processed alloy shows both equiaxed and elongated grains, which are marginally smaller (3.2-3.4 µm) than that of the wrought counterpart (3.6 µm). Withstanding such marginal gain size refinement, the increase in shear stress and hardness of the L-PBF alloy was striking. The L-PBF-processed alloy possess about 1.92-2.12 GPa of hardness, which was about 1.5 times higher than that of wrought alloy (1.30 GPa), and about 1.15 times more resistant against plastic flow of material. Similarly, L-PBF-processed alloy possess higher maximum shear stress (274.5-294.4 MPa) than that of the wrought alloy (175.9 MPa).

Characterization of Mechanical Properties and Grain Size of Stainless Steel 316L via Metal Powder Injection Molding.

The metal powder injection molding process is completed by mixing a metal powder and a binder, performing an injection molding and degreasing process, and then performing a sintering process for high density. The disadvantage of metal powder injection molding is that defects occurring during the process affect mechanical properties, which are worse in mechanical properties than in products manufactured by cold-rolling. In this study, the mechanical properties and microstructure of stainless steel 316L manufactured by the metal powder injection molding process were analyzed. Mechanical properties such as density, tensile strength, and fatigue life were analyzed. The density was measured using Archimedes' principle, and a relative density of 94.62% was achieved compared to the theoretical density. The tensile strength was approximately 539.42 MPa and the elongation to fracture was approximately 92%. The fatigue test was performed at 80% of maximum tensile strength and a stress ratio of R = 0.1. The fatigue life was found in 55% (297 MPa) of maximum tensile strength that achieved 106 cycles. The microstructure was observed through scanning electron microscope after etching, and as a result, the average grain size was 88.51 µm. Using electron backscatter diffraction, inverse pole figure map, image quality map, and kernel average misorientation map of the specimen were observed in three different areas which were undeformed, uniformly deformed, and deformed. Based on these results, it is expected that research is needed to apply the metal powder injection molding process to the manufacture of agricultural machinery parts with complex shapes.

Powder plasma spheroidization treatment and the characterization of microstructure and mechanical properties of SS 316L powder and L-PBF builds.

A plasma spheroidization treatment was applied to stock stainless steel 316L powder for additive manufacturing. The normal and treated powders were compared both in the powder state as well as in the resulting laser powder bed fusion (L-PBF) builds. The plasma spheroidization process slightly increased treated powder aspect ratio and sphericity and shifted the size distribution to larger diameters relative to the normal powder. The normal powder was austenitic in nature whereas the plasma spheroidization process introduced a small fraction (∼3.5 vol %) of ferrite in the treated powder. Ferrite in the powder was not retained in the printed samples and was not shown to negatively affect the build quality. Porosity areal fraction was generally smaller in the treated powder builds. The normal powder builds had a 6% higher yield strength than treated, however the scatter was significantly larger in the 45° and horizontal orientations compared to the treated powder builds.

Reveal the Viscoplastic Behaviour and Microstructure Evolution of Stainless Steel 316L.

Stainless steel 316L is a widely used structural material in the nuclear industry because of its excellent corrosion resistance and mechanical properties. However, very little research can be found on its viscoplastic behaviour and microstructure evolution at warm and hot deformation conditions, which hinder the possible application of advanced manufacturing technologies for producing complex parts, such as superplastic forming or hydroforming. The aims of this study are to explore stainless steel 316L's viscoplastic behaviour, to determine its strain rate sensitivities, and to reveal its underlying microstructure evolution; this will allow appropriate manufacturing (forming) technologies and the optimal forming condition to be determined. Hence, isothermal tensile tests at 700 °C, 800 °C, 900 °C, and 1000 °C at strain rates of 0.01 s-1 and 0.001 s-1 have been conducted. Moreover, the corresponding microstructure evolution, including the grain orientation and geometrically necessary dislocation density, has been revealed by the electron backscatter diffraction method. The data show the viscoplastic behaviour of stainless steel 316L under various thermomechanical deformation conditions and how microstructure evolution influences the viscoplastic flow stress.

Laser Welding of 316L Austenitic Stainless Steel in an Air and a Water Environment.

Laser welding is an innovative method that is frequently used and required by different disciplines and represents a technique of choice in a wide range of applications due to important advantages such as precision, speed, and flexibility. However, the welding method must be used properly otherwise it may deteriorate the mechanical properties of the welded metal and its environment. Therefore, the laser parameters should be precisely determined and carefully applied to the sample. The primary objective of this study was to investigate and propose optimal welding parameters that should be adjusted during the neodymium-doped yttrium aluminum garnet (Nd: YAG)-pulsed laser welding of austenitic stainless steel 316L in an air welding environment by using Argon shielding gas and in wet welding settings in serum medium. The investigation of the welding process in serum medium was conducted in order to propose the most suitable welding parameters being important for future possible medical applications of laser welding in in-vivo settings and thus to investigate the possibilities of the welding process inside the human body. In order to evaluate the quality of welding in air and of wet welding (in serum), a detailed parameter study has been conducted by variation of the laser energy, the welding speed and the focal position. The relationship between the depth of penetration and specific point energy (SPE) was also evaluated. The microstructure of the welded metal was examined by an optical microscope and scanning electron microscope (SEM). Based on the microscopy results, it was found that the largest depth of penetration (1380 µm) was achieved with 19 J laser energy in air medium, while the depth reached the largest value (1240 µm) in serum medium at 28 J laser energy. The increasing energy level showed opposite behavior for air and serum. The results of our study imply that when welding of 316L stainless steel is implemented properly in the body fluid, it would be a promising start for future in-vivo studies.

Elevated Temperature Baseplate Effect on Microstructure, Mechanical Properties, and Thermal Stress Evaluation by Numerical Simulation for Austenite Stainless Steel 316L Fabricated by Directed Energy Deposition.

In the present study, the effect of material deposition at the elevated temperature baseplate on the microstructure and mechanical properties was investigated and correlated to the unique thermal history by using numerical simulation. Numerical results agreed well with the experimental results of microstructure and mechanical properties. Numerical results revealed a significant decrease in temperature gradient and a 40% decrease in thermal stress due to material deposition on the elevated temperature baseplate. The reduced thermal stress and temperature gradient resulted in coarser grain features, which in turn led to a decrease in hardness and tensile strength, especially for the bottom region near the baseplate. Meanwhile, no significant effect could be found for ductility. In addition, an elevated temperature baseplate promoted less heterogeneity in hardness and tensile properties along the building direction. The current work demonstrates a collective and direct understanding of the baseplate preheating effect on thermal stress, microstructure and mechanical properties and their correlations, which is believed beneficial for the better utilization of baseplate preheating positive effects.

Effect of Interlayer Delay on the Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Wall Structures.

Wire arc additive manufacturing is a metal additive manufacturing technique that allows the fabrication of large size components at a high deposition rate. During wire arc additive manufacturing, multi-layer deposition results in heat accumulation, which raises the preheat temperature of the previously built layer. This causes process instabilities, resulting in deviations from the desired dimensions and variations in material properties. In the present study, a systematic investigation is carried out by varying the interlayer delay from 20 to 80 s during wire arc additive manufacturing deposition of the wall structure. The effect of the interlayer delay on the density, geometry, microstructure and mechanical properties is investigated. An improvement in density, reduction in wall width and wall height and grain refinement are observed with an increase in the interlayer delay. The grain refinement results in an improvement in the micro-hardness and compression strength of the wall structure. In order to understand the effect of interlayer delay on the temperature distribution, numerical simulation is carried out and it is observed that the preheat temperature reduced with an increase in interlayer delay resulting in variation in geometry, microstructure and mechanical properties. The study paves the direction for tailoring the properties of wire arc additive manufacturing-built wall structures by controlling the interlayer delay period.

Post-Processing and Surface Characterization of Additively Manufactured Stainless Steel 316L Lattice: Implications for BioMedical Use.

Additive manufacturing of stainless steel is becoming increasingly accessible, allowing for the customisation of structure and surface characteristics; there is little guidance for the post-processing of these metals. We carried out this study to ascertain the effects of various combinations of post-processing methods on the surface of an additively manufactured stainless steel 316L lattice. We also characterized the nature of residual surface particles found after these processes via energy-dispersive X-ray spectroscopy. Finally, we measured the surface roughness of the post-processing lattices via digital microscopy. The native lattices had a predictably high surface roughness from partially molten particles. Sandblasting effectively removed this but damaged the surface, introducing a peel-off layer, as well as leaving surface residue from the glass beads used. The addition of either abrasive polishing or electropolishing removed the peel-off layer but introduced other surface deficiencies making it more susceptible to corrosion. Finally, when electropolishing was performed after the above processes, there was a significant reduction in residual surface particles. The constitution of the particulate debris as well as the lattice surface roughness following each post-processing method varied, with potential implications for clinical use. The work provides a good base for future development of post-processing methods for additively manufactured stainless steel.

Computational Approaches of Quasi-Static Compression Loading of SS316L Lattice Structures Made by Selective Laser Melting.

Additive manufacturing methods (AM) allow the production of complex-shaped lattice structures from a wide range of materials with enhanced mechanical properties, e.g., high strength to relative density ratio. These structures can be modified for various applications considering a transfer of a specific load or to absorb a precise amount of energy with the required deformation pattern. However, the structure design requires knowledge of the relationship between nonlinear material properties and lattice structure geometrical imperfections affected by manufacturing process parameters. A detailed analytical and numerical computational investigation must be done to better understand the behavior of lattice structures under mechanical loading. Different computational methods lead to different levels of result accuracy and reveal various deformational features. Therefore, this study focuses on a comparison of computational approaches using a quasi-static compression experiment of body-centered cubic (BCC) lattice structure manufactured of stainless steel 316L by selective laser melting technology. Models of geometry in numerical simulations are supplemented with geometrical imperfections that occur on the lattice structure's surface during the manufacturing process. They are related to the change of lattice struts cross-section size and actual shape. Results of the models supplemented with geometrical imperfections improved the accuracy of the calculations compared to the nominal geometry.

Impact of the Allowed Compositional Range of Additively Manufactured 316L Stainless Steel on Processability and Material Properties.

This work aims to show the impact of the allowed chemical composition range of AISI 316L stainless steel on its processability in additive manufacturing and on the resulting part properties. ASTM A276 allows the chromium and nickel contents in 316L stainless steel to be set between 16 and 18 mass%, respectively, 10 and 14 mass%. Nevertheless, the allowed compositional range impacts the microstructure formation in additive manufacturing and thus the properties of the manufactured components. Therefore, this influence is analyzed using three different starting powders. Two starting powders are laboratory alloys, one containing the maximum allowed chromium content and the other one containing the maximum nickel content. The third material is a commercial powder with the chemical composition set in the middle ground of the allowed compositional range. The materials were processed by laser-based powder bed fusion (PBF-LB/M). The powder characteristics, the microstructure and defect formation, the corrosion resistance, and the mechanical properties were investigated as a function of the chemical composition of the powders used. As a main result, solid-state cracking could be observed in samples additively manufactured from the starting powder containing the maximum nickel content. This is related to a fully austenitic solidification, which occurs because of the low chromium to nickel equivalent ratio. These cracks reduce the corrosion resistance as well as the elongation at fracture of the additively manufactured material that possesses a low chromium to nickel equivalent ratio of 1.0. A limitation of the nickel equivalent of the 316L type steel is suggested for PBF-LB/M production. Based on the knowledge obtained, a more detailed specification of the chemical composition of the type 316L stainless steel is recommended so that this steel can be PBF-LB/M processed to defect-free components with the desired mechanical and chemical properties.

Physicochemical and Biological Properties of Graphene-Oxide-Coated Metallic Materials.

In this article, we present graphene oxide (produced by a modified Hummers' method) coatings obtained using two different methods: electrophoretic deposition on 316L stainless steel and chemical modification of the surface of gold applied to the steel. The coating properties were characterized by microscopic and spectrometric techniques. The contact angle was also determined, ranging from 50° to 70°. Our results indicated that GO coatings on steel and gold were not toxic towards L929 cells in a direct cell adhesion test-on all tested materials, it was possible to observe the growth of L929 cells during 48 h of culture. The lack of toxic effect on cells was also confirmed in two viability tests, XTT and MTT. For most of the tested materials, the cell viability was above 70%. They showed that the stability of the coating is the crucial factor for such GO coatings, and prove that GO in the form of coating is non-toxic; however, it can show toxicity if detached from the surface. The obtained materials also did not show any hemolytic properties, as the percentage of hemolysis was on the level of the negative control, which is very promising in the light of future potential applications.

Point-of-Care 3D Printing: A Feasibility Study of Using 3D Printing for Orthopaedic Trauma.

AIM: The aim of this study was to assess the feasibility of 3D printing a customised implant at the point of care from a manufacturing and logistics perspective. We hypothesised that customised plate production would be possible within a clinically relevant time frame of 72 hours using currently available technology. MATERIALS AND METHODS: This study uses 6 cadaveric lower limbs to simulate real-life surgical patients. Split-depressed lateral tibial plateau fractures were created in an identical fashion in the cadaveric lower limbs. CT scans of the fractures were obtained and digital reconstructions were used to design customised patient and fracture-specific 3D-printed plates. These were subsequently printed in medical grade stainless steel 316L and post-processed at a local additive manufacturing centre. Surgical fixation of the fractures was then carried out using these plates, following which post-operative X-rays were obtained. The time taken for each step in plate production from the initiation of pre-operative CT scan to the completion of the post-operative X-ray was recorded. RESULTS: Six customised proximal tibia locking plates were produced with accompanying surgical drill guides. The mean total time taken for plate fabrication from completion of CT scan was approximately 24 hours and 7 minutes, with a maximum of 28 hours and 46 minutes. CONCLUSION: Production of patient-specific 3D printed plates for fixation of proximal tibia fractures at the point of care is achievable within a clinically acceptable time frame provided adequate manufacturing facilities and skilled manpower are in place.

The Effect of Welding Current and Electrode Force on the Heat Input, Weld Diameter, and Physical and Mechanical Properties of SS316L/Ti6Al4V Dissimilar Resistance Spot Welding with Aluminum Interlayer.

Welding parameters obviously determine the joint quality during the resistance spot welding process. This study aimed to investigate the effect of welding current and electrode force on the heat input and the physical and mechanical properties of a SS316L and Ti6Al4V joint with an aluminum interlayer. The weld current values used in this study were 11, 12, and 13 kA, while the electrode force values were 3, 4, and 5 kN. Welding time and holding time remained constant at 30 cycles. The study revealed that, as the welding current and electrode force increased, the generated heat input increased significantly. The highest tensile-shear load was recorded at 8.71 kN using 11 kA of weld current and 3 kN of electrode force. The physical properties examined the formation of a brittle fracture and several weld defects on the high current welded joint. The increase in weld current also increased the weld diameter. The microstructure analysis revealed no phase transformation on the SS316L interface; instead, the significant grain growth occurred. The phase transformation has occurred on the Ti6Al4V interface. The intermetallic compound layer was also investigated in detail using the EDX (Energy Dispersive X-Ray) and XRD (X-Ray Diffraction) analyses. It was also found that both stainless steel and titanium alloy have their own fusion zone, which is indicated by the highest microhardness value.

316L Stainless Steel Powders for Additive Manufacturing: Relationships of Powder Rheology, Size, Size Distribution to Part Properties.

Laser-Powder Bed Fusion (L-PBF) of metallic parts is a highly multivariate process. An understanding of powder feedstock properties is critical to ensure part quality. In this paper, a detailed examination of two commercial stainless steel 316L powders produced using the gas atomization process is presented. In particular, the effects of the powder properties (particle size and shape) on the powder rheology were examined. The results presented suggest that the powder properties strongly influence the powder rheology and are important factors in the selection of suitable powder for use in an additive manufacturing (AM) process. Both of the powders exhibited a strong correlation between the particle size and shape parameters and the powder rheology. Optical microscope images of melt pools of parts printed using the powders in an L-PBF machine are presented, which demonstrated further the significance of the powder morphology parameters on resulting part microstructures.

Monotonic Tension-Torsion Experiments and FE Modeling on Notched Specimens Produced by SLM Technology from SS316L.

The aim of this work was to monitor the mechanical behavior of 316L stainless steel produced by 3D printing in the vertical direction. The material was tested in the "as printed" state. Digital Image Correlation measurements were used for 4 types of notched specimens. The behavior of these specimens under monotonic loading was investigated in two loading paths: tension and torsion. Based on the experimental data, two yield criteria were used in the finite element analyses. Von Mises criterion and Hill criterion were applied, together with the nonlinear isotropic hardening rule of Voce. Subsequently, the load-deformation responses of simulations and experiments were compared. Results of the Hill criterion show better correlation with experimental data. The numerical study shows that taking into account the difference in yield stress in the horizontal direction of printing plays a crucial role for modeling of notched geometries loaded in the vertical direction of printing. Ductility of 3D printed specimens in the "as printed" state is also compared with 3D printed machined specimens and specimens produced by conventional methods. "As printed" specimens have 2/3 lower ductility than specimens produced by a conventional production method. Machining of "as printed" specimens does not affect the yield stress, but a significant reduction of ductility was observed due to microcracks arising from the pores as a microscopic surface study showed.