Assessment of nanoparticle emission in additive manufacturing: Comparing wire and powder laser metal deposition processes.

Additive manufacturing (AM), often referred to as 3D printing, is an emerging technology with a wide range of industrial applications and process typologies. Although the release of metal nanoparticles as by-products could occur, occupational exposure limits and cogent safety standards are not currently available due to the novelty of the technology. To support the definition of benchmarks, this study aims to provide a preliminary comparison between the nanoparticle release patterns of laser metal deposition, adopting different feedstocks, namely, metal wire and metal powder. The monitored device is a university research setup, and the work presents the results of two different processes with AISI 316 L as a feedstock in powder and wired form, respectively. The monitoring confirmed the outcomes of previous studies, with a high release of nanoparticles from the powder head on the device (average 138,713 n/cm3 during printing, with maximum values exceeding 106 n/cm3). Moreover, the results show a significant concentration of nanoparticles with a wire head during the printing phase (average release of 628,156 n/cm3 with a maximum of 1,114,987 n/cm3) and pauses (average of 32,633 n/cm3 and a maximum of 733,779 n/cm3). The monitored values during pauses are particularly relevant since no personal protection equipment was used in the wire processes and the operators could access the printing room during pauses for device interventions, thus being exposed to significant nanoparticle concentrations. This study presents a preliminary evaluation of the potential exposure during laser metal deposition while implementing different technologies and provides evidence for defining effective operational safety procedures for the operators.

Probing multipulse laser ablation by means of self-mixing interferometry.

In this work, self-mixing interferometry (SMI) is implemented inline to a laser microdrilling system to monitor the machining process by probing the ablation-induced plume. An analytical model based on the Sedov-Taylor blast wave equation is developed for the expansion of the process plume under multiple-pulse laser percussion drilling conditions. Signals were acquired during laser microdrilling of blind holes on stainless steel, copper alloy, pure titanium, and titanium nitride ceramic coating. The maximum optical path difference was measured from the signals to estimate the refractive index changes. An amplitude coefficient was derived by fitting the analytical model to the measured optical path differences. The morphology of the drilled holes was investigated in terms of maximum hole depth and dross height. The results indicate that the SMI signal rises when the ablation process is dominated by vaporization, changing the refractive index of the processing zone significantly. Such ablation conditions correspond to limited formation of dross. The results imply that SMI can be used as a nonintrusive tool in laser micromachining applications for monitoring the process quality in an indirect way.

Characterizing Nanoparticle Release Patterns of Laser Powder Bed Fusion in Metal Additive Manufacturing: First Step Towards Mitigation Measures.

Laser Powder Bed Fusion (L-PBF) is a well-known Additive Manufacturing (AM) technology with a wide range of industrial applications. Potential occupational exposures to metal nanoparticles (NP) as by-products could occur in these processes, and no cogent occupational exposure limits are available. To contribute to this assessment, a monitoring campaign to measure the NP release pattern in two metal L-PBF facilities was carried out in two academic laboratories adopting L-PBF technology for research purposes. The monitored processes deal with two devices and three feedstock types, namely stainless steel (AISI 316L), aluminium-silicon alloy (A357) and pure copper, which are associated with different levels of industrial maturity. Prolonged environmental and personal real-time monitoring of NP concentration and size were performed, temperature and relative humidity were also measured during environmental monitoring. The measurements reveal a controlled NP release of the monitored processes, resulting in an average reduced exposure of the operators during the whole working shift, in compliance with proposed limit values (20 000 n cm-3 for density >6000 kg m-3 or 40 000 n cm-3 for density <6000 kg m-3). Nonetheless, the monitoring results show release events with an increase in NP concentration and a decrease in NP size corresponding with several actions usually performed during warm-up and cleaning, leading to exposures over 40-50 000 n cm-3 during a considerable time interval, especially during the manufacturing of pure copper powder. The results show that the actions of the operators, boundary conditions (relative humidity) and set-up of the L-PBF device have an impact on the amount of NP released and their size. Several release events (significant increase in NP concentration and decrease in NP size) are identified and associated with specific job tasks of the workers as well as building conditions. These results contribute to the definition of NP release benchmarks in AM processes and provide information to improve the operational conditions of L-PBF processes as well as safety guidelines for operators.

Particle measurements of metal additive manufacturing to assess working occupational exposures: a comparative analysis of selective laser melting, laser metal deposition and hybrid laser metal deposition.

This paper presents the results of a measurement campaign for assessing the release of particles and the potential exposure of workers in metal additive manufacturing. The monitoring deals with three environments, i.e., two academic laboratories and one production site, while printing different metallic alloys for chemical composition and size. The monitored devices implement different metal 3D printing processes, named Selective Laser Melting, Laser Metal Deposition and Hybrid Laser Metal Deposition, providing a wide overview of the current laser-based Additive Manufacturing technologies. Despite showing the generation of metal powders during the printing processes, the usual measurements based on gravimetric analysis did not highlight concentrations higher than the international exposure limits for the selected metals (i.e., chromium, cobalt, iron, nickel, and copper). Additional data, collected through a cascade impactor and particle counter coupled with the achievements from previous measurements reported in literature, indicate that during the printing operations, fine and ultrafine metal particles might be generated. Finally, the authors introduced a preliminary characterisation of the particles released during the different phases of the investigated AM processes (powder charging, printing, part cleaning and support removal), highlighting how the different operations may affect the particle size and concentration.

Additively manufactured iron-manganese for biodegradable porous load-bearing bone scaffold applications.

Selective laser melting (SLM) can produce complex hierarchical architectures paving the way for highly customisable biodegradable load-bearing bone scaffolds. For the first time, an in-depth analysis on the performance of SLM-manufactured iron-manganese bone scaffolds suitable for load-bearing applications is presented. Microstructural, mechanical, corrosion and biological characterisations were performed on SLM-manufactured iron-manganese scaffolds. The microstructure of the scaffold consisted primarily of γ-austenite, leading to high ductility. The mechanical properties of the scaffold were sufficient for load-bearing applications even after 28 days immersion in simulated body fluids. Corrosion tests showed that the corrosion rate was much higher than bulk pure iron, attributed to a combination of the manufacturing method, the addition of Mn to the alloy and the design of the scaffold. In vitro cell testing showed that the scaffold had good biocompatibility and viability towards mammalian cells. Furthermore, the presence of filopodia showed good osteoblast adhesion. In vivo analysis showed successful bone integration with the scaffold, with new bone formation observed after 4 weeks of implantation. Overall the SLM manufactured porous Fe-35Mn implants showed promise for biodegradable load-bearing bone scaffold applications. STATEMENT OF SIGNIFICANCE: Biodegradable iron scaffolds are emerging as a promising treatment for critical bone defects. Within this field, selective laser melting (SLM) has become a popular method of manufacturing bespoke scaffolds. There is limited knowledge on SLM-manufactured iron bone scaffolds, and no knowledge on their application for load-bearing situations. The current manuscript is the first study to characterise SLM manufactured iron-manganese bone scaffolds for load-bearing applications and also the first study to perform In vivo testing on SLM produced biodegradable iron scaffolds. In this study, for the first time, the mechanical, corrosion and biological properties of an iron-manganese scaffold manufactured using SLM were investigated. In summary the SLM-manufactured porous iron-manganese implants displayed great potential for biodegradable load-bearing bone scaffolds.

Comparative study of CW, nanosecond- and femtosecond-pulsed laser microcutting of AZ31 magnesium alloy stents.

Magnesium alloys constitute an interesting solution for cardiovascular stents due to their biocompatibility and biodegradability in human body. Laser microcutting is the industrially accepted method for stent manufacturing. However, the laser-material interaction should be well investigated to control the quality characteristics of the microcutting process that concern the surface roughness, chemical composition, and microstructure of the final device. Despite the recent developments in industrial laser systems, a universal laser source that can be manipulated flexibly in terms of process parameters is far from reality. Therefore, comparative studies are required to demonstrate processing capabilities. In particular, the laser pulse duration is a key factor determining the processing regime. This work approaches the laser microcutting of AZ31 Mg alloy from the perspective of a comparative study to evaluate the machining capabilities in continuous wave (CW), ns- and fs-pulsed regimes. Three industrial grade machining systems were compared to reach a benchmark in machining quality, productivity, and ease of postprocessing. The results confirmed that moving toward the ultrashort pulse domain the machining quality increases, but the need for postprocessing remains. The real advantage of ultrashort pulsed machining was the ease in postprocessing and maintaining geometrical integrity of the stent mesh after chemical etching. Resultantly, the overall production cycle time was shortest for fs-pulsed laser system, despite the fact that CW laser system provided highest cutting speed.

Laser surface structuring of AZ31 Mg alloy for controlled wettability.

Structured surfaces exhibit functional properties that can enhance the performance of a bioimplant in terms of biocompatibility, adhesion, or corrosion behavior. In order to tailor the surface property, chemical and physical methods can be used in a sequence of many steps. On the other hand, laser surface processing can provide a single step solution to achieve the designated surface function with the use of simpler equipment and high repeatability. This work provides the details on the surface structuring of AZ31, a biocompatible and biodegradable Mg alloy, by a single-step laser surface structuring based on remelting. The surfaces are characterized in terms of topography, chemistry, and physical integrity, as well as the effective change in the surface wetting behavior is demonstrated. The results imply a great potential in local or complete surface structuring of medical implants for functionalization by the flexible positioning of the laser beam.