Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components.

In recent years, the creative use of polymers has been expanded as the range of achievable material properties and options for manufacturing and post-processing continually grows. The main goal of this research was to design and develop a fully-functioning material extrusion additive manufacturing device with the capability to produce functionally graded high-temperature thermoplastic PEEK (polyether ether ketone) materials through the manipulation of microstructure during manufacturing. Five different strategies to control the chamber temperature and crystallinity were investigated, and concepts of thermal control were introduced to govern the crystallisation and cooling mechanics during the extrusion process. The interaction of individually deposited beads of material during the printing process was investigated using scanning electron microscopy to observe and quantify the porosity levels and interlayer bonding strength, which affect the quality of the final part. Functional testing of the printed parts was carried out to identify crystallinity, boundary layer adhesion, and mechanical behaviour. Furnace cooling and annealing were found to be the most effective methods, resulting in the highest crystallinity of the part. Finally, a functionally graded material cylindrical part was printed successfully, incorporating both low and high crystalline regions.

Multipart Build Effects on Temperature and Residual Stress by Laser Beam Powder Bed Fusion Additive Manufacturing.

Laser beam powder bed fusion (PBF-LB) is a leading technique among metal additive manufacturing (AM), and it has a wide range of applications in aerospace and medical devices. Most of the existing PBF-LB process modeling is mainly based on the fabrication of a single part on a large build plate, which is not reflective of the practical multipart PBF-LB manufacturing. The effects of batch size on the thermal and mechanical behavior of additively manufactured parts have not been investigated. In this work, the multipart PBF-LB thermomechanical modeling framework was proposed for the first time. The effects of sample numbers (1, 2, and 4) on temperature and residual stress (RS) of part-scale components were computationally investigated. It is found that RS within the parts decreased with increasing number of components per build. Parts located at the central areas of the build plate had larger RS than at the border. These findings can be beneficial for informing AM designers and operators of the optimum printing setup to minimize RS of metal parts in PBF-LB.

Advancements in Functionally Graded Polyether Ether Ketone Components: Design, Manufacturing, and Characterisation Using a Modified 3D Printer.

Functionally Graded Materials represent the next generation of engineering design for metal and plastic components. In this research, a specifically modified and optimised 3D printer was used to manufacture functionally graded polyether ether ketone components. This paper details the design and manufacturing methodologies used in the development of a polyether ether ketone printer capable of producing functionally graded materials through the manipulation of microstructure. The interaction of individually deposited beads of material during the printing process was investigated using scanning electron microscopy, to observe and quantify the porosity levels and interlayer bonding strength, which affects the quality of the final parts. Specimens were produced under varying process conditions and tested to characterise the influence of the process conditions on the resulting material properties. The specimens printed at high enclosure temperatures exhibited greater strength than parts printed without the active addition of heat, due to improved bond formation between individual layers of the print and a large degree of crystallinity through maintenance at these elevated temperatures.

Computational modelling of dynamic recrystallisation of Ni-based superalloy during linear friction welding.

Linear friction welding (LFW) is an advanced joining technology used for manufacturing and repairing complex assemblies like blade integrated disks (blisks) of aeroengines. This paper presents an integrated multiphysics computational modelling for predicting the thermomechanical-microstructural processes of IN718 alloy (at the component-scale) during LFW. Johnson-Mehl-Avrami-Kolmogorov (JMAK) model was implemented for predicting the dynamic recrystallisation of γ grain, which was coupled with thermomechanical modelling of the LFW process. The computational modelling results of this paper agree well with experimental results from the literature in terms of γ grain size and weld temperature. Twenty different LFW process parameter configurations were systematically analysed in the computations by using the integrated model. It was found that friction pressure was the most influential process parameter, which significantly affected the dynamic recrystallisation of γ grains and weld temperature during LFW. The integrated multiphysics computational modelling was employed to find the appropriate process window of IN718 LFW.

Material Characterisation and Computational Thermal Modelling of Electron Beam Powder Bed Fusion Additive Manufacturing of Ti2448 Titanium Alloy.

Ti-24Nb-4Zr-8Sn (Ti2448) is a metastable ß-type titanium alloy developed for biomedical applications. In this work, cylindrical samples of Ti2448 alloy have been successfully manufactured by using the electron beam powder bed fusion (PBF-EB) technique. The thermal history and microstructure of manufactured samples are characterised using computational and experimental methods. To analyse the influence of thermal history on the microstructure of materials, the thermal process of PBF-EB has been computationally predicted using the layer-by-layer modelling method. The microstructure of the Ti2448 alloy mainly includes ß phase and a small amount of α″ phase. By comparing the experimental results of material microstructure with the computational modelling results of material thermal history, it can be seen that aging time and aging temperature lead to the variation of α″ phase content in manufactured samples. The computational modelling proves to be an effective tool that can help experimentalists to understand the influence of macroscopic processes on material microstructural evolution and hence potentially optimise the process parameters of PBF-EB to eliminate or otherwise modify such microstructural gradients.

Data on a computationally efficient approximation of part-powder conduction as surface free convection in powder bed fusion process modelling.

This article is related to research article entitled "Resolution, energy and time dependency on layer scaling in finite element modelling of laser beam powder bed fusion additive manufacturing" [1]. This data article presents a computationally efficient approximation of part-powder interface conduction heat transfer, as convection heat transfer, thus eliminating the need for powder elements in the finite element model. The heat loss profile due to part-powder conduction was first characterised for a Ti6Al4V Powder Bed Fusion process. Cooling rate data was obtained for a range of powder in-plane depths. A matching cooling rate profile was obtained from free convection from the part surface, by calibration of the convection coefficient.

Failure modelling of trabecular bone using a non-linear combined damage and fracture voxel finite element approach.

Trabecular bone tissue failure can be considered as consisting of two stages: damage and fracture; however, most failure analyses of 3D high-resolution trabecular bone samples are confined to damage mechanisms only, that is, without fracture. This study aims to develop a computational model of trabecular bone consisting of an explicit representation of complete failure, incorporating damage criteria, fracture criteria, cohesive forces, asymmetry and large deformation capabilities. Following parameter studies on a test specimen, and experimental testing of bone sample to complete failure, the asymmetric critical tissue damage and fracture strains of ovine vertebral trabecular bone were calibrated and validated to be compression damage -1.16 %, tension damage 0.69 %, compression fracture -2.91 % and tension fracture 1.98 %. Ultimate strength and post-ultimate strength softening were captured by the computational model, and the failure of individual struts in bending and shear was also predicted. This modelling approach incorporated a cohesive parameter that provided a facility to calibrate ductile-brittle behaviour of bone tissue in this non-linear geometric and non-linear constitutive property analyses tool. Finally, the full accumulation of tissue damage and tissue fracture has been monitored from range of small magnitude (normal daily loading) through to specimen yielding, ultimate strength and post-ultimate strength softening.

An experimental and computational investigation of the post-yield behaviour of trabecular bone during vertebral device subsidence.

Interbody fusion device subsidence has been reported clinically. An enhanced understanding of the mechanical behaviour of the surrounding bone would allow for accurate predictions of vertebral subsidence. The multiaxial inelastic behaviour of trabecular bone is investigated at a microscale and macroscale level. The post-yield behaviour of trabecular bone under hydrostatic and confined compression is investigated using microcomputed tomography-derived microstructural models, elucidating a mechanism of pressure-dependent yielding at the macroscopic level. Specifically, microstructural trabecular simulations predict a distinctive yield point in the apparent stress-strain curve under uniaxial, confined and hydrostatic compression. Such distinctive apparent stress-strain behaviour results from localised stress concentrations and material yielding in the trabecular microstructure. This phenomenon is shown to be independent of the plasticity formulation employed at a trabecular level. The distinctive response can be accurately captured by a continuum model using a crushable foam plasticity formulation in which pressure-dependent yielding occurs. Vertebral device subsidence experiments are also performed, providing measurements of the trabecular plastic zone. It is demonstrated that a pressure-dependent plasticity formulation must be used for continuum level macroscale models of trabecular bone in order to replicate the experimental observations, further supporting the microscale investigations. Using a crushable foam plasticity formulation in the simulation of vertebral subsidence, it is shown that the predicted subsidence force and plastic zone size correspond closely with the experimental measurements. In contrast, the use of von Mises, Drucker-Prager and Hill plasticity formulations for continuum trabecular bone models lead to over prediction of the subsidence force and plastic zone.

Comparison of trabecular bone behavior in core and whole bone samples using high-resolution modeling of a vertebral body.

Computational analysis of trabecular bone normally involves the modeling of (experimental tests of) cored samples. However, the lack of constraint on the sides of the extracted trabecular bone samples limits the information that can be inferred regarding true in situ behavior. Here, the element-by-element voxel-based finite element method was applied via, a custom-written software suite (FEEBE), to a 72 microm resolution model of an ovine vertebra. The difference between the apparent modulus of eight concentric core cylinders when modeled as part of the whole bone (containing 84 x 10(6) degrees of freedom) and independent of the whole bone was investigated. The results showed that cored trabecular bone apparent modulus depended significantly on the core diameter when modeled as an extracted core (r (2) = 0.975) and as part of a whole bone (r (2) = 0.986). The cause of this result was separated into the side-artifact effect and bone volume fraction (BV/TV) effect. For the independently modeled cores, the apparent modulus of an inner core region of interest varied with increasing thickness of the outer annulus. This was attributed to the side-artifact effect, given that the BV/TV of the core region was constant. Within the whole trabecular structure, the side artifact was eliminated as the entire bone structure was modeled. However, a BV/TV effect influenced the apparent modulus depending on the size of the core selected for determining apparent modulus. Changing the size of the core varied the overall BV/TV of the core, and this significantly (r (2) = 0.999) influences the apparent modulus. Therefore, determining a 'true' apparent modulus for trabecular bone was not achievable. The independently modeled cores consistently under-predict the in vivo apparent modulus. It is recommended that if a 'true' apparent modulus is required, the BV/TV at which it is required needs to be first determined. Apparent modeling of entire bones at microscale resolution allowed regions of low and high tissue strains to be identified, consistent with patterns of trabecular bone remodeling and resorption reported in literature. The basivertebral vein cavity underwent the highest strains within the entire vertebral body, suggesting that failure might initiate here, despite containing visibly thicker struts and plate trabeculae. Although computationally expensive, analysis of the entire vertebral body provided a full picture of in situ trabecular bone deformation.

Heterogeneous linear elastic trabecular bone modelling using micro-CT attenuation data and experimentally measured heterogeneous tissue properties.

High-resolution voxel-based finite element software, such as FEEBE developed at the NCBES, is widely used for studying trabecular bone at the micro-scale. A new approach to determine heterogeneous bone tissue material properties for computational models was proposed in this study. The specimen-specific range of tissue moduli across strut width was determined from nanoindentation testing. This range was mapped directly using linear interpolation to that specimen's micro-computed tomography (microCT) grey value range as input material properties for finite element analysis. The method was applied to cuboid trabecular bone samples taken from eight, 4-year-old (skeletally mature) ovine L5 vertebrae. Before undergoing experimental uniaxial compression tests, the samples were microCT scanned and 30 microm resolution finite element models were generated. The linear elastic finite element models were compressed to 1% strain. This material property assignment method for computational models accurately reproduced the experimentally determined apparent modulus and concentrations of stress at locations of failure.