On the Importance of Secondary Component Properties for Cold Spray Metallization of Carbon Fiber Reinforced Polymers.

In previous studies at McGill University, tin was successfully cold sprayed onto carbon fiber reinforced polymers (CFRPs). A "crack-filling" mechanism was described as the deposition mechanism that allowed deposition of tin onto the CFRP. Improving the coating conductivity for lightning strike protection (LSP) purposes was explored by adding other metal powders (aluminum, copper, zinc) to tin and cold spraying on the CFRP. At the same time, it was noticed that the addition of this secondary component (SC) provided an increase in deposition efficiency (DE); tamping was initially hypothesized to explain this improvement, thus prompting a study solely on the effect of SC hardness. However, it is recognized that other powder characteristics may also be influencing the DE. Thus, in this study, SCs with a wider variety of particle sizes, morphologies, densities and hardness values were mixed with tin and sprayed on CFRPs. The effect of SC properties on tin deposition is discussed and, while SC particle size, morphology and density individually do not notably influence the DE, the impact energy of the SC does. This opens a discussion on optimal parameters for deposition of metals on CFRP, based on results and observations from the literature.

Scanning Electron Microscopy versus Transmission Electron Microscopy for Material Characterization: A Comparative Study on High-Strength Steels.

The microstructures of quenched and tempered steels have been traditionally explored by transmission electron microscopy (TEM) rather than scanning electron microscopy (SEM) since TEM offers the high resolution necessary to image the structural details that control the mechanical properties. However, scanning electron microscopes, apart from providing larger area coverage, are commonly available and cheaper to purchase and operate compared to TEM and have evolved considerably in terms of resolution. This work presents detailed comparison of the microstructure characterization of quenched and tempered high-strength steels with TEM and SEM electron channeling contrast techniques. For both techniques, similar conclusions were made in terms of large-scale distribution of martensite lath and plates and nanoscale observation of nanotwins and dislocation structures. These observations were completed with electron backscatter diffraction to assess the martensite size distribution and the retained austenite area fraction. Precipitation was characterized using secondary imaging in the SEM, and a deep learning method was used for image segmentation. In this way, carbide size, shape, and distribution were quantitatively measured down to a few nanometers and compared well with the TEM-based measurements. These encouraging results are intended to help the material science community develop characterization techniques at lower cost and higher statistical significance.

Development of a micro-scale method to assess the effect of corrosion on the mechanical properties of a biodegradable Fe-316L stent material.

The application of biodegradable materials to stent design has the potential to transform coronary artery disease treatment. It is critical that biodegradable stents have sustained strength during degradation and vessel healing to prevent re-occlusion. Proper assessment of the impact of corrosion on the mechanical behaviour of potential biomaterials is important. Investigations within literature frequently implement simplified testing conditions to understand this behaviour and fail to consider size effects associated with strut thickness, or the increase in corrosion due to blood flow, both of which can impact material properties. A protocol was developed that utilizes micro-scale specimens, in conjunction with dynamic degradation, to assess the effect of corrosion on the mechanical properties of a novel Fe-316L material. Dynamic degradation led to increased specimen corrosion, resulting in a greater reduction in strength after 48 h of degradation in comparison to samples statically corroded. It was found that thicker micro-tensile samples (h > 200 µm) had a greater loss of strength in comparison to its thinner counterpart (h < 200 µm), due to increased corrosion of the thicker samples (203 MPa versus 260 MPa after 48 h, p = 0.0017). This investigation emphasizes the necessity of implementing physiologically relevant testing conditions, including dynamic corrosion and stent strut thickness, when evaluating potential biomaterials for biodegradable stent application.

A manufacturing and annealing protocol to develop a cold-sprayed Fe-316L stainless steel biodegradable stenting material.

Biodegradable stents show promise to revolutionize coronary artery disease treatment. Its successful implementation in the global market remains limited due to the constraints of current generation biodegradable materials. Cold gas dynamic spraying (CGDS) has been proposed as a manufacturing approach to fabricate a metallic biodegradable amalgamate for stent application. Iron and 316L stainless steel powders are combined in a 4:1 ratio to create a novel biomaterial through cold spray. Cold spray processing however, produces a coating in a work hardened state, with limited ductility, which is a critical mechanical property in stent design. To this end, the influence of annealing temperature on the mechanical and corrosion performances of the proposed Fe-316L amalgamate is investigated. It was found that annealing at 1300 °C yielded a complex material microstructure, with an ultimate tensile strength of approximately 280 MPa and ductility of 23%. The static corrosion rate determined at this annealing temperature was equal to 0.22 mg cm-2 day-1, with multiple corrosion species identified within the degradation layers. Precipitates were observed throughout the microstructure, which appeared to accelerate the overall corrosion behaviour. It was shown that cold-sprayed Fe-316L has significant potential to be implemented in a clinical setting. STATEMENT OF SIGNIFICANCE: Biodegradable stents have potential to significantly improve treatment of coronary artery disease by decreasing or potentially eliminating late-term complications, including stent fracture and in-stent restenosis. Current generation polymer biodegradable stents have led to poorer patient outcomes in comparison to drug-eluting stents, however, and it is evident that metallic biomaterials are required, which have increased strength. To this end, a novel iron and stainless steel 316L biomaterial is proposed, fabricated through cold-gas dynamic spraying. This study analyses the effect of annealing on the Fe-316L biomaterial through corrosion, mechanical, and microstructural investigations. The quantitative data presented in this work suggests that Fe-316L, in its annealed condition, has the mechanical and corrosion properties necessary for biodegradable stent application.

Machinability of Rene 65 Superalloy.

Nickel-based superalloys are heavily used in the aerospace and power industries due to their excellent material and mechanical properties. They offer high strength at elevated temperatures, high hardness, corrosion resistance, thermal stability and improved fatigue properties. These superalloys were developed to address the demand for materials with the enhanced heat and stress capabilities needed to increase operational temperatures and speeds in jet and turbine engines. However, most of these properties come with machining difficulty, high wear rate, increased force and poor surface finish. Rene 65 is one of the next generation wrought nickel superalloys that addresses these demands at a reduced cost versus powder metallurgy superalloys. It is strengthened by the presence of gamma prime precipitates in its microstructure, which enhance its strength at high temperatures. Notwithstanding its advantages, Rene 65 must also deal with the reality of the poor workability and machinability generally associated with Ni-based superalloys. This study examines the machinability-using drilling tests-of Rene 65 and seeks to establish the influence of hardness (with varying microstructure) and cutting conditions on machinability indicators (surface finish, forces and chip formation). The experimental setup is based on a set of experimental drilling tests using three different heat-treated samples of varying hardness. The results indicate a negligible effect from material hardness, ranging from 41 HRC to 52 HRC, on generated cutting forces and a similarly low effect from cutting speeds. The feed rate was identified as the main factor of relevance in cutting force and chip morphology during the machining of this new superalloy.

Bio-inspired and optimized interlocking features for strengthening metal/polymer interfaces in additively manufactured prostheses.

Biomedical and dental prostheses combining polymers with metals often suffer failure at the interface. The weak chemical bond between these two dissimilar materials can cause debonding and mechanical failure. This manuscript introduces a new mechanical interlocking technique to strengthen metal/polymer interfaces through optimized additively manufactured features on the metal surface. To reach an optimized design of interlocking features, we started with the bio-mimetic stress-induced material transformation (SMT) optimization method. The considered polymer and metal materials were cold-cured Poly(methyl methacrylate) (PMMA) and laser-sintered Cobalt-Chromium (Co-Cr), respectively. Optimal dimensions of the bio-inspired interlocking features were then determined by mesh adaptive direct search (MADS) algorithm combined with finite element analysis (FEA) and tensile experiments such that they provide the maximum interfacial tensile strength and stiffness while minimizing the stress in PMMA and the displacement of PMMA at the Co-Cr/PMMA interface. The SMT optimization process suggested a Y-shape as a more favorable design, which was similar to mangrove tree roots. Experiments confirmed that our optimized interlocking features increased the strength of the Co-Cr/PMMA interface from 2.3 MPa (flat interface) to 34.4 ±â€¯1 MPa, which constitutes 85% of the tensile failure strength of PMMA (40.2 ±â€¯1 MPa). STATEMENT OF SIGNIFICANCE: The objective of this study was to improve metal/polymer interfacial strength in dental and orthopedic prostheses. This was achieved by additive manufacturing of optimized interlocking features on metallic surfaces using laser-sintering. The interlocking design of the features, which was a Y-shape similar to the roots of mangrove trees, was inspired by a bio-memetic optimization algorithm. This interlocking design lowered the PMMA displacement at the Co-Cr/PMMA interface by 70%, enhanced the interfacial strength by more than 12%, and increased the stiffness by 18% compared with a conventional bead design, meanwhile no significant difference was found in the toughness of both designs.

Development of a Novel Biodegradable Metallic Stent Based on Microgalvanic Effect.

The implementation of biodegradable stents has the potential to revolutionize obstructive coronary artery disease treatment. Limitations still currently exist, however, that prevent biodegradable stents from replacing permanent metallic stents in the global market. The ideal combination of stent properties, including sufficient mechanical strength, controlled degradation, and biocompatibility, has yet to be realized. A novel manufacturing process is proposed that utilizes cold gas-dynamic spraying to fabricate a metal structure with significantly reduced grain size. Iron and stainless steel 316L are combined to form a novel amalgamate with enhanced mechanical strength and a controllable degradation rate, due to the resulting microgalvanic reaction. Flat specimens composed of iron and 316L are fabricated in various compositions, and mechanical and degradation tests were conducted. Femto laser techniques are utilized to produce stents composed of 80% Fe and 20% stainless steel 316L. The in vitro degradation behaviour of the stent is investigated using static and dynamic corrosion tests. It is shown that the corrosion rate can be adjusted to desired values, by varying the weight percentage of iron and stainless steel 316L within the amalgamate.

Quantitative comparison of long-wavelength Alexa Fluor dyes to Cy dyes: fluorescence of the dyes and their bioconjugates.

Amine-reactive N-hydroxysuccinimidyl esters of Alexa Fluor fluorescent dyes with principal absorption maxima at about 555 nm, 633 nm, 647 nm, 660 nm, 680 nm, 700 nm, and 750 nm were conjugated to antibodies and other selected proteins. These conjugates were compared with spectrally similar protein conjugates of the Cy3, Cy5, Cy5.5, Cy7, DY-630, DY-635, DY-680, and Atto 565 dyes. As N-hydroxysuccinimidyl ester dyes, the Alexa Fluor 555 dye was similar to the Cy3 dye, and the Alexa Fluor 647 dye was similar to the Cy5 dye with respect to absorption maxima, emission maxima, Stokes shifts, and extinction coefficients. However, both Alexa Fluor dyes were significantly more resistant to photobleaching than were their Cy dye counterparts. Absorption spectra of protein conjugates prepared from these dyes showed prominent blue-shifted shoulder peaks for conjugates of the Cy dyes but only minor shoulder peaks for conjugates of the Alexa Fluor dyes. The anomalous peaks, previously observed for protein conjugates of the Cy5 dye, are presumably due to the formation of dye aggregates. Absorption of light by the dye aggregates does not result in fluorescence, thereby diminishing the fluorescence of the conjugates. The Alexa Fluor 555 and the Alexa Fluor 647 dyes in protein conjugates exhibited significantly less of this self-quenching, and therefore the protein conjugates of Alexa Fluor dyes were significantly more fluorescent than those of the Cy dyes, especially at high degrees of labeling. The results from our flow cytometry, immunocytochemistry, and immunohistochemistry experiments demonstrate that protein-conjugated, long-wavelength Alexa Fluor dyes have advantages compared to the Cy dyes and other long-wavelength dyes in typical fluorescence-based cell labeling applications.