Optimisation of single contour strategy in selective laser melting of Ti-6Al-4V lattices
Optimisation of single contour strategy in selective laser melting of Ti-6Al-4V lattices
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DOI：
10.1108/rpj-04-2021-0103
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发表时间：
2022-02
影响因子：
3.9
通讯作者：
Xue Cao;L. Carter;Victor M. Villapún;F. Cantaboni;Giulia De Sio;Morgan Lowther;S. Louth;L. Grover;Paola Ginestra;S. Cox
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文献类型：
--
作者：
Xue Cao;L. Carter;Victor M. Villapún;F. Cantaboni;Giulia De Sio;Morgan Lowther;S. Louth;L. Grover;Paola Ginestra;S. Cox
选择性激光熔化（SLM）越来越多地用于制造钛合金骨植入物，特别是对多孔晶格结构。这些复杂结构已被证明能够匹配天然骨力学行为，从而改善骨整合，同时提供许多临床优势，鼓励其在医疗器械中的广泛应用。然而，生产与典型SLM熔池尺寸相似的支撑直径的晶格，或使用用于大块固体部件的相同工艺参数和扫描策略，可能会导致几何不精确。本研究的目的是评估和优化生产Ti-6Al-4V晶格的单一轮廓策略。设计/方法/方法在此，与单一轮廓和填充方法（SC + F）相比，探索了未填充单轮廓（SC）扫描策略在提高多孔晶格重现性方面的潜力。为此，对不同支撑尺寸和扫描策略的Ti-6Al-4V金刚石单元晶格进行了两次参数分析。孔隙率和精度测量与加工参数和印刷策略相关，为晶格制造提供最佳的加工窗口。SC被证明是一种可行的策略，用于生产Ti-6Al-4V晶格，支撑直径低于350µm。参数分析强调了该方法在生产具有能量密度的全密支柱方面的局限性，该能量密度是指导参数选择某些方面的有用实用工具（在本研究中，设计支柱直径达到约0.1 J/mm）。最后，结合两种参数研究的数据，给出了一个过程图，用于指导、预测和控制使用SC策略获得的晶格支撑几何形状和孔隙度。这些结果探讨了使用非标准SC扫描策略作为一种可行的方法来生产基于支柱的晶格结构，并与传统的轮廓和填充方法（SC + F）进行了比较。
Purpose Selective laser melting (SLM) is increasingly used to manufacture bone implants from titanium alloys with particular interest in porous lattice structures. These complex constructs have been shown to be capable of matching native bone mechanical behaviour leading to improved osseointegration while providing numerous clinical advantages, encouraging their broad use in medical devices. However, producing lattices with a strut diameter similar in scale to a typical SLM melt pool or using the same process parameters and scan strategies intended for bulk solid components may lead to geometric inaccuracies. The purpose of this study is to evaluate and optimise the single contour strategy for the production of Ti-6Al-4V lattices. Design/methodology/approach Herein, the potential of an unfilled single contour (SC) scanning strategy to improve the reproducibility of porous lattices when compared with a single contour and fill approach (SC + F) is explored. For this purpose, two parametric analysis were carried out on Ti-6Al-4V diamond unit cell lattices with different strut sizes and scan strategies. Porosity and accuracy measurements were correlated with processing parameters and printing strategy to provide the optimal processing window for lattice manufacturing. Findings SC is shown to be a viable strategy for production of Ti-6Al-4V lattices with a strut diameter below 350 µm. Parametric analysis highlights the limits of this method in producing fully dense struts with energy density presented as a useful practical tool to guide some aspects of parameter selection (design strut diameter achieved at approximately 0.1 J/mm in this study). Finally, a process map combining data from both parametric studies is provided to guide, predict and control lattice strut geometry and porosity obtained using the SC strategy. Originality/value These results explore the use of non-standard SC scanning strategy as a viable method for producing strut-based lattice structures and compare against the traditional contour and fill approach (SC + F).