A survey on mechanisms and critical parameters on solidification of selective laser melting during fabrication of Ti-6Al-4V prosthetic acetabular cup

Amir Mahyar Khorasani*, Ian Gibson, Moshe Goldberg, Guy Littlefair

*Corresponding author for this work

    Research output: Contribution to journalArticleAcademicpeer-review

    33 Citations (Scopus)

    Abstract

    Additive Manufacturing (AM) includes a range of approaches that correlate with computer aided design (CAD) and manufacturing by fabrication via precise layers and is a promising method for the production of medical tools. In this study, different aspects and mechanisms of solidification for curved surfaces based on equilibrium at curved interfaces, Monge patch, interfacial and Gibbs energy will be discussed. Also, the effect of capillarity, geometry, substrate temperature, cooling rate and scanning parameters in the solidification of a prosthetic acetabular cup (PAC) using selective laser melting (SLM) is analysed. The contributions of this work are analysing solidification and effective factors in this process to produce parts with a higher quality and mechanical properties such as strength, strain, porosity, relative density and hardness. Results indicate that due to the surface to volume (S/V) ratio, and the increasing effect of the radius on Monge patch, thermal stresses and surface forces are more prevalent on outer surfaces. Moreover, solidification and mechanical properties are related to capillarity, geometry, substrate temperature, cooling rate, scanning power and speed. The results also indicate the interaction of solute diffusion and heat transfer with interatomic forces in large S/V ratio and at small scales tend to improve solidification.

    Original languageEnglish
    Pages (from-to)348-355
    Number of pages8
    JournalMaterials and Design
    Volume103
    DOIs
    Publication statusPublished - 5 Aug 2016

    Keywords

    • Acetabular shell
    • Gibbs free energy
    • Selective laser melting
    • Solidification
    • Surface energy
    • Thermal stress

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