Search for: All records

Additive manufacturing (AM) of metals attracts attention because it can produce complex structures in a single step without part-specific tooling. Wire arc additive manufacturing (WAAM), a welding-based method that deposits metal layer by layer, is gaining popularity due to its low cost of operation, feasibility for large-scale part fabrication, and ease of operation. This article presents the fabrication of cylindricalshaped mild steel (ER70S-6) samples with a gas metal arc (MIG)—based hybrid WAAM system. A mechanism for actively cooling the substrate is implemented. Deposition parameters are held constant to evaluate the impact of active cooling on deposition quality, inter-pass cooling time, and internal defects. Surface and volume defects can be seen on the cylindrical sample fabricated without an active cooling setup. Defect quantification and phase analysis are performed. The primary phase formed was α-iron in all samples. Actively cooled deposition cross section showed a 99% decrease of incomplete fusion or porosity, with temperature measured 60 s after deposition averaging 235°C less than non-cooled. Microstructural analysis revealed uniformity along the build direction for actively cooled deposition but non-uniform microstructures without cooling. Hardness decreased by approximately 22HV from the first layer to the final layer in all cases. Property variation can be attributed to the respective processing strategies. The current study has demonstrated that active cooling can reduce production time and porosity while maintaining uniform microstructure along the build direction. Such an approach is expected to enhance the reliability of WAAM-processed parts in the coming days. 

Abstract The presence of in-plane chiral effects, hence spin–orbit coupling, is evident in the changes in the photocurrent produced in a TiS 3 (001) field-effect phototransistor with left versus right circularly polarized light. The direction of the photocurrent is protected by the presence of strong spin–orbit coupling and the anisotropy of the band structure as indicated in NanoARPES measurements. Dark electronic transport measurements indicate that TiS 3 is n-type and has an electron mobility in the range of 1–6 cm 2 V −1 s −1 . I – V measurements under laser illumination indicate the photocurrent exhibits a bias directionality dependence, reminiscent of bipolar spin diode behavior. Because the TiS 3 contains no heavy elements, the presence of spin–orbit coupling must be attributed to the observed loss of inversion symmetry at the TiS 3 (001) surface. 

Processing and characterization for zirconia toughened alumina (ZTA) coatings on Ti6Al4V (Ti64) alloy by directed energy deposition (DED)-based additive manufacturing (AM) is presented here. The objective of the study was to achieve a dense ZTA coating with the intent of providing an alternative to fully ceramic implants for articulating surfaces of total hip arthroplasty (THA). Preliminary work resulted in failed samples due to cracking, porosity, and delamination. After careful parameter optimization, a Ti64+5wt.%ZTA (5ZTA) composition produced a metallurgically sound and coherent coating with minimal porosity. Additionally, bulk structures were also feasible with the optimized coating parameters. Characterization of the 5ZTA composition displayed a 27.0% increase in hardness, 25% reduction in normalized wear rate, an increase in contact resistance during in vitro tribological testing along with a faster surface re-passivation post-tribological testing. 

Titanium has been used in various biomedical applications; however, titanium exhibits poor wear resistance, and its bioinert surface slows osseointegration in vivo. In this study, directed energy deposition (DED)-based additive manufacturing (AM) was used to process hydroxyapatite (HA) reinforced Ti6Al4V (Ti64) composites to improve biocompatibility and wear resistance simultaneously. Electron micrographs of the composites revealed dense microstructures where HA is observed at the β-phase grain boundaries. Hardness was observed to increase by 57% and 71% for 2 and 3 wt.% HA in Ti64 composites, respectively. XRD analysis revealed no change in the present phases. Tribological studies revealed an increase in contact resistance due to in situ HA-based tribofilm formation, reduction in wear rate when testing in DMEM with a ZrO2 counter wear ball, ˂1% wear ball volume loss, and suppression of cohesive failure of the Ti matrix. Histomorphometric analysis from a rat distal femur study revealed an increase in the osteoid surface over the bone surface (OS/BS) for 3 wt.% HA composite over the control Ti64 from 9 ± 1% to 14 ± 1%. Shear modulus was also observed to increase from 17 ± 3 MPa for control Ti64 to 32 ± 5 MPa for the 3 wt.% HA composite after 5 weeks. Our study demonstrates that the addition of HA in Ti64 can simultaneously improve bone tissue-implant response and wear resistance. 

Directed energy deposition (DED) was used to produce niobium carbide (NbC)‐reinforced Ti6Al4V (Ti64) metal–matrix‐composite (MMC) structures. The objective was to improve upon Ti64's wear and oxidation resistance. The characterization techniques consisted of scanning electron microscopy (SEM), backscattered electron (BSE) imaging, energy‐dispersive X‐ray spectroscopy (EDS), X‐ray diffraction analysis (XRD), thermogravimetric analysis (TGA), Vickers micro‐ and nanoindentation‐derived hardness, as well as tribological testing at varying normal loads. DED produced compositions were of Ti64, Ti64 + 5 wt.% NbC (5NbC), and Ti64 + 10 wt.% NbC (10NbC). Electron micrographs revealed crack‐ and delamination‐free structures. Tribological analysis revealed a 25.1% reduction in specific wear rate. XRD and EDS results indicated the presence of a Ti‐Nb solid solution. It was deduced that the NbC particles coupled with the Ti‐Nb solid solution aided in increasing Ti64's resistance to plastic shear as the superficial microstructure remained unchanged compared to pure Ti64. Additionally, TGA displayed a reduction in total oxidation mass gain and suppressed oxidation kinetics to parabolic behavior with increased NbC. Application‐based composite structures with site‐specific mechanical properties were fabricated in the form of a composite cylinder, gear and compositionally graded cylinder. The graded cylinder displayed a 0%–45%NbC presence—end‐to‐end—equating to a hardness increase from 161.6 ± 4.0HV_0.2to 1055.9 ± 157.4HV_0.2.