Study on the geometric characteristics and distribution of porosities in three-dimensional printed Ti-6Al-4V titanium alloy_Journal of Biomedical Engineering

Authors：

WAN Zhipeng ^1,3 , JIANG Wentao ^2,3 ,  WANG Chong ^1,2,4 , WANG Qingyuan ^1,2,4 , LI Yalan ^2,3

1. Key Laboratory of Deep Underground Science and Engineering (Sichuan University), Ministry of Education, Chengdu 610065, P.R.China;
2. Department of Sichuan University Mechanical Science and Engineering, Sichuan University, Chengdu 610065, P.R.China;
3. Sichuan Province Biomechanical Engineering Laboratory, Sichuan University, Chengdu 610065, P.R.China;
4. Key Laboratory of Mechanics and Engineering Disaster Prevention and Mitigation of Sichuan Province, Sichuan University, Chengdu 610065, P.R.China;

Corresponding author：

WANG Chong, Email: wangchongscu@163.com

Keywords：

electron beam melting; material defects; pores density; sphericity; distribution of porosities

DOI：

10.7507/1001-5515.201703048

Video：

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Three dimensional (3D) printing is considered as an advanced manufacturing technology because of its additive nature. Electron beam melting (EBM) is a widely used 3D printing processes for the manufacturing of metal components. However, the products printed via this process generally contain micro porosities which affect mechanical properties, especially the fatigue property. In this paper, two types of EBM printed samples of the Ti-6Al-4V alloy, one with a round cross section and the other with a triangle cross section, were employed to investigate the existence of porosities using computed tomography (CT). Statistical analyses were conducted on the number, volume, shape, and distribution of pores. The results show that small pores (less than 0.000 2 mm³) account for 80% of all pores in each type of samples. Additionally, to some extent, the shape of sample has influence on the number of micro porosities in EBM made Ti-6Al-4V. The sphericity of the pores is relatively low and is inversely proportional to pore volume. It is found that re-melting on the free surface effectively reduce pore density near the surface. This study may help produce a medical implant with better fatigue resistance.

Citation： WAN Zhipeng, JIANG Wentao, WANG Chong, WANG Qingyuan, LI Yalan. Study on the geometric characteristics and distribution of porosities in three-dimensional printed Ti-6Al-4V titanium alloy. Journal of Biomedical Engineering, 2017, 34(6): 876-882. doi: 10.7507/1001-5515.201703048 Copy

1.	Huang Y, Han S, Pang X, et al. Electro deposition of porous hydroxyapatite/calcium silicate composite coating on titanium for biomedical applications. Appl Surf Sci, 2013, 271(6): 299-302.
2.	Qiao Feng, Li Dichen, Jin Zhongmin, et al. Application of 3D printed customized external fixator in fracture reduction. Injury, 2015, 46(6): 1150-1155.
3.	Cohen J, Reyes S A. Creation of a 3D printed temporal bone model from clinical CT data. Am J Otolaryngol, 2015, 36(5): 619-624.
4.	胡堃, 李路海, 余均武, 等. 3D 打印技术在骨科个性化治疗中的应用. 高分子通报, 2015(9): 61-70.
5.	杨永强, 宋长辉, 王迪. 激光选区熔化技术及其在个性化医学中的应用. 机械工程学报, 2014(21): 140-151.
6.	罗丽娟, 余森, 于振涛, 等. 3D 打印钛合金人体植入物的应用与研究. 钛工业进展, 2015(5): 1-6.
7.	罗丽娟, 余森, 于振涛, 等. 3D 打印钛及钛合金医疗器械的优势及临床应用现状. 生物骨科材料与临床研究, 2015, 12(6): 72-75.
8.	邱冰, 张明娇, 唐本森, 等. 基于 3D 打印个性化手术导航模板辅助下的人工全膝关节置换. 中国组织工程研究, 2015, 19(48): 7731-7735.
9.	Shah F A, Snis A, Matic A, et al. 3D printed Ti6Al4V implant surface promotes bone maturation and retains a higher density of less aged osteocytes at the bone-implant interface. Acta Biomater, 2016, 30: 357-367.
10.	Cunningham R, Narra S P, Ozturk T, et al. Evaluating the effect of processing parameters on porosity in electron beam melted Ti-6Al-4V via synchrotron X-ray microtomography. JOM, 2016, 68(3): 765-771.
11.	Güenther J, Krewerth D, Lippmann T, et al. Fatigue Life of additively manufactured Ti-6Al-4V in the very high cycle fatigue regime. Int J Fatigue, 2017, 94(2, SI): 236-245.
12.	Sterling A, Shamsaei N, Torries B, et al. Fatigue behaviour of additively manufactured Ti-6Al-4V. Procedia Engineering, 2015, 133: 576-589.
13.	Seifi M, Salem A, Satko D, et al. Defect distribution and microstructure heterogeneity effects on fracture resistance and fatigue behavior of EBM Ti-6Al-4V. Int J Fatigue, 2017, 94(2, SI): 263-287.
14.	Guo Ruipeng, Xu Lei, Wu Jie, et al. Microstructural evolution and mechanical properties of powder metallurgy Ti-6Al-4V alloy based on heat response. Materials Science and Engineering A, 2015, 639: 327-334.
15.	Chen Xiaojun, Xu Lu, Wang Yiping, et al. Image-guided installation of 3D-printed patient-specific implant and its application in pelvic tumor resection and Reconstruction surgery. Comput Methods Programs Biomed, 2016, 125: 66-78.
16.	Kim Y C, Jeong W S, Park T K, et al. The accuracy of patient specific implant prebented with 3D-printed rapid prototype model for orbital wall reconstruction. J Craniomaxillofac Surg, 2017, 45(6): 928-936.
17.	Limmahakhun S, Oloyede A, Sitthiseripratip K, et al. 3D-printed cellular structures for bone biomimetic implants. Additive Manufacturing, 2017, 15: 93-101.
18.	Palmquist A, Shah F A, Emanuelsson L, et al. A technique for evaluating bone ingrowth into 3D printed, porous Ti6Al4V implants accurately using X-ray micro-computed tomography and histomorphometry. Micron, 2017, 94: 1-8.
19.	Lenders S, Thöene M, Riemer A, et al. On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: Fatigue resistance and crack growth performance. Int J Fatigue, 2013, 48(3): 300-307.
20.	Benedetti M, Cazzolli M, Fontanari V, et al. Fatigue limit of Ti6Al4V alloy produced by Selective Laser Sintering. Procedia Structural Integrity, 2016, 2: 3158-3167.
21.	Plessis A D, Roux S G L, Els J, et al. Application of microCT to the non-destructive testing of an additive manufactured titanium component. Case Studies in Nondestructive Testing & Evaluation, 2015, 4: 1-7.
22.	万谦, 赵海东, 葛继龙. 微观孔洞对铝合金压铸件疲劳性能的影响. 中国有色金属学报, 2015, 25(3): 568-574.
23.	Gao Y X, Yi J Z, Lee P D, et al. The effect of porosity on the fatigue life of cast aluminium-silicon alloys. Fatigue & Fracture of Engineering Materials & Structures, 2004, 27(7): 559-570.
24.	Mo Defeng, He Guoqiu, Hu Zhengfei, et al. Crack initiation and propagation of cast A356 aluminum alloy under multi-axial cyclic loadings. Int J Fatigue, 2008, 30(10/11): 1843-1850.
25.	Gerard D A, Koss D A. The influence of porosity on short fatigue crack growth at large strain amplitudes. Int J Fatigue, 1991, 13(4): 345-352.
26.	Borbély A, Mughrabi H, Eisenmeier G, et al. A finite element modelling study of strain localization in the vicinity of near-surface cavities as a cause of subsurface fatigue crack initiation. International Journal of Fracture, 2002, 115(3): 227-232.
27.	杨正伟, 刘国权. 一种定量描述点的空间分布的新方法. 解剖学杂志, 1995(2): 89-92.
28.	Antonysamy A A, Meyer J, Prangnell P B. Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti-6Al-4V by selective electron beam melting. Materials Characterization, 2013, 84: 153-168.
29.	Al-Bermani S S, Blackmore M L, Zhang W, et al. The origin of microstructural diversity, texture, and mechanical properties in electron beam melted Ti-6Al-4V. Metallurgical and Materials Transactions A, 2010, 41(13): 3422-3434.
30.	Minjares J, Mireles J, Gaytan S M, et al. Installation and thermal feedback from a multi-wavelength pyrometer in electron beam melting// Proceedings of 25th Annual International Solid Freeform Fabrication Symposium. Austin: University of Texas, 2014: 288-297.
31.	Price S, Lydon J, Cooper K, et al. Experimental temperature analysis of powder-based electron beam additive manufacturing// Proceedings of 24th Annual International Solid Freeform Fabrication Symposium. Austin: University of Texas, 2013: 162-173.

1. Huang Y, Han S, Pang X, et al. Electro deposition of porous hydroxyapatite/calcium silicate composite coating on titanium for biomedical applications. Appl Surf Sci, 2013, 271(6): 299-302.
2. Qiao Feng, Li Dichen, Jin Zhongmin, et al. Application of 3D printed customized external fixator in fracture reduction. Injury, 2015, 46(6): 1150-1155.
3. Cohen J, Reyes S A. Creation of a 3D printed temporal bone model from clinical CT data. Am J Otolaryngol, 2015, 36(5): 619-624.
4. 胡堃, 李路海, 余均武, 等. 3D 打印技术在骨科个性化治疗中的应用. 高分子通报, 2015(9): 61-70.
5. 杨永强, 宋长辉, 王迪. 激光选区熔化技术及其在个性化医学中的应用. 机械工程学报, 2014(21): 140-151.
6. 罗丽娟, 余森, 于振涛, 等. 3D 打印钛合金人体植入物的应用与研究. 钛工业进展, 2015(5): 1-6.
7. 罗丽娟, 余森, 于振涛, 等. 3D 打印钛及钛合金医疗器械的优势及临床应用现状. 生物骨科材料与临床研究, 2015, 12(6): 72-75.
8. 邱冰, 张明娇, 唐本森, 等. 基于 3D 打印个性化手术导航模板辅助下的人工全膝关节置换. 中国组织工程研究, 2015, 19(48): 7731-7735.
9. Shah F A, Snis A, Matic A, et al. 3D printed Ti6Al4V implant surface promotes bone maturation and retains a higher density of less aged osteocytes at the bone-implant interface. Acta Biomater, 2016, 30: 357-367.
10. Cunningham R, Narra S P, Ozturk T, et al. Evaluating the effect of processing parameters on porosity in electron beam melted Ti-6Al-4V via synchrotron X-ray microtomography. JOM, 2016, 68(3): 765-771.
11. Güenther J, Krewerth D, Lippmann T, et al. Fatigue Life of additively manufactured Ti-6Al-4V in the very high cycle fatigue regime. Int J Fatigue, 2017, 94(2, SI): 236-245.
12. Sterling A, Shamsaei N, Torries B, et al. Fatigue behaviour of additively manufactured Ti-6Al-4V. Procedia Engineering, 2015, 133: 576-589.
13. Seifi M, Salem A, Satko D, et al. Defect distribution and microstructure heterogeneity effects on fracture resistance and fatigue behavior of EBM Ti-6Al-4V. Int J Fatigue, 2017, 94(2, SI): 263-287.
14. Guo Ruipeng, Xu Lei, Wu Jie, et al. Microstructural evolution and mechanical properties of powder metallurgy Ti-6Al-4V alloy based on heat response. Materials Science and Engineering A, 2015, 639: 327-334.
15. Chen Xiaojun, Xu Lu, Wang Yiping, et al. Image-guided installation of 3D-printed patient-specific implant and its application in pelvic tumor resection and Reconstruction surgery. Comput Methods Programs Biomed, 2016, 125: 66-78.
16. Kim Y C, Jeong W S, Park T K, et al. The accuracy of patient specific implant prebented with 3D-printed rapid prototype model for orbital wall reconstruction. J Craniomaxillofac Surg, 2017, 45(6): 928-936.
17. Limmahakhun S, Oloyede A, Sitthiseripratip K, et al. 3D-printed cellular structures for bone biomimetic implants. Additive Manufacturing, 2017, 15: 93-101.
18. Palmquist A, Shah F A, Emanuelsson L, et al. A technique for evaluating bone ingrowth into 3D printed, porous Ti6Al4V implants accurately using X-ray micro-computed tomography and histomorphometry. Micron, 2017, 94: 1-8.
19. Lenders S, Thöene M, Riemer A, et al. On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: Fatigue resistance and crack growth performance. Int J Fatigue, 2013, 48(3): 300-307.
20. Benedetti M, Cazzolli M, Fontanari V, et al. Fatigue limit of Ti6Al4V alloy produced by Selective Laser Sintering. Procedia Structural Integrity, 2016, 2: 3158-3167.
21. Plessis A D, Roux S G L, Els J, et al. Application of microCT to the non-destructive testing of an additive manufactured titanium component. Case Studies in Nondestructive Testing & Evaluation, 2015, 4: 1-7.
22. 万谦, 赵海东, 葛继龙. 微观孔洞对铝合金压铸件疲劳性能的影响. 中国有色金属学报, 2015, 25(3): 568-574.
23. Gao Y X, Yi J Z, Lee P D, et al. The effect of porosity on the fatigue life of cast aluminium-silicon alloys. Fatigue & Fracture of Engineering Materials & Structures, 2004, 27(7): 559-570.
24. Mo Defeng, He Guoqiu, Hu Zhengfei, et al. Crack initiation and propagation of cast A356 aluminum alloy under multi-axial cyclic loadings. Int J Fatigue, 2008, 30(10/11): 1843-1850.
25. Gerard D A, Koss D A. The influence of porosity on short fatigue crack growth at large strain amplitudes. Int J Fatigue, 1991, 13(4): 345-352.
26. Borbély A, Mughrabi H, Eisenmeier G, et al. A finite element modelling study of strain localization in the vicinity of near-surface cavities as a cause of subsurface fatigue crack initiation. International Journal of Fracture, 2002, 115(3): 227-232.
27. 杨正伟, 刘国权. 一种定量描述点的空间分布的新方法. 解剖学杂志, 1995(2): 89-92.
28. Antonysamy A A, Meyer J, Prangnell P B. Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti-6Al-4V by selective electron beam melting. Materials Characterization, 2013, 84: 153-168.
29. Al-Bermani S S, Blackmore M L, Zhang W, et al. The origin of microstructural diversity, texture, and mechanical properties in electron beam melted Ti-6Al-4V. Metallurgical and Materials Transactions A, 2010, 41(13): 3422-3434.
30. Minjares J, Mireles J, Gaytan S M, et al. Installation and thermal feedback from a multi-wavelength pyrometer in electron beam melting// Proceedings of 25th Annual International Solid Freeform Fabrication Symposium. Austin: University of Texas, 2014: 288-297.
31. Price S, Lydon J, Cooper K, et al. Experimental temperature analysis of powder-based electron beam additive manufacturing// Proceedings of 24th Annual International Solid Freeform Fabrication Symposium. Austin: University of Texas, 2013: 162-173.

Journal of Biomedical Engineering

Study on the geometric characteristics and distribution of porosities in three-dimensional printed Ti-6Al-4V titanium alloy

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