Analysis of variability in additive manufactured open cell porous structures

2017 ◽  
Vol 231 (6) ◽  
pp. 534-546
Author(s):  
Sam Evans ◽  
Eric Jones ◽  
Pete Fox ◽  
Chris Sutcliffe
Keyword(s):  
Porous Material ◽  
Pore Size ◽  
Porous Structures ◽  
Micro Computed Tomography ◽  
Microscopy Imaging ◽  
Geometric Properties ◽  
Open Cell ◽  
Material Thickness ◽  
Cell Structures ◽  
The Mean

In this article, a novel method of analysing build consistency of additively manufactured open cell porous structures is presented. Conventionally, methods such as micro computed tomography or scanning electron microscopy imaging have been applied to the measurement of geometric properties of porous material; however, high costs and low speeds make them unsuitable for analysing high volumes of components. Recent advances in the image-based analysis of open cell structures have opened up the possibility of qualifying variation in manufacturing of porous material. Here, a photogrammetric method of measurement, employing image analysis to extract values for geometric properties, is used to investigate the variation between identically designed porous samples measuring changes in material thickness and pore size, both intra- and inter-build. Following the measurement of 125 samples, intra-build material thickness showed variation of ±12%, and pore size ±4% of the mean measured values across five builds. Inter-build material thickness and pore size showed mean ranges higher than those of intra-build, ±16% and ±6% of the mean material thickness and pore size, respectively. Acquired measurements created baseline variation values and demonstrated techniques suitable for tracking build deviation and inspecting additively manufactured porous structures to indicate unwanted process fluctuations.

scholarly journals Photogrammetric analysis of additive manufactured metallic open cell porous structures

2018 ◽  
Vol 24 (8) ◽  
pp. 1380-1391 ◽  
Author(s):  
Samuel Evans ◽  
Eric Jones ◽  
Peter Fox ◽  
Chris Sutcliffe
Keyword(s):  
Pore Size ◽  
Low Cost ◽  
High Volume ◽  
Porous Structures ◽  
Micro Computed Tomography ◽  
Open Cell ◽  
Content Type ◽  
Material Thickness ◽  
Computed Tomography Scanning ◽  
Photogrammetric Method

PurposeThis paper aims to introduce a novel method for the analysis of open cell porous components fabricated by laser-based powder bed metal additive manufacturing (AM) for the purpose of quality control. This method uses photogrammetric analysis, the extraction of geometric information from an image through the use of algorithms. By applying this technique to porous AM components, a rapid, low-cost inspection of geometric properties such as material thickness and pore size is achieved. Such measurements take on greater importance, as the production of porous additive manufactured orthopaedic devices increases in number, causing other, slower and more expensive methods of analysis to become impractical.Design/methodology/approachHere the development of the photogrammetric method is discussed and compared to standard techniques including scanning electron microscopy, micro computed tomography scanning and the recently developed focus variation (FV) imaging. The system is also validated against test graticules and simple wire geometries of known size, prior to the more complex orthopaedic structures.FindingsThe photogrammetric method shows an ability to analyse the variability in build fidelity of AM porous structures for use in inspection purposes to compare component properties. While measured values for material thickness and pore size differed from those of other techniques, the new photogrammetric technique demonstrated a low deviation when repeating measurements, and was able to analyse components at a much faster rate and lower cost than the competing systems, with less requirement for specific expertise or training.Originality/valueThe advantages demonstrated by the image-based technique described indicate the system to be suitable for implementation as a means of in-line process control for quality and inspection applications, particularly for high-volume production where existing methods would be impractical.

scholarly journals APPROPRIATE MODELS FOR SIMULATING OPEN-POROUS MATERIALS

2017 ◽  
Vol 36 (2) ◽  
pp. 107 ◽  
Author(s):  
Tomasz Wejrzanowski ◽  
Samih Haj Ibrahim ◽  
Jakub Skibinski ◽  
Karol Cwieka ◽  
Krzysztof Jan Kurzydlowski
Keyword(s):  
Porous Materials ◽  
Pore Size ◽  
Open Porosity ◽  
Diameter Distribution ◽  
Cell Diameter ◽  
Micro Computed Tomography ◽  
Open Cell ◽  
Geometrical Features ◽  
Open Cell Foams ◽  
Number Of Faces

In the present paper two representative models applied for modeling of two types of porous materials - open-cell foams and open-porosity tapes - are addressed. Algorithms presented here base on Laguerre-Voronoi tessellations (open-cell foams) and the sphere representation (open-porosity tapes) and enable creating the desired porosity and pore size distribution. The geometrical features of the models, such as: porosity, mean pore size, cell diameter distribution and number of faces per cell were compared with those obtained by 3D micro-computed tomography and good agreement was obtained.

scholarly journals 3D Printing of Porous Scaffolds with Controlled Porosity and Pore Size Values

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1532 ◽  
Author(s):  
Irene Buj-Corral ◽  
Ali Bagheri ◽  
Oriol Petit-Rojo
Keyword(s):  
Pore Size ◽  
Pore Diameter ◽  
Desirability Function ◽  
Fused Deposition Modelling ◽  
Medical Applications ◽  
Porous Structures ◽  
Average Value ◽  
Fused Deposition ◽  
Body Tissues ◽  
The Mean

3D printed scaffolds can be used, for example, in medical applications for simulating body tissues or for manufacturing prostheses. However, it is difficult to print porous structures of specific porosity and pore size values with fused deposition modelling (FDM) technology. The present paper provides a methodology to design porous structures to be printed. First, a model is defined with some theoretical parallel planes, which are bounded within a geometrical figure, for example a disk. Each plane has randomly distributed points on it. Then, the points are joined with lines. Finally, the lines are given a certain volume and the structure is obtained. The porosity of the structure depends on three geometrical variables: the distance between parallel layers, the number of columns on each layer and the radius of the columns. In order to obtain mathematical models to relate the variables with three responses, the porosity, the mean of pore diameter and the variance of pore diameter of the structures, design of experiments with three-level factorial analysis was used. Finally, multiobjective optimization was carried out by means of the desirability function method. In order to favour fixation of the structures by osseointegration, porosity range between 0.5 and 0.75, mean of pore size between 0.1 and 0.3 mm, and variance of pore size between 0.000 and 0.010 mm2 were selected. Results showed that the optimal solution consists of a structure with a height between layers of 0.72 mm, 3.65 points per mm2 and a radius of 0.15 mm. It was observed that, given fixed height and radius values, the three responses decrease with the number of points per surface unit. The increase of the radius of the columns implies the decrease of the porosity and of the mean of pore size. The decrease of the height between layers leads to a sharper decrease of both the porosity and the mean of pore size. In order to compare calculated and experimental values, scaffolds were printed in polylactic acid (PLA) with FDM technology. Porosity and pore size were measured with X-ray tomography. Average value of measured porosity was 0.594, while calculated porosity was 0.537. Average value of measured mean of pore size was 0.372 mm, while calculated value was 0.434 mm. Average value of variance of pore size was 0.048 mm2, higher than the calculated one of 0.008 mm2. In addition, both round and elongated pores were observed in the printed structures. The current methodology allows designing structures with different requirements for porosity and pore size. In addition, it can be applied to other responses. It will be very useful in medical applications such as the simulation of body tissues or the manufacture of prostheses.

Effect of Sintering Temperature on Microstructure of Porous Materials Using Iron Tailing and Shale

2011 ◽  
Vol 84-85 ◽  
pp. 53-57
Author(s):  
Hui Xiao ◽  
Yang Lv ◽  
Bao Guo Ma
Keyword(s):  
Porous Material ◽  
Porous Materials ◽  
Pore Size ◽  
Sintering Temperature ◽  
Mineral Phase ◽  
Foaming Agent ◽  
The Mean ◽  
Section Topography

A type of porous material was prepared mainly using iron tailings and shale, adding foaming agent, fusing agent and flexibility agent. To determine the sintering system of porous materials basing on iron tailing and shale, the effect of sintering temperature on the microstructure of the samples was investigated by XRD and SEM as well as section topography. The results indicate that both the porosity and pore size of the samples become higher and bigger respectively as sintering temperature increases from 1100°C to 1130°C, while mineral phase anorthite decreases; when sintered at 1120°C, the size of pores is approximately the same with the mean pore size of 1.5mm; the pores are larger and some get connected to the adjacent pores when the sintering temperature increases to 1130°C.

Observation of the Pulp Chamber of Maxillary First Premolars: A Micro-computed Tomographic Study

2020 ◽  
Vol 16 (3) ◽  
pp. 224-230
Author(s):  
Gozde Serindere ◽  
Ceren Aktuna Belgin ◽  
Kaan Orhan
Keyword(s):  
Root Canal ◽  
Age Groups ◽  
Slice Thickness ◽  
Micro Ct ◽  
Micro Computed Tomography ◽  
Pulp Chamber ◽  
Anatomical Structures ◽  
Computed Tomographic ◽  
The Mean ◽  
Chamber Floor

Background: There are a few studies about the evaluation of maxillary first premolars internal structure with micro-computed tomography (micro-CT). The aim of this study was to assess morphological features of the pulp chamber in maxillary first premolar teeth using micro- CT. Methods: Extracted 15 maxillary first premolar teeth were selected from the patients who were in different age groups. The distance between the pulp orifices, the diameter of the pulp and the width of the pulp chamber floor were measured on the micro-CT images with the slice thickness of 13.6 µm. The number of root canal orifices and the presence of isthmus were evaluated. Results: The mean diameter of orifices was 0.73 mm on the buccal side while it was 0.61 mm on palatinal side. The mean distance between pulp orifices was 2.84 mm. The mean angle between pulp orifices was -21.53°. The mean height of pulp orifices on the buccal side was 4.32 mm while the mean height of pulp orifices on the palatinal side was 3.56 mm. The most observed shape of root canal orifices was flattened ribbon. No isthmus was found in specimens. Conclusion: Minor anatomical structures can be evaluated in more detail with micro-CT. The observation of the pulp cavity was analyzed using micro-CT.

scholarly journals Enhancing Density-Based Mining Waste Alkali-Activated Foamed Materials Incorporating Expanded Cork

CivilEng ◽  
2021 ◽  
Vol 2 (2) ◽  
pp. 523-540
Author(s):  
Imed Beghoura ◽  
Joao Castro-Gomes
Keyword(s):  
Mechanical Properties ◽  
Compressive Strength ◽  
Pore Size ◽  
Physical And Mechanical Properties ◽  
Critical Parameters ◽  
Porous Structures ◽  
Foaming Agent ◽  
Al Powder ◽  
Highly Porous ◽  
Alkali Activated

This study focuses on the development of an alkali-activated lightweight foamed material (AA-LFM) with enhanced density. Several mixes of tungsten waste mud (TWM), grounded waste glass (WG), and metakaolin (MK) were produced. Al powder as a foaming agent was added, varying from 0.009 w.% to 0.05 w.% of precursor weight. Expanded granulated cork (EGC) particles were incorporated (10% to 40% of the total volume of precursors). The physical and mechanical properties of the foamed materials obtained, the effects of the amount of the foaming agent and the percentage of cork particles added varying from 10 vol.% to 40% are presented and discussed. Highly porous structures were obtained, Pore size and cork particles distribution are critical parameters in determining the density and strength of the foams. The compressive strength results with different densities of AA-LFM obtained by modifying the foaming agent and cork particles are also presented and discussed. Mechanical properties of the cured structure are adequate for lightweight prefabricated building elements and components.

Computational and Experimental Studies of Cellular Samples Manufactured Using Additive Methods for Use in Advanced Lightweight Designs of Engine Parts

2020 ◽  
Author(s):  
Liubov Magerramova ◽  
Michael Volkov ◽  
Oleg Volgin ◽  
Pavel Kolos
Keyword(s):  
Fatigue Testing ◽  
Low Cycle Fatigue ◽  
Cell Structure ◽  
Experimental Studies ◽  
Cellular Structures ◽  
Uniaxial Tensile ◽  
Porous Structures ◽  
Lattice Cell ◽  
Cell Structures ◽  
Homogeneous Materials

Abstract The use of cellular structures is one way to reduce the weight of engine parts. Cellular structures are used to provide rigidity and strength for parts subject to compression, bending, and shock loads. Failure of the individual elements of a lattice/cell structure does not result in the destruction of the entire part; this stands in contrast to the structure of a conventional homogeneous metal object, in which cracks will continue to increase with increasing load, causing the destruction of the entire part. Lattice/cell structures have relatively high characteristics of rigidity and strength, excellent thermal insulation properties, energy absorption characteristics, and high fatigue resistance. The use of this type of structure in engine part construction opens up new opportunities for advanced aviation applications. However, the deformation behavior of porous and metallic structures differs significantly from that of conventional homogeneous materials. Samples with cellular and porous structures are themselves designs. Therefore, procedures for strength testing and interpretation of experimental results for cellular and porous structures differ from those for samples derived from homogeneous materials. The criteria for determining the properties of cellular structures include density, stiffness, ability to accumulate energy, etc. These parameters depend on the configuration of the cells, the size of each cell, and the thickness of the connecting elements. Mechanical properties of cellular structures can be established experimentally and confirmed numerically. Special cellular specimens have been designed for uniaxial tensile, bending, compression, shear, and low-cycle fatigue testing. Several variants of cell structures with relative densities ranging from 13 to 45% were considered. Specifically, the present study examined the stress-strain states of cell structures from brands “CobaltChrome MP1” powder compositions obtained by laser synthesis on an industrial 3D printer Concept Laser M2 Cusing Single Laser 400W. Numerical simulations of the tests were carried out by the finite element method. Then, the most rational cellular structures in terms of mass and strength were established on the basis of both real and numerical experiments.

Open-Cell Foam Metal Production and Characterization by Aluminum Solid Mold Investment Casting

2019 ◽  
Author(s):  
Kerem Altug Guler
Keyword(s):  
Investment Casting ◽  
Replication Process ◽  
Open Cell ◽  
Metal Fabrication ◽  
Cell Structures ◽  
Closed Cell ◽  
Small Complex ◽  
Open Cell Foam ◽  
Foam Metal ◽  
Cell Foam

Foam metals can be categorized in two basic classes: open-cell and closed-cell structures, which both have different numerous unique properties. Up to the present, several production processes have been developed for each class. Investment casting is known as a replication process for open-cell foam metal fabrication. Solid mold, which can be evaluated as a subtechnique of the investment casting, is specialized especially for small complex shapes with ultrathin sections. This work is a presentation of aluminum open-cell foam production with solid mold investment casting using two different kinds of patterns. The first one is “burnable,” in which liquid metal directly fills the shape of pattern and the second is “leachable,” in which metal takes the form of intergranular network shape of porous salt preforms.

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