TY - JOUR A1 - Khrapov, D. A1 - Paveleva, A. A1 - Kozadayeva, M. A1 - Evsevleev, Sergei A1 - Mishurova, Tatiana A1 - Bruno, Giovanni A1 - Surmenev, R. A1 - Koptyug, A. A1 - Surmeneva, M. T1 - Trapped powder removal from sheet-based porous structures based on triply periodic minimal surfaces fabricated by electron beam powder bed fusion N2 - Electron Beam Powder Bed Fusion-manufactured (E-PBF) porous components with narrow pores or channels and rough walls or struts can be filled with trapped powder after the manufacturing process. Adequate powder removal procedures are required, especially for high-density porous structures. In the present research, sheetbased porous structures with different thicknesses based on triply periodic minimal surfaces fabricated by EPBF were subjected to different post-processing methods, including a traditional powder recovery system for EPBF, chemical etching and ultrasound vibration-assisted powder removal. Wall thickness, internal defects, microstructure and morphology features, powder distribution inside the specimens, mechanical properties and deformation modes were investigated. A powder recovery system could not remove all residual powder from dense structures. In turn, chemical etching was effective for surface morphology changes and subsurface layers elimination but not for powder removal, as it affected the wall thickness, considerably influencing the mechanical properties of the whole structure. The ultrasound vibration method was quite effective for the removal of residual powder from sheet-based TMPS structures and without a severe degradation of mechanical properties. 10.1016/j.msea.2022.144479 Ultrasound vibration also caused grain refinement. KW - Additive manufacturing KW - Residual powder removal KW - Ti6Al4V alloy KW - Electron beam powder bed fusion KW - TPMS structures PY - 2023 U6 - https://doi.org/10.1016/j.msea.2022.144479 VL - 862 SP - 1 EP - 16 PB - Elsevier B.V. AN - OPUS4-56564 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Khrapov, D. A1 - Kozadayeva, M. A1 - Manabaev, K. A1 - Panin, A. A1 - Sjöström, W. A1 - Koptyug, A. A1 - Mishurova, Tatiana A1 - Evsevleev, Sergei A1 - Meinel, Dietmar A1 - Bruno, Giovanni A1 - Cheneler, D. A1 - Surmenev, R. A1 - Surmeneva, M. T1 - Different approaches for manufacturing Ti-6Al-4V alloy with triply periodic minimal surface sheet-based structures by electron beam melting N2 - Targeting biomedical applications, Triply Periodic Minimal Surface (TPMS) gyroid sheet-based structures were successfully manufactured for the first time by Electron Beam Melting in two different production Themes, i.e., inputting a zero (Wafer Theme) and a 200 µm (Melt Theme) wall thickness. Initial assumption was that in both cases, EBM manufacturing should yield the structures with similar mechanical properties as in a Wafer-mode, as wall thickness is determined by the minimal beam spot size of ca 200 µm. Their surface morphology, geometry, and mechanical properties were investigated by means of electron microscopy (SEM), X-ray Computed Tomography (XCT), and uniaxial tests (both compression and tension). Application of different manufacturing Themes resulted in specimens with different wall thicknesses while quasi-elastic gradients for different Themes was found to be of 1.5 GPa, similar to the elastic modulus of human cortical bone tissue. The specific energy absorption at 50% strain was also similar for the two types of structures. Finite element simulations were also conducted to qualitatively analyze the deformation process and the stress distribution under mechanical load. Simulations demonstrated that in the elastic regime wall, regions oriented parallel to the load are primarily affected by deformation. We could conclude that gyroids manufactured in Wafer and Melt Themes are equally effective in mimicking mechanical properties of the bones. KW - Electron beam melting KW - Scaffold KW - Lightweight structures KW - Computed tomography PY - 2021 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-531595 SN - 1996-1944 VL - 14 IS - 17 SP - 1 EP - 21 PB - MDPI CY - Basel AN - OPUS4-53159 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Evsevleev, Sergei A1 - Mishurova, Tatiana A1 - Khrapov, D. A1 - Paveleva, A. A1 - Meinel, Dietmar A1 - Surmenev, R. A1 - Surmeneva, M. A1 - Koptyug, A. A1 - Bruno, Giovanni T1 - X-ray Computed Tomography Procedures to Quantitatively Characterize the Morphological Features of Triply Periodic Minimal Surface Structures N2 - Additively manufactured (AM) metallic sheet-based Triply Periodic Minimal Surface Structures (TPMSS) meet several requirements in both bio-medical and engineering fields: Tunable mechanical properties, low sensitivity to manufacturing defects, mechanical stability, and high energy absorption. However, they also present some challenges related to quality control, which can prevent their successful application. In fact, the optimization of the AM process is impossible without considering structural characteristics as manufacturing accuracy, internal defects, as well as surface topography and roughness. In this study, the quantitative non-destructive analysis of TPMSS manufactured from Ti-6Al-4V alloy by electron beam melting was performed by means of X-ray computed tomography (XCT). Several advanced image analysis workflows are presented to evaluate the effect of build orientation on wall thicknesses distribution, wall degradation, and surface roughness reduction due to the chemical etching of TPMSS. It is shown that the manufacturing accuracy differs for the structural elements printed parallel and orthogonal to the manufactured layers. Different strategies for chemical etching show different powder removal capabilities and both lead to the loss of material and hence the gradient of the wall thickness. This affects the mechanical performance under compression by reduction of the yield stress. The positive effect of the chemical etching is the reduction of the surface roughness, which can potentially improve the fatigue properties of the components. Finally, XCT was used to correlate the amount of retained powder with the pore size of the functionally graded TPMSS, which can further improve the manufacturing process. KW - Metamaterials KW - Functionally graded porous structure KW - Triply periodic minimal surface structures KW - Roughness analysis KW - Powder removal KW - Deep learning segmentation PY - 2021 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-528142 VL - 14 IS - 11 SP - 3002 PB - MDPI AN - OPUS4-52814 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Khrapov, D. A1 - Surmeneva, M. A1 - Koptioug, A. A1 - Evsevleev, Sergei A1 - Léonard, Fabien A1 - Bruno, Giovanni A1 - Surmenev, R. T1 - X-ray computed tomography of multiple-layered scaffolds with controlled gradient cell lattice structures fabricated via additive manufacturing N2 - In this paper we report on the characterization by X-ray computed tomography of calcium phosphate (CaP) and polycaprolactone (PCL) coatings on Ti-6Al-4V alloy scaffolds used as a material for medical implants. The cylindrical scaffold has greater porosity of the inner part than the external part, thus, mimicking trabecular and cortical bone, respectively. The prismatic scaffolds have uniform porosity. Surface of the scaffolds was modified with calcium phosphate (CaP) and polycaprolactone (PCL) by dip-coating to improve biocompatibility and mechanical properties. Computed tomography performed with X-ray and synchrotron radiation revealed the defects of structure and morphology of CaP and PCL coatings showing small platelet-like and spider-web-like structures, respectively.  KW - Mechanical Engineering KW - Maskinteknik PY - 2019 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-510763 SN - 17426588 VL - 1145 SP - 012044 PB - IOP AN - OPUS4-51076 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Khrapov, D A1 - Koptyug, A. A1 - Manabaev, K. A1 - Léonard, Fabien A1 - Mishurova, Tatiana A1 - Bruno, Giovanni A1 - Cheneler, D. A1 - Loza, K. A1 - Epple, M. A1 - Surmenev, R. A1 - Surmeneva, M. T1 - The impact of post manufacturing treatment of functionally graded Ti6Al4V scaffolds on their surface morphology and mechanical strength N2 - An ultrasonic vibration post-treatment procedure was suggested for additively manufac-tured lattices. The aim of the present research was to investigate mechanical properties andthe differences in mechanical behavior and fracture modes of Ti6Al4V scaffolds treated withtraditional powder recovery system (PRS) and ultrasound vibration (USV). Scanning electronmicroscopy (SEM) was used to investigate the strut surface and the fracture surface mor-phology. X-ray computed tomography (CT) was employed to evaluate the inner structure,strut dimensions, pore size, as well as the surface morphology of additively manufacturedporous scaffolds. Uniaxial compression tests were conducted to obtain elastic modulus,compressive ultimate strength and yield stress. Finite element analysis was performedfor a body-centered cubic (BCC) element-based model and for CT-based reconstructiondata, as well as for a two-zone scaffold model to evaluate stress distribution during elasticdeformation. The scaffold with PRS post treatment displayed ductile behavior, while USVtreated scaffold displayed fragile behavior. Double barrel formation of PRS treated scaffoldwas observed during deformation. Finite element analysis for the CT-based reconstructionrevealed the strong impact of surface morphology on the stress distribution in comparisonwith BCC cell model because of partially molten metal particles on the surface of struts,which usually remain unstressed. KW - Additive manufacturing KW - Electron beam melting KW - Computed tomography KW - FEM KW - Lattice structures PY - 2020 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-505960 SN - 2238-7854 VL - 9 IS - 2 SP - 1866 EP - 1881 PB - Elsevier B.V. AN - OPUS4-50596 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Surmeneva, M. A1 - Koptyug, A. A1 - Khrapov, D. A1 - Ivanov, Yuriy A1 - Mishurova, Tatiana A1 - Evsevleev, Sergei A1 - Prymak, O. A1 - Loza, K. A1 - Epple, M. A1 - Bruno, Giovanni A1 - Surmenev, R. T1 - In situ synthesis of a binary Ti–10at% Nb alloy by electron beam melting using a mixture of elemental niobium and titanium powders N2 - This study reports the results of the preliminary assessment to fabricate Ti-10at% Nb alloy by electron beam melting (EBM®) from a blend of elemental Nb and Ti powders. The microstructure of the EBM-manufactured Ti-10at% Nb alloys is sensitive to the following factors: different sintering properties of Nb and Ti powders, powder particle properties, material viscosities at varying melt pool temperatures, β-stabilizer element content and the EBM® process parameters. Three phases were observed in as-manufactured Ti-10at% Nb alloy: μm-size Nb phase, a Nb-rich β-solid solution surrounding Nb phase, lamellar structured α-phase and β-solid solution with different distribution and volume fraction. Thus, the combination of powder particle characteristics, very short time material spends in molten condition and sluggish kinetics of mixing and diffusional process in Ti-Nb alloy results in heterogeneous microstructures depending on the local Nb content in the powder blend and the EBM® process conditions. KW - Additive manufacturing KW - Electron beam melting KW - Ti-Nb alloy KW - In situ alloying PY - 2020 U6 - https://doi.org/10.1016/j.jmatprotec.2020.116646 VL - 282 SP - 116646 PB - Elsevier B.V. AN - OPUS4-50457 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Khrapov, D. A1 - Surmeneva, M. A1 - Koptioug, A. A1 - Evsevleev, Sergei A1 - Léonard, Fabien A1 - Bruno, Giovanni A1 - Surmenev, R. T1 - X-ray computed tomography of multiple-layered scaffolds with controlled gradient cell lattice structures fabricated via additive manufacturing N2 - In this paper we report on the characterization by X-ray computed tomography of calcium phosphate (CaP) and polycaprolactone (PCL) coatings on Ti-6Al-4V alloy scaffolds used as a material for medical implants. The cylindrical scaffold has greater porosity of the inner part than the external part, thus, mimicking trabecular and cortical bone, respectively. The prismatic scaffolds have uniform porosity. Surface of the scaffolds was modified with calcium phosphate (CaP) and polycaprolactone (PCL) by dip-coating to improve biocompatibility and mechanical properties. Computed tomography performed with X-ray and synchrotron radiation revealed the defects of structure and morphology of CaP and PCL coatings showing small platelet-like and spider-web-like structures, respectively. KW - Additive manufacturing KW - Lattice structure KW - Multiple-layered scaffold KW - Coating KW - Medical implants KW - Computed tomography KW - Polycaprolactone KW - Calcium phosphate PY - 2019 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-471931 UR - http://stacks.iop.org/1742-6596/1145/i=1/a=012044 SN - 1742-6596 VL - 1145 SP - 012044, 1 EP - 7 PB - IOP AN - OPUS4-47193 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Khrapov, D. A1 - Kozadayeva, M. A1 - Koptyug, A. A1 - Mishurova, Tatiana A1 - Meinel, Dietmar A1 - Surmenev, R. A1 - Surmeneva, M. T1 - Geometrical features and mechanical properties of the sheet-based gyroid scaffolds with functionally graded porosity manufactured by electron beam melting N2 - Functionally graded porous scaffolds (FGPS) constructed with pores of different size arranged as spatially continuous structure based on sheet-based gyroid with three different scaling factors of 0.05, 0.1 and 0.2 were produced by electron beam powder bed fusion. The pore dimensions of the obtained scaffolds satisfy the values required for optimal bone tissue ingrowth. Agglomerates of residual powder were found inside all structures, which required post-manufacturing treatment. Using X-ray Computed Tomography powder agglomerations were visualized and average wall thickness, wall-to-wall distances, micro- and macro-porosities were evaluated. The initial cleaning by powder recovery system (PRS) was insufficient for complete powder removal. Additional treatment by dry ultrasonic vibration (USV) was applied and was found successful for gyroids with the scaling factors of 0.05 and 0.1. Mechanical properties of the samples, including quasi-elastic gradients and first maximum compressive strengths of the structures before and after USV were evaluated to prove that additional treatment does not produce structural damage. The estimated quasi-elastic gradients for gyroids with different scaling factors lie in a range between 2.5 and 2.9 GPa, while the first maximum compressive strength vary from 52.5 for to 59.8 MPa, compressive offset stress vary from 46.2 for to 53.2 MPa. KW - Additive manufacturing KW - Electron beam KW - Powder bed fusion KW - Triply periodic minimal surfaces KW - Functionally graded porous scaffolds KW - X-ray computed tomography PY - 2023 U6 - https://doi.org/10.1016/j.mtcomm.2023.106410 SN - 2352-4928 VL - 35 SP - 1 EP - 9 PB - Elsevier Ltd. AN - OPUS4-57682 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -