Laser additive manufacturing of Zn porous scaffolds: Shielding gas flow, surface quality and densification

doi:10.1016/j.jmst.2018.09.065

材料科学与技术 ›› 2019, Vol. 35 ›› Issue (2): 368-376.DOI: 10.1016/j.jmst.2018.09.065

收稿日期:2018-06-29 修回日期:2018-07-21 接受日期:2018-09-23 出版日期:2019-02-05 发布日期:2018-12-21

Laser additive manufacturing of Zn porous scaffolds: Shielding gas flow, surface quality and densification

Peng Wen^a^b^*(), Yu Qin^b^c, Yanzhe Chen^b^c, Maximilian Voshage^d, Lucas Jauer^e, Reinhart Poprawe^e, Johannes Henrich Schleifenbaum^d^e

^aThe State Key Laboratory of Tribology, Tsinghua University, 100084 Beijing, China
^bKey Laboratory for Advanced Materials Processing Technology, MOE, Tsinghua University, 100084 Beijing, China
^cDepartment of Mechanical Engineering, Tsinghua University, 100084 Beijing, China
^dDigital Additive Production (DAP), RWTH Aachen University, Steinbachstraβe 15, 52074 Aachen, Germany
^eFraunhofer Institute for Laser Technology (ILT), Steinbachstraβe 15, 52074 Aachen, Germany

Received:2018-06-29 Revised:2018-07-21 Accepted:2018-09-23 Online:2019-02-05 Published:2018-12-21
Contact: Wen Peng

摘要/Abstract

Abstract:

Zn based metals have exhibited promising prospects as a structural material for biodegradable applications. Pure Zn porous scaffolds were produced by laser powder bed fusion (LPBF) based on data files of designing and CT scanning. Massive Zn evaporation during laser melting largely influenced the formation quality during LPBF of Zn metal. The metal vapor in processing chamber was blown off and suctioned out efficiently by an optimized gas circulation system. Numerical analysis was used to design and testify the performance of gas flow. The surface of scaffolds was covered with numerous particles in different sizes. Processing pores occurred near the outline contour of struts. The average grain size in width was 8.5 μm, and the hardness was 43.8 HV. Chemical plus electrochemical polishing obtained uniform and smooth surface without processing pores, but the diameter of struts reduced to 250 μm from the design value 300 μm. The poor surface quality and processing pores were resulted by the splashing particles included spatters and powders due to the recoil force of evaporation, and the horizontal movement of liquid metal due to overheating and wetting. The insufficient melting at the outline contour combined with good wetting of Zn liquid metal further increased the surface roughness and processing pores.

Key words: Additive manufacturing, Powder bed fusion, Laser, Porous scaffold, Zn

. [J]. 材料科学与技术, 2019, 35(2): 368-376.

Peng Wen, Yu Qin, Yanzhe Chen, Maximilian Voshage, Lucas Jauer, Reinhart Poprawe, Johannes Henrich Schleifenbaum. Laser additive manufacturing of Zn porous scaffolds: Shielding gas flow, surface quality and densification[J]. J. Mater. Sci. Technol., 2019, 35(2): 368-376.

图/表 13

Fig. 1. Powder observation: (a) powder shape, (b) powder cross section.

Fig. 2. Schematic of LPBF machine and gas circulation system: (a) LPBF machine, (b) cross section of the processing chamber in YZ direction.

Table 1 Parameters table for LPBF process.

Parameters	Notation	Unit	Value
Spot diameter	D	μm	75
Defocus distance	H	mm	0
Layer thickness	Ds	μm	30
Laser power	P	W	80
Scanning speed	V	mm/s	400
Hatch spacing	Hs	μm	70

Fig. 3. Different structures of blow-off screens.

Fig. 4. Velocity distribution with different types of blow-off screens.

Fig. 5. Mass fraction contours of Zn metal vapor under the optimized gas flow.

Fig. 6. Zn vapor captured by high speed camera: (a) high illumination; (b) low illumination.

Fig. 7. Zn porous scaffolds obtained by LPBF: (a) and (b) lattice structures with different geometries, (c) a part of greater trochanter bone.

Fig. 8. Local parts of Zn porous scaffold under SEM: (a) as melted, (b) after sandblasting, (c) after chemical polishing, (d) after chemical plus electrochemical polishing.

Fig. 9. Enlarged struts of Zn porous structure under SEM, (a) as melted, (b) after sandblasting, (c) after chemical polishing, (d) after chemical plus electrochemical polishing.

Fig. 10. CT reconstruction of porous scaffolds, (a) total overview, (b) cross section overview, (c) (d) enlarged cross section, (e) density distribution contour.

Fig. 11. Cross sections of struts under OM at different struts.

Fig. 12. Microstructures by EBSD observation.

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Laser additive manufacturing of Zn porous scaffolds: Shielding gas flow, surface quality and densification

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