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Selective Laser Melting (SLM) is a powder-based additive manufacturing process that has gained substantial interest in recent years due to its feasibility of producing geometrically- complex metallic components for end-use in various industries, with or without post-treatment procedures. This paper presents recent research undertaken on different scanning strategies and process parameters with the purpose of providing an overview of the achievable material performance of Ti6Al4V components, and comparing its properties with the conventionally-produced parts. In order to understand their output, differences in the building strategies of the systems studied are analysed, and their influence on the resulting mechanical and metallurgical properties is highlighted.

In industry, post-process heat treatments of Ti-6Al-4V are performed with the aim of improving its tensile behaviour. While heat treatments of wrought Ti6Al4V have been standardised (e.g., Aerospace Material Specification H-81200), heat treatments of selective laser melting (SLM)-produced Ti-6Al-4V lacks research and understanding. Significant concern exists about SLM Ti6-Al-4V’s achievable ductility attributed to its martensitic (α’) phase. In this research, heat treatments at a range of temperatures are applied to SLM-produced Ti-6Al-4V tensile samples. Microstructural analysis (both optically and through electron backscatter diffraction) was used to identify links between heat treatments and microstructure. Subsequently, uniaxial tensile tests were performed to determine the respective tensile properties of all samples. Correlations in the data show a significant loss in strength with respect to an increase in annealing temperature due to grain growth, while no noticeable trend was observed for fracture strain with regard to annealing temperatures.

LaserCUSING® is a selective laser melting (SLM) process that is capable of manufacturing parts by melting powder with heat input from a laser beam. LaserCUSING demonstrates potential for producing the intricate geometries specifically required for biomedical implants and aerospace applications. One main limitation to this form of rapid prototyping is the lack of published studies on the material performance of the resulting material. Studies of the material’s performance are often complicated by dependence on several factors, including starting powder properties, laser parameters, and post-processing heat treatments. This study aims to investigate the mechanical properties of LaserCUSING-produced Ti-6Al-4V and its performance relative to the conventional wrought counterpart. A combination of conventional and LaserCUSING-tailored heat treatments is performed. The resulting microstructures are studied and linked to the properties obtained from hardness tests. The findings highlight that LaserCused Ti-6Al-4V is competitive with traditional materials, provided that optimal parameters are chosen and parts are subject to tailored post-processing. In the as-built condition, LaserCused Ti-6Al-4V displays superior strength and hardness as a result of a martensitic microstructure, and a poorer performance in ductility. However, the material performance can be improved using tailored heat treatments. Careful consideration must be given to suitable post-processing before application in critical components in the aerospace or biomedical industry can occur

Direct metal laser sintering (DMLS) is a selective laser melting (SLM) manufacturing process that can produce near net shape parts from metallic powders. A range of materials are suitable for SLM; they include various metals such as titanium, steel, aluminium, and cobalt-chrome alloys. This paper forms part of a research drive that aims to evaluate the material performance of the SLM-manufactured metals. It presents DMLS-produced Ti-6Al-4V, a titanium alloy often used in biomedical and aerospace applications. This paper also studies the effect of several heat treatments on the microstructure and mechanical properties of Ti-6Al-4V processed by SLM. It reports the achievable mechanical properties of the alloy, including quasi-static, crack growth behaviour, density and porosity distribution, and post-processing using various heat-treatment conditions.

The study of vertical crustal motion in the contiguous United States (CONUS) has traditionally focused on the high-amplitude deformation caused by glacial isostatic adjustment. To better understand more subtle vertical crustal motion resulting from other geophysical processes, we take advantage of the ongoing expansion of continuous Global Positioning System (GPS) networks, whose geodetic observations provide ever-increasing accuracy and spatial resolution of surface deformation. Using position data for 2,782 GPS stations operating between 2007 and 2017, we produce a new vertical crustal velocity field for the CONUS region. We estimate our own station velocities to ensure consistent treatment of time series outliers, noise, and offsets, and we use adaptive smoothing and interpolation to account for spatially varying station density. Our velocity field reveals spatially coherent vertical features that are representative of regional tectonics, hydrologic, and anthropogenic processes. By removing the effects of modeled glacial isostatic adjustment and hydrologic loading estimated from Gravity Recovery and Climate Experiment (GRACE) data, we reduce the variance in our velocity field by 36% and show residuals potentially due to geocenter motion and underlying tectonics.

To what extent mechanical anisotropy is required to explain the dynamics of the lithosphere is an important yet unresolved question. If anisotropy affects stress and deformation, and hence processes such as fault loading, how can we quantify its role from observations? Here, we derive analytical solutions and build a theoretical framework to explore how a shear zone with linear anisotropic viscosity can lead to deviatoric stress heterogeneity, strain-rate enhancement, as well as non-coaxial principal stress and strain rate. We develop an open-source finite-element software based on FEniCS for more complicated scenarios in both 2-D and 3-D. Mechanics of shear zones with transversely isotropic and orthorhombic anisotropy subjected to misoriented shortening and simple shearing are explored. A simple regional example for potential non-coaxiality for the Leech River Schist above the Cascadia subduction zone is presented. Our findings and these tools may help to better understand, detect and evaluate mechanical anisotropy in natural settings, with potential implications including the transfer of lithospheric stress and deformation through fault loading. [ABSTRACT FROM AUTHOR]

The tectonic configuration of the Caribbean plate is defined by inward‐dipping double subduction at its boundaries with the North American and Cocos plates. This geometry resulted from a Paleogene plate reorganization, which involved the abandonment of an older subduction system, the Great Arc of the Caribbean (GAC), and conversion into a transform margin during Lesser Antilles (LA) arc formation. Previous models suggest that a collision between the GAC and the Bahamas platform along the North American passive margin caused this event. However, geological and geophysical constraints from the Greater Antilles do not show a large‐scale compressional episode that should correspond to such a collision. We propose an alternative model for the evolution of the region where lower mantle penetration of the Farallon slab promotes the onset of subduction at the LA. We integrate tectonic constraints with seismic tomography to analyze the timing and dynamics of the reorganization, showing that the onset of LA subduction corresponds to the timing of Farallon/Cocos slab penetration. With numerical subduction models, we explore whether slab penetration constitutes a dynamically feasible set of mechanisms to initiate subduction in the overriding plate. In our models, when the first slab (Farallon/Cocos) enters the lower mantle, compressive stresses increase at the eastern margin of the upper plate, and a second subduction zone (LA) is initiated. The resulting first‐order slab geometries, timings, and kinematics compare well with plate reconstructions. More generally, similar slab dynamics may provide a mechanism not only for the Caribbean reorganization but also for other tectonic episodes throughout the Americas. Plain Language Summary: The Caribbean tectonic plate is bounded by subduction to the east and west. However, it is unclear how this plate configuration was achieved. Previous models suggest that the North American continental margin entered an ancient Caribbean subduction zone between 66 and 34 Mya, converting the margin to strike‐slip and initiating subduction to the east at the Lesser Antilles. However, the deformation expected for this event is absent at the site of the supposed collision. Considering geological and geophysical constraints across the Caribbean, we instead suggest that mantle processes drove the reorganization. Combining tomographic images of the mantle with plate modeling, we reconstruct subduction below the Caribbean. Then, through numerical mantle convection modeling, we simulate the Caribbean subduction setting at the time of the reorganization. Our results show that when a subducting plate enters the lower, higher viscosity part of the mantle, it affects mantle flow, causing compression in the overriding plate and the potential initiation of a second subduction zone. The timing when the first slab enters the lower mantle and subduction initiates aligns well with our reconstructions and geological constraints in the Caribbean. We hypothesize that a similar process may explain other major deformation episodes throughout the Americas. Key Points: Tectonic constraints conflict with previously proposed collision and escape models for Paleogene Caribbean reorganizationSlab reconstructions and geodynamic models suggest Farallon slab anchoring induced tectonic reorganizationIn this model, lower mantle slab penetration triggers mantle flow, lithospheric compression, and subduction initiation [ABSTRACT FROM AUTHOR]

The effect of mantle plumes is secondary to that of subducting slabs for modern plate tectonics when considering plate driving forces. However, the impact of plumes on tectonics and planetary surface evolution may nonetheless have been significant. We use numerical mantle convection models in a 3‐D spherical chunk geometry with damage rheology to study some of the dynamics of plume‐slab interactions. Substantiating our earlier 2‐D results, we observe a range of interaction scenarios, and that the plume‐driven subduction terminations we had identified earlier persist in more realistic convective flow. We analyze the dynamics of plume affected subduction, including in terms of their geometry, frequency, and the overall effect of plumes on surface dynamics as a function of the fraction of internal to bottom heating. Some versions of such plume‐slab interplay may be relevant for geologic events, for example, for the inferred ∼183 Ma Karoo large igneous province formation and associated slab disruption. More recent examples may include the impingement of the Afar plume underneath Africa leading to disruption of the Hellenic slab, and the current complex structure imaged for the subduction of the Nazca plate under South America. Our results imply that plumes may play a significant role not just in kick‐starting plate tectonics, but also in major modifications of slab‐driven plate motions, including for the present‐day mantle. Plain Language Summary: Subduction of cold, strong lithospheric slabs is the main plate driving force within mantle convection. However, hot upwellings, mantle plumes, may have a greater role in modulating plate motions and slab trajectories than previously thought. We use 3‐D numerical convection models that account for the weakening of rocks due to the accumulation of deformation to understand the effect that mantle plumes can have on subduction zones. We show that plumes can terminate subduction in a range of circumstances. We also test the effect of the amount of internal heating compared to heat from the core which is the major convective control on the importance of plumes. We discuss cases where these plume‐slab terminations may have occurred on Earth, in the geological past, and for the present day through plate reconstructions and consideration of seismic tomography. Key Points: Mantle plumes can terminate subduction in 3‐D, damage rheology convectionPlumes can modulate subducting slabs and plate tectonic regimesPlume‐slab interactions are plausible contributions to the Karoo‐Gondwana event [ABSTRACT FROM AUTHOR]

This study used laser powder bed fusion to produce highly dense Ti-4.7Mo-4.5Fe through in-situ alloying. The relative density range of the printed samples was from 96. 3 to 99.5 %. Partially unmelted Mo and lack of fusion pores were observed on some samples produced using a laser power of 80 W with a high scanning speed. Better diffusion of Mo in the Ti matrix and pores were observed at a higher laser power of 164-200 W. The microhardness of the printed samples was higher than that of other β-Ti with Mo as β stabiliser and was comparable to the microhardness of the Ti-4.7Mo-4.5Fe alloy produced using conventional methods. The phase identification of the printed samples indicated that samples of Ti-4.7Mo-4.5Fe containing α+β phases were produced, with β being the dominant phase. Microstructural analyses showed that the lamellar α structure was embedded within the equiaxed columnar β grains.

Predicting and preventing stress induced support failure during laser powder bed fusion (LPBF) processing requires knowledge of the fracture toughness of the material in its as-built condition. When performing laboratory measurement of fracture toughness, large residual stresses that are present in the part due to the LPBF process can significantly affect the measurement and must be taken into consideration. In this article, fracture toughness in the as-built condition was measured to be 26 MPa.m1/2 and the residual stress distribution in the crack plane was determined with simulation. Finally, the effective fracture toughness of the material was calculated, using the principle of superposition, to be ~ 47 MPa.m1/2.

Biomedical implants require stiffnesses matching those of the surrounding bone to avoid stress shielding. Triply-periodic-minimal-surface (TPMS) structures have shown promising characteristics in preventing stress shielding; however, they are limited in allowing for anisotropic stiffness properties that are typically inherent in bone. This paper presents an approach to simplifying a TPMS structure so that common geometries can be used to approximate it. The wall thickness is varied until the desired functional and directional stiffnesses are determined through finite element modelling. Validation of the finite element models is provided through the compression testing of laser powder bed fusion (LPBF) produced specimens. The displacement response to compression testing is presented along with the final structure, which closely matches the stiffness of bone. This approach has the potential to increase implant longevity and improve the lives of implant recipients.

Earth's style of planetary heat transport is characterized by plate tectonics which requires rock strength to be reduced plastically in order to break an otherwise stagnant lithospheric lid, and for rocks to have a memory of past deformation to account for strain localization and the hysteresis implied by geological sutures. Here, we explore ∼107 Rayleigh number, visco‐plastic, 3‐D global mantle convection with damage. We show that oceanic lithosphere‐only models generate strong toroidal‐poloidal power ratios and features such as a mix of long‐wavelength tectonic motions and smaller‐scale, back‐arc tectonics driven by downwellings. Undulating divergent plate boundaries can evolve to form overlapping spreading centers and microplates, promoted and perhaps stabilized by the effects of damage with long memory. The inclusion of continental rafts enhances heat flux variability and toroidal flow, including net rotation of the lithosphere, to a level seen in plate reconstructions for the Cenozoic. Both the super‐continental cycle and local rheological descriptions affect heat transport and tectonic deformation across a range of scales, and we showcase both general tectonic dynamics and regionally applied continental breakup scenarios. Our work points toward avenues for renewed analysis of the typical, mean behavior as well as the evolution of fluctuations in geological and model plate boundary evolution scenarios. Key Points: Results from global, ∼107 Rayleigh number, visco‐plastic mantle convection models with damageStrong toroidal‐poloidal coupling and mix of small and large‐scale plate tectonic features generatedSupercontinental rafts interact with oceanic lithosphere to generate complex spreading center morphologies [ABSTRACT FROM AUTHOR]

Several continuum damage mechanics (CDM) modelling approaches for predicting creep deformation of tempered ferritic steels have been developed in the literature, which have evolved from efforts to extend the operability of power plant components. Few of these models, however, focus on damage assessment of ex-service states of power plant steels through the extraction of damage parameters. Furthermore, few CDM approaches leverage the high density of creep curve data available through full-field strain measurement techniques such as digital image correlation (DIC). This work uses multiple creep curves obtained from DIC computed strain data at several stresses and temperatures from individual specimens of X20CrMoV12-1 (X20) piping steel. These curves serve as input data to a modified Oruganti continuum damage mechanics (CDM) model whereby microstructural-specific damage parameters can be extracted. Good agreement is noted between CDM-extracted parameters and microstructural, creep cavity density and hardness damage indicators. Damage parameters based on subgrain growth are particularly sensitive to the ex-service state of the X20 steel. The proposed CDM approach using DIC computed creep curves is shown to be a material efficient alternative to traditional damage assessment methods of ex-service material. [ABSTRACT FROM AUTHOR]

Understanding the causes of intraplate earthquakes is challenging, as it requires extending plate tectonic theory to the dynamics of continental deformation. Seismicity in the western United States away from the plate boundary is clustered along a meandering, north-south trending 'intermountain' belt (1). This zone coincides with a transition from thin, actively deforming to thicker, less tectonically active crust and lithosphere. Although such structural gradients have been invoked to explain seismicity localization (2,3), the underlying cause of seismicity remains unclear. Here we show results from improved mantle flow models that reveal a relationship between seismicity and the rate change of 'dynamic topography' (that is, vertical normal stress from mantle flow). The associated predictive skill is greater than that of any of the other forcings we examined. We suggest that active mantle flow is a major contributor to seismogenic intraplate deformation, while gravitational potential energy variations have a minor role. Seismicity localization should occur where convective changes in vertical normal stress are modulated by lithospheric strength heterogeneities. Our results on deformation processes appear consistent with findings from other mobile belts (4), and imply that mantle flow plays a significant and quantifiable part in shaping topography, tectonics, and seismic hazard within intraplate settings., Interplate earthquakes are well described by plate tectonics as a consequence of horizontal motion gradients within the surface boundary layer of thermo-chemical mantle convection. For seismicity away from plate boundaries, [...]

Mobile belts are long-lived deformation zones composed of an ensemble of crustal fragments, distributed over hundreds of kilometres inside continental convergent margins (1,2). The Mediterranean represents a remarkable example of this tectonic setting (3):the region hosts a diffuse boundary between the Nubia and Eurasia plates comprised of a mosaic of microplates that move and deform independently from the overall plate convergence (4). Surface expressions of Mediterranean tectonics include deep, subsiding backarc basins, intraplate plateaux and uplifting orogenic belts. Although the kinematics of the area are now fairly well defined, the dynamical origins of many of these active features are controversial and usually attributed to crustal and lithospheric interactions. However, the effects of mantle convection, well established for continental interiors (5-7), should be particularly relevant in a mobile belt, and modelling may constrain important parameters such as slab coherence and lithospheric strength. Here we compute global mantle flow on the basis of recent, high-resolution seismic tomography to investigate the role of buoyancy-driven and plate-motion-induced mantle circulation for the Mediterranean. We show that mantle flow provides an explanation for much of the observed dynamic topography and microplate motion in the region. More generally, vigorous small-scale convection in the uppermost mantle may also underpin other complex mobile belts such as the North American Cordillera or the Himalayan-Tibetan collision zone., Deep to intermediate seismicity in the Mediterranean is restricted to the Hellenic and Calabria Wadati--Benioff zones and locally beneath the Alboran region (8), although fast seismic velocity anomalies (9-11) run [...]

Tectonic plate motions predominantly result from a balance between the potential energy change of the subducting slab and viscous dissipation in the mantle, bending lithosphere and slab–upper plate interface. A wide range of observations from active subduction zones and exhumed rocks suggest that subduction interface shear zone rheology is sensitive to the composition of subducting crustal material—for example, sediments versus mafic igneous oceanic crust. Here we use 2-D numerical models of dynamically consistent subduction to systematically investigate how subduction interface viscosity influences large-scale subduction kinematics and dynamics. Our model consists of an oceanic slab subducting beneath an overriding continental plate. The slab includes an oceanic crustal/weak layer that controls the rheology of the interface. We implement a range of slab and interface strengths and explore how the kinematics respond for an initial upper mantle slab stage, and subsequent quasi-steady-state ponding near a viscosity jump at the 660-km-discontinuity. If material properties are suitably averaged, our results confirm the effect of interface strength on plate motions as based on simplified viscous dissipation analysis: a ∼2 order of magnitude increase in interface viscosity can decrease convergence speeds by ∼1 order of magnitude. However, the full dynamic solutions show a range of interesting behaviour including an interplay between interface strength and overriding plate topography and an end-member weak interface-weak slab case that results in slab break-off/tearing. Additionally, for models with a spatially limited, weak sediment strip embedded in regular interface material, as might be expected for the subduction of different types of oceanic materials through Earth's history, the transient response of enhanced rollback and subduction velocity is different for strong and weak slabs. Our work substantiates earlier suggestions as to the importance of the plate interface, and expands the range of quantifiable links between plate reorganizations, the nature of the incoming and overriding plate and the potential geological record. [ABSTRACT FROM AUTHOR]