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Residual stress is a major problem for most metal-based laser powder bed fusion (L-PBF) components. Residual stress can be reduced by appropriate build planning and post-process heat treatments; however, it is not always avoidable and can lead to build failures due to distortion and cracking. Accurate measurement of residual stress levels can be difficult due to high equipment set-up costs and long processing times. This paper introduces a simple but novel method of measuring residual stresses via a three-pronged cantilever component, the three-prong method (TPM). The method allows for a quick and easy characterisation of residual stress for a wide range of machine parameters, build strategies and materials. Many different cantilever designs have been used to indicate residual stress within additive manufacturing techniques. All of which share the same shortcoming that they indicate stress in one direction. If the principal component of stress is not aligned with the beam geometry, it will underestimate peak stress values. A novel three-prong design is proposed which covers two dimensions by utilising three adjoined cantilever beams, a configuration which echoes that of hole-drilling where three measurements are used to calculate the stress field around a drilled hole. Each arm of the component resembles a curved bridge-like structure; one end of each bridge is cut away from the base plate leaving the centre intact. Deformation of the beams is then measured using a co-ordinate measurement machine. Stress profiles are then estimated using finite element analysis by meshing the deflected structure and forcing it back to its original shape. In this paper, the new TPM is used to compare the residual stress levels of components built in Ti–6Al–4V with different hatch patterns, powers and exposure times. [ABSTRACT FROM AUTHOR]

We report the photochemical atomic layer deposition of Al2O3 thin films and the use of this process to achieve area-selective film deposition. A shuttered vacuum ultraviolet (VUV) light source is used to excite molecular oxygen and trimethyl aluminum to deposit films at 60°C. In-situ QCM and post-deposition ellipsometric measurements both show that the deposition rate is saturative as a function of irradiation time. Selective area deposition was achieved by projecting the VUV light through a metalized magnesium fluoride photolithographic mask and the selectivity of deposition on the illuminated and masked regions of the substrate is a logarithmic function of the UV exposure time. The Al2O3 films exhibit dielectric constants of 8 - 10 at 1 MHz after forming gas annealing, similar to films deposited by conventional thermal ALD. [ABSTRACT FROM AUTHOR]

A range of metallic lattice structures were manufactured using the selective laser melting (SLM) rapid prototyping technique. The lattices were based assemblies of repeating unit-cells with their strands oriented at 0°, ±45°, and 90° to the vertical when viewed from the front. Mechanical tests on the strands and the lattice blocks showed that these systems exhibit a high level of reproducibility in terms of their basic mechanical properties. An examination of the compression failure mechanisms showed that the [±45°] and [±45°, 90°] lattices failed in bending and stretching modes of failure, whereas the [0°, ±45°] lattices failed as a result of buckling of the vertical pillars. Sandwich structures were manufactured by binding woven carbon-fiber reinforced plastic to the lattice structures. Subsequent threepoint bend tests on these structures identified the principal failure mechanisms under flexural loading conditions. Here, cell crushing, hinge rotation, and gross plastic deformation in the strands were observed directly under the point of loading. Lowvelocity impact tests were conducted on the sandwich beams and a simple energybalance model was used to understand how energy is absorbed by the sandwich structures. The model suggests that the majority of the incident energy of the projectile was absorbed in indentation effects, predominantly in the core material, directly under the steel indenter. [ABSTRACT FROM AUTHOR]

Porous titanium implants are a common choice for bone augmentation. Implants for spinal fusion and repair of non-union fractures must encourage blood flow after implantation so that there is sufficient cell migration, nutrient and growth factor transport to stimulate bone ingrowth. Additive manufacturing techniques allow a large number of pore network designs. This study investigates how the design factors offered by selective laser melting technique can be used to alter the implant architecture on multiple length scales to control and even tailor the flow. Permeability is a convenient parameter that characterises flow, correlating to structure openness (interconnectivity and pore window size), tortuosity and hence flow shear rates. Using experimentally validated computational simulations, we demonstrate how additive manufacturing can be used to tailor implant properties by controlling surface roughness at a microstructual level (microns), and by altering the strut ordering and density at a mesoscopic level (millimetre)., (Copyright © 2013 The Authors. Published by Elsevier B.V. All rights reserved.)

Doppler ultrasound is widely used in the diagnosis and monitoring of arterial disease. Current clinical measurement systems make use of continuous and pulsed ultrasound to measure blood flow velocity; however, the uncertainty associated with these measurements is great, which has serious implications for the screening of patients for treatment. Because local blood flow dynamics depend to a great extent on the geometry of the affected vessels, there is a need to develop anatomically accurate arterial flow phantoms with which to assess the accuracy of Doppler blood flow measurements made in diseased vessels. In this paper, we describe the computer-aided design and manufacturing (CAD-CAM) techniques that we used to fabricate anatomical flow phantoms based on images acquired by time-of-flight magnetic resonance imaging (TOF-MRI). Three-dimensional CAD models of the carotid bifurcation were generated from data acquired from sequential MRI slice scans, from which solid master patterns were made by means of stereolithography. Thereafter, an investment casting procedure was used to fabricate identical flow phantoms for use in parallel experiments involving both laser and Doppler ultrasound measurement techniques.