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The FeAl coatings deposited by Laser Engineered Net Shaping

Durejko T., Łazińska M., Senderowski C., Napadłek W.

Inżynieria Materiałowa

2017

Vol. 38, nr 3

125--130

The process of manufacturing FeAl coatings by LENS method was presented in this work. The spherical alloy powder of Fe40Al0.05Zr–50 ppm B (at. %) was used as a row material for deposition protective coating on turbine blades. The layered coatings with Ni or 316L zone were also considered. Samples were prepared using LENS 850R system with 1000 W fiber laser and two independently controlled powder feeders. The microscopic examination showed that each technological variants have porosity inherited of porosity of powder particle. A scanning with 700 W of laser beam of deposition area enables substantial elimination of this discontinuities type. The positive effect of this technological solution was also noted for microhardness distribution of samples. The deposited coatings is characterized by 600 HV of microhardness with smooth transition zone between coating/substrate. The strength test (three-point bending) showed the mechanical properties of FeAl samples prepared with LENS are lower by about thirty percent (bending strength, ductility) than the substrate.

Materiały na osnowie fazy FeAl stanowią trudną technologicznie grupę „intermetalików”, będącą atrakcyjną alternatywą dla drogich stopów żarowytrzymałych. Obecnie poszukuje się nowych metod przetwarzania tego typu tworzyw, ze szczególnym uwzględnieniem technik przyrostowych. Celem pracy było wielowariantowe wytwarzanie napoin FeAl techniką laserowego kształtowania przyrostowego LENS połączone z oceną ich jakości metalurgicznej i wybranych właściwości użytkowych.

Development process and manufactu-ring of modern medical implants with LENS technology

Balazic M., Recek D., Kramar D., Milfelner M., Kopac J.

Journal of Achievements in Materials and Manufacturing Engineering

2009

Vol. 32, nr 1

46-52

Purpose: Research and development of modern medical implants is complex and demanding process focused on fulfilling requirements regarding materials, machining technologies and functionality. Typical example of modern medical implant is elbow nail for fixation of Caput radii fractures. It could be manufactured with classical machining technologies and with advanced Rapid Prototyping technologies such as highly targeted metal deposition technology LENS (Laser Engineered Net Shaping). Design/methodology/approach: Development of modern medical implants is a multi-stage design and manufacturing process primarily based on computer aided design (CAD), computer simulations, machinability of certificated biomaterials, in-vitro biofunctionality and in-vivo tests. Findings: LENS technology enables rapid and agile manufacturing, improved design flexibility, repair and re-manufacture. Material built with LENS technology has equal or even better mechanical and material properties. In medical application LENS technology enables development and rapid prototyping of special surgical instruments, trauma and orthopaedic high-performance implants which are hollow and thin walled. Research limitations/implications: To confirm assumption regarding better material and mechanical properties of products made with LENS technology additional static, dynamic (the High-Cycle-Fatigue test) and material (porosity and microstructure) tests will be carried out in the near future. Practical implications: Three different designs of bone fixation nail prototype made of titanium alloy had been manufactured with conventional machining techniques where some disadvantages due to the technology had been identified. To solve those problems LENS technology had been applied. As fourth design hollow thin walled fixation bone nail prototype made of titanium alloy powder (grain size 45 micrometers) had been manufactured and tested. Originality/value: Paper presents case study where LENS technology is being applied to manufacture modern medical implants. Particular focus of the paper is on material quality and quality benefits obtained in current and future medical application.