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Parameter optimization and compressive property of the TC31 titanium alloy X‑type lattice structure by the superplastic forming/diffusion bonding process

100%

Wu D. , Chen M. , Fan R. , Xiao W. , Wu Y.

Archives of Civil and Mechanical Engineering

2023

tom Vol. 23, no. 2

art. no. e137, 2023

The superplastic forming and diffusion bonding (SPF/DB) process was investigated for the manufacture of the TC31 titanium alloy X-type lattice structure. The finite element (FE) model was used to simulate the SPF process and compression behavior of the X-type lattice structure, and the deformation and compression failure modes were analyzed. A theoretical model was revised to predict the structural compressive strength. The results showed that the material processed by heat treatment still had great plasticity with the maximum elongation of 142.5% at 920 °C. The bonding rate, thinning rate and shear strength of the TC31 alloy joint bonded at 920 °C/3 MPa/60 min were 97.1%, 5.56% and 364 MPa, respectively, which indicated it was suitable for the X-type lattice truss structure to formed in the process parameter. Based on the result of the fundamental test and FE simulation, the X-type lattice structure could be fabricated by DB at 920 °C/3 MPa/60 min and SPF at 920 °C with a target strain rate of 0.001 s-1. Thickness measurements indicated that the area with a maximum thinning rate of 32.9% was located at the transition filet between the bonding areas and the ribs. The surface compressive strength of the X-type lattice structure was 1.51 MPa with a relative density of 0.015 when rib width was 5 mm, and the rib plastic buckling was considered as the failure mode of the TC31 titanium alloy lattice structure formed by SPF/DB. The surface compressive strength of the simulation results is 1.59 MPa with an error of 5.3%. The decrease of material properties and rib local thinning affect the accuracy of the theoretical predictions, and the revised theoretical result is 1.52 MPa with an error of 0.7%.

Mathematical approach to design 3D scaffolds for the 3D printable bone implant

80%

Wojnicz W. , Augustyniak M. , Borzyszkowski P.

Biocybernetics and Biomedical Engineering

2021

tom Vol. 41, no. 2

667--678

This work demonstrates that an artificial scaffold structure can be designed to exhibit mechanical properties close to the ones of real bone tissue, thus highly reducing the stress-shielding phenomenon. In this study the scan of lumbar vertebra fragment was reproduced to create a numerical 3D model (this model was called the reference bone sample). New nine 3D scaffold samples were designed and their numerical models were created. Using the finite element analysis, a static compression test was performed to assess the effective Young modulus of each tested sample. Also, two important metrics of each sample were assessed: relative density and surface area. Each new designed 3D scaffold sample was analyzed by considering two types of material properties: metal alloy properties (Ti-6Al-4V) and ABS polymer properties. Numerical analysis results of this study confirm that 3D scaffold used to design a periodic structure, either based on interconnected beams (A, B, C, D, E and F units) or made by removing regular shapes from base solid cubes (G, H, I units), can be refined to obtain mechanical properties similar to the ones of trabecular bone tissue. Experimental validation was performed on seven scaffolds (A, B, C, D, E, F and H units) printed from ABS material without any support materials by using Fused Deposition Modeling (FMD) technology. Results of experimental Young modulus of each printed scaffold are also presented and discussed.