Fabrication Technologies of the Sintered Materials Including Materials for Medical and Dental Application

This chapter of the book presents the basis of classical powder metallurgy technolo‐ gies and discusses powder fabrication, preparation, preliminary moulding, sintering and finish treatment operations. A general description of the materials and products manufactured with the classical powder metallurgy methods is presented. New variants are characterised along with special and hybrid technologies finding their applications in powder metallurgy. Special attention was drawn to microporous titanium and to TiAl6V4 alloy fabricated using hybrid rapid manufacturing technologies with selective laser sintering/selective laser melting (SLS/SLM) used for innovative implant scaffolds in medicine and regenerative dentistry. Laser deposition, thermal spraying and detonation spraying of powders are also discussed as special methods in which powders of metals and other materials are used as raw materials.

[1]  L. Dobrzański,et al.  Comparison of structure and properties of the HS12-1-5-5 type high- speed steel fabricated using the pressureless forming and PIM methods , 2005 .

[2]  Francis H. Froes,et al.  The Additive Manufacturing (AM) of Titanium Alloys , 2014 .

[3]  G. Kaupp Reactive milling with metals for environmentally benign sustainable production , 2011 .

[4]  L. Dobrzański Overview and general ideas of the development of constructions, materials, technologies and clinical applications of scaffolds engineering for regenerative medicine , 2014 .

[5]  Helen V. Atkinson,et al.  Fundamental aspects of hot isostatic pressing: An overview , 2000 .

[6]  H. Ghasemi,et al.  Wear Behavior of Al-20Vol. %SiCp Composites Manufactured by Dynamic Consolidation , 2013 .

[7]  Wai Yee Yeong,et al.  Laser and electron‐beam powder‐bed additive manufacturing of metallic implants: A review on processes, materials and designs , 2016, Journal of orthopaedic research : official publication of the Orthopaedic Research Society.

[8]  L. Dobrzański,et al.  Sintering in different atmospheres of T15 and M2 high speed steels produced by a modified metal injection moulding process , 2004 .

[9]  T. Hussain,et al.  Cold Spraying of Titanium: A Review of Bonding Mechanisms, Microstructure and Properties , 2012 .

[10]  I. Baker,et al.  Experiments and simulations of directionally annealed ODS MA 754 , 2008 .

[11]  J. Legoux,et al.  Cold-spray processing of titanium and titanium alloys , 2015 .

[12]  Jie Zhou,et al.  Fabrication of Metallic Biomedical Scaffolds with the Space Holder Method: A Review , 2014, Materials.

[13]  Saeed Maleksaeedi,et al.  Powder Processing of Bulk Components in Manufacturing , 2013 .

[14]  Z. Bojar,et al.  Factors influencing abrasive wear of gas detonation sprayed FeAl - based intermetallic coatings , 2004 .

[15]  A. Dupuy,et al.  Effects of applied pressure on the densification rates in current-activated pressure-assisted densification (CAPAD) of nanocrystalline materials , 2014 .

[16]  Adolfo Fernández,et al.  Challenges and Opportunities for Spark Plasma Sintering: A Key Technology for a New Generation of Materials , 2013 .

[17]  C. Berndt,et al.  Thermal spray forming of titanium and its alloys , 2015 .

[18]  J. Torralba,et al.  Development of high performance powder metallurgy steels by high-energy milling , 2013 .

[19]  W. Jones,et al.  Fundamental principles of powder metallurgy , 1960 .

[20]  L. Dobrzański,et al.  Toughness of Laser-Treated Surface Layers Obtained by Alloying and Feeding of Ceramic Powders , 2015 .

[21]  L. Dobrzański,et al.  Influence of cobalt portion on structure and properties of FGHM , 2008 .

[22]  L. Dobrzański,et al.  Laser Surface Treatment in Manufacturing , 2014 .

[23]  O. Guillon,et al.  Field‐Assisted Sintering Technology/Spark Plasma Sintering: Mechanisms, Materials, and Technology Developments , 2014 .

[24]  M. Jafari,et al.  Microstructural and mechanical properties of advanced HVOF-sprayed WC-based cermet coatings , 2016 .

[25]  R. German Powder metallurgy and particulate materials processing : the processes, materials, products, properties and applications , 2005 .

[26]  S. Kuroda,et al.  Effect of nitrogen flow rate on microstructures and mechanical properties of metallic coatings by warm spray deposition , 2013 .

[27]  L. Dobrzański,et al.  Alloying the X40CrMoV5-1 steel surface layer with tungsten carbide by the use of a high power diode laser , 2005 .

[28]  L. Dobrzański,et al.  Structure and properties of laser alloyed surface layers on the hot-work tool steel , 2006 .

[29]  L. Dobrzański Applications of newly developed nanostructural and microporous materials in biomedical, tissue and mechanical engineering , 2015 .

[30]  L. Dobrzański,et al.  Aluminium AlMg1SiCu Matrix Composite Materials Reinforced with Halloysite Particles , 2014 .

[31]  T. Ebel,et al.  Metal injection molding of titanium , 2015 .

[32]  L. Dobrzański,et al.  Structures, properties and development trends of laser-surface-treated hot-work steels, light metal alloys and polycrystalline silicon , 2015 .

[33]  A. Al-Azzawi,et al.  Mechanical Alloying and Milling , 2015 .

[34]  K. F. Russell,et al.  Nanometer scale precipitation in ferritic MA/ODS alloy MA957 , 2004 .

[35]  F. Froes,et al.  A perspective on the future of titanium powder metallurgy , 2015 .

[36]  L. Dobrzański,et al.  Selective Laser Sintering And Melting of Pristine Titanium and Titanium Ti6Al4V Alloy Powders and Selection of Chemical Environment for Etching of Such Materials , 2015 .

[37]  L. Dobrzański,et al.  Effect Of Milling Time On Microstructure Of AA6061 Composites Fabricated Via Mechanical Alloying , 2015 .

[38]  T. Fujisawa,et al.  Effects of MA environment on the mechanical and microstructural properties of ODS ferritic steels , 2011 .

[39]  A. Kimura,et al.  Structure of Oxide Nanoparticles in Fe-16Cr MA/ODS Ferritic Steel , 2010 .

[40]  A. Fais,et al.  On the application of Electro-sinter-forging to the sintering of high-karatage gold powders , 2015, Gold Bulletin.

[41]  L. A. Dobrzański,et al.  The structure and properties of PM composite materials based on EN AW-2124 aluminum alloy reinforced with the BN or Al2O3 ceramic particles , 2006 .

[42]  P. Fauchais,et al.  Latest Developments in Suspension and Liquid Precursor Thermal Spraying , 2009, International Thermal Spray Conference.

[43]  Structure and mechanical properties of HSS HS6-5-2- and HS12-1-5-5-type steel produced by modified powder injection moulding process , 2004 .

[44]  L. Berger Application of hardmetals as thermal spray coatings , 2015 .

[45]  H. M. Hosseini,et al.  The effect of mechanical milling on the soft magnetic properties of amorphous FINEMET alloy , 2015 .

[46]  Tomasz Kik,et al.  Robotized GMA surfacing of cermetalic layers , 2006 .

[47]  Y. Y. Li,et al.  Phase, microstructure and properties evolution of fine-grained W–Mo–Ni–Fe alloy during spark plasma sintering , 2012 .

[48]  Dae-Yong Kang,et al.  An experimental study on the optimization of powder forging process parameters for an aluminum-alloy piston , 2001 .

[49]  L. Dobrzański,et al.  Structure and Properties of the Aluminium Alloy AlSi12CuNiMg after Laser Surface Treatment , 2014 .

[50]  L. Dobrzański,et al.  Fabrication Of Scaffolds From Ti6Al4V Powders Using The Computer Aided Laser Method , 2015 .

[51]  L. Dobrzański,et al.  Structure, properties and corrosion resistance of PM composite materials based on EN AW-2124 aluminum alloy reinforced with the Al2O3 ceramic particles , 2005 .

[52]  L. Dobrzański,et al.  Comparison of the surface alloying of the 32CrMoV12-28 tool steel using TiC and WC powder , 2007 .

[53]  A. Fais,et al.  Influence of processing parameters on the mechanical properties of Electro-Sinter-Forged iron based powders , 2016 .

[54]  Chen Jiang,et al.  The Solution Precursor Plasma Spray (SPPS) Process: A Review with Energy Considerations , 2015, Journal of Thermal Spray Technology.

[55]  K. Chou,et al.  Review on Phase-Field Modeling of Microstructure Evolutions: Application to Electron Beam Additive Manufacturing , 2014 .

[56]  Wei Xu,et al.  Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: A review. , 2016, Biomaterials.

[57]  Tomislav Šarić,et al.  Different Approaches to the Investigation and Testing of the Ni-Based Self-Fluxing Alloy Coatings—A Review. Part 1: General Facts, Wear and Corrosion Investigations , 2014 .

[58]  L. A. Dobrzański,et al.  Abrasion resistance of GMA metal cored wires surfaced deposits , 2005 .

[59]  C. Kay Thermal Spray Applications in the Steel Industry , 2013 .

[60]  A. Atrens,et al.  Optimisation of the high velocity oxygen fuel (HVOF) parameters to produce effective corrosion control coatings on AZ91 magnesium alloy , 2015 .

[61]  B. Torres,et al.  316L stainless steel coatings on ZE41 magnesium alloy using HVOF thermal spray for corrosion protection , 2016 .

[62]  L. Dobrzański,et al.  The study of the technology of laser and plasma surfacing of engine valves face made of X40CrSiMo10-2 steel using cobalt-based powders , 2006 .

[63]  J. J. Dunkley Advances in atomisation techniques for the formation of metal powders , 2013 .

[64]  L. Dobrzański,et al.  Comparison of the abrasion wear resistance of the laser alloyed hot work tool steels , 2012 .

[65]  F. Froes,et al.  Fabrication of near-net-shape cost-effective titanium components by use of prealloyed powders and hot isostatic pressing , 2015 .

[66]  F. Froes,et al.  The Additive Manufacturing (AM) of Titanium Alloys , 2014 .

[67]  E. Olevsky,et al.  Electric pulse consolidation: an alternative to spark plasma sintering , 2014, Journal of Materials Science.

[68]  A. K. Sharma,et al.  Crystallographic, microstructure and mechanical characteristics of dynamically processed IN718 superalloy , 2014 .

[69]  E. Olevsky,et al.  Contribution of Electric Current into Densification Kinetics During Spark Plasma Sintering of Conductive Powder , 2015 .

[70]  L. Dobrzański,et al.  Shaping of Surface Layer Structure and Mechanical Properties After Laser Treatment of Aluminium Alloys , 2015 .

[71]  L. Dobrzański,et al.  HPDL laser alloying of Al-Si-Cu alloy with Al2O3 powder , 2013 .

[72]  L. Dobrzański,et al.  The study of properties of Ni–W2C and Co–W2C powders thermal sprayed deposits , 2005 .

[73]  Makoto Watanabe,et al.  Current Status and Future Prospects of Warm Spray Technology , 2011 .

[74]  Christoph Leyens,et al.  Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review , 2015, Journal of Thermal Spray Technology.

[75]  L. Dobrzański,et al.  Structure and Properties of the 32CrMoV12-28 Steel Alloyed with WC Powder Using HPDL Laser , 2006 .

[76]  Xiao-jie Li,et al.  Dynamic consolidation of W–Cu nanocomposites from W–CuO powder mixture , 2010 .

[77]  T. Babul Structures and Properties of Amorphous Layers Formed by Gas Detonation and Other Powder Spraying Methods , 1995 .

[78]  J. Cizek,et al.  Influence of Cold-Sprayed, Warm-Sprayed, and Plasma-Sprayed Layers Deposition on Fatigue Properties of Steel Specimens , 2015, Journal of Thermal Spray Technology.

[79]  L. Dobrzański,et al.  HPDL laser alloying of heat treated Al-Si-Cu alloy , 2012 .