Frontiers of Additively Manufactured Metallic Materials

Additive manufacturing (AM) (=3D printing) has emerged during the last few years as a powerful technological platform for fabrication of functional parts with unique complex geometries and superior functionalities that are next to impossible to achieve using conventional manufacturing techniques. Due to their importance in industrial applications and the maturity of the applicable AM techniques, metallic materials are at the forefront of the developments in AM. In this editorial, which has been written as a preamble to the special issue “Perspectives on Additively Manufactured Metallic Materials”, I will highlight some of the frontiers of research on AM of metallic materials to help readers better understand the cutting edge of research in this area. Some of these topics are addressed in the articles appearing in this special issue, while others constitute worthy avenues for future research.

[1]  Yaoyao Fiona Zhao,et al.  A Survey of Modeling of Lattice Structures Fabricated by Additive Manufacturing , 2017 .

[2]  H. Maier,et al.  On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: Fatigue resistance and crack growth performance , 2013 .

[3]  A. A. Zadpoor,et al.  Simultaneous Delivery of Multiple Antibacterial Agents from Additively Manufactured Porous Biomaterials to Fully Eradicate Planktonic and Adherent Staphylococcus aureus , 2017, ACS applied materials & interfaces.

[4]  H Weinans,et al.  Additively Manufactured and Surface Biofunctionalized Porous Nitinol. , 2017, ACS applied materials & interfaces.

[5]  H Meier,et al.  The biocompatibility of dense and porous Nickel-Titanium produced by selective laser melting. , 2013, Materials science & engineering. C, Materials for biological applications.

[6]  Amir A. Zadpoor,et al.  Computational prediction of the fatigue behavior of additively manufactured porous metallic biomaterials , 2016 .

[7]  Di Wang,et al.  An integrated approach of topology optimized design and selective laser melting process for titanium implants materials. , 2013, Bio-medical materials and engineering.

[8]  D. Gu,et al.  Parametric analysis of thermal behavior during selective laser melting additive manufacturing of aluminum alloy powder , 2014 .

[9]  Kozo Osakada,et al.  Microstructure and mechanical properties of pure titanium models fabricated by selective laser melting , 2004 .

[10]  Reinhart Poprawe,et al.  Densification behavior, microstructure evolution, and wear performance of selective laser melting processed commercially pure titanium , 2012 .

[11]  Franz Sebastian Schwindling,et al.  Two-Body Wear of CoCr Fabricated by Selective Laser Melting Compared with Different Dental Alloys , 2015, Tribology Letters.

[12]  Jean-Pierre Kruth,et al.  Revival of pure titanium for dynamically loaded porous implants using additive manufacturing. , 2015, Materials science & engineering. C, Materials for biological applications.

[13]  D. Gu,et al.  Selective laser melting additive manufacturing of Inconel 718 superalloy parts: Densification, microstructure and properties , 2014 .

[14]  Christopher J. Sutcliffe,et al.  Selective laser melting of aluminium components , 2011 .

[15]  Eric Farrell,et al.  Selective laser melting porous metallic implants with immobilized silver nanoparticles kill and prevent biofilm formation by methicillin-resistant Staphylococcus aureus. , 2017, Biomaterials.

[16]  Jun Wei,et al.  Effects of Processing Parameters on Surface Roughness of Additive Manufactured Ti-6Al-4V via Electron Beam Melting , 2017, Materials.

[17]  K. Lietaert,et al.  Influence of layer thickness and post-process treatments on the fatigue properties of CoCr scaffolds produced by laser powder bed fusion , 2018, Additive Manufacturing.

[18]  T. Nakamoto,et al.  Microstructures and mechanical properties of A356 (AlSi7Mg0.3) aluminum alloy fabricated by selective laser melting , 2016 .

[19]  N. Fang,et al.  Lightweight Mechanical Metamaterials with Tunable Negative Thermal Expansion. , 2016, Physical review letters.

[20]  Bert Müller,et al.  Tailoring Selective Laser Melting Process Parameters for NiTi Implants , 2012, Journal of Materials Engineering and Performance.

[21]  H Weinans,et al.  Antibacterial Behavior of Additively Manufactured Porous Titanium with Nanotubular Surfaces Releasing Silver Ions. , 2016, ACS applied materials & interfaces.

[22]  J. Kruth,et al.  Effects of build orientation and heat treatment on the microstructure and mechanical properties of selective laser melted Ti6Al4V lattice structures , 2015 .

[23]  Liang Hao,et al.  Advanced lightweight 316L stainless steel cellular lattice structures fabricated via selective laser melting , 2014 .

[24]  Dariusz Grzesiak,et al.  Selective laser melting of TiB2/H13 steel nanocomposites: Influence of hot isostatic pressing post-treatment , 2017 .

[25]  L. Murr,et al.  Microstructures and mechanical behavior of Inconel 718 fabricated by selective laser melting , 2012 .

[26]  Amir A. Zadpoor,et al.  Design for Additive Bio-Manufacturing: From Patient-Specific Medical Devices to Rationally Designed Meta-Biomaterials , 2017, International journal of molecular sciences.

[27]  Jean-Pierre Kruth,et al.  Texture and anisotropy in selective laser melting of NiTi alloy , 2016 .

[28]  Inger Odnevall Wallinder,et al.  In vitro biocompatibility of CoCrMo dental alloys fabricated by selective laser melting. , 2014, Dental materials : official publication of the Academy of Dental Materials.

[29]  M. Elahinia,et al.  The influence of heat treatment on the thermomechanical response of Ni-rich NiTi alloys manufactured by selective laser melting , 2016 .

[30]  Ming Gao,et al.  The microstructure and mechanical properties of deposited-IN718 by selective laser melting , 2012 .

[31]  Per Dérand,et al.  Imaging, Virtual Planning, Design, and Production of Patient-Specific Implants and Clinical Validation in Craniomaxillofacial Surgery , 2012, Craniomaxillofacial trauma & reconstruction.

[32]  M. Benedetti,et al.  Fatigue and biological properties of Ti-6Al-4V ELI cellular structures with variously arranged cubic cells made by selective laser melting. , 2018, Journal of the mechanical behavior of biomedical materials.

[33]  S. Cummer,et al.  Three-dimensional broadband omnidirectional acoustic ground cloak. , 2014, Nature materials.

[34]  Jenn‐Ming Yang,et al.  Selective laser melting of TiB2/316L stainless steel composites: The roles of powder preparation and hot isostatic pressing post-treatment , 2017 .

[35]  Huanyang Chen,et al.  Acoustic cloaking in three dimensions using acoustic metamaterials , 2007 .

[36]  A. A. Zadpoor,et al.  Mechanical properties of regular porous biomaterials made from truncated cube repeating unit cells: Analytical solutions and computational models. , 2016, Materials science & engineering. C, Materials for biological applications.

[37]  Damiano Pasini,et al.  Multiscale isogeometric topology optimization for lattice materials , 2017 .

[38]  K. Prashanth,et al.  Influence of Powder Characteristics on Processability of AlSi12 Alloy Fabricated by Selective Laser Melting , 2018, Materials.

[39]  Amir A. Zadpoor,et al.  Mechanical behavior of additively manufactured porous biomaterials made from truncated cuboctahedron unit cells , 2016 .

[40]  Mika Salmi,et al.  Patient‐specific reconstruction with 3D modeling and DMLS additive manufacturing , 2012 .

[41]  Wei Liu,et al.  Textures formed in a CoCrMo alloy by selective laser melting , 2015 .

[42]  Rainer Bader,et al.  Mechanical Properties of a Newly Additive Manufactured Implant Material Based on Ti-42Nb , 2018, Materials.

[43]  Li Wang,et al.  Densification behavior of gas and water atomized 316L stainless steel powder during selective laser melting , 2010 .

[44]  C. Zhang,et al.  Improved bioactivity of selective laser melting titanium: Surface modification with micro-/nano-textured hierarchical topography and bone regeneration performance evaluation. , 2016, Materials science & engineering. C, Materials for biological applications.

[45]  C. Colin,et al.  As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting , 2011 .

[46]  A. Uriondo,et al.  The present and future of additive manufacturing in the aerospace sector: A review of important aspects , 2015 .

[47]  Matthias Markl,et al.  Predictive Simulation of Process Windows for Powder Bed Fusion Additive Manufacturing: Influence of the Powder Bulk Density , 2017, Materials.

[48]  T. Pollock,et al.  3D printing of high-strength aluminium alloys , 2017, Nature.

[49]  L. Murr.  Frontiers of 3D Printing/Additive Manufacturing: from Human Organs to Aircraft Fabrication† , 2016 .

[50]  Ali Gökhan Demir,et al.  Additive manufacturing of cardiovascular CoCr stents by selective laser melting , 2017 .

[51]  I. Yadroitsava,et al.  Functionalization of Biomedical Ti6Al4V via In Situ Alloying by Cu during Laser Powder Bed Fusion Manufacturing , 2017, Materials.

[52]  U. Glatzel,et al.  Microstructure and mechanical properties of selective laser melted Inconel 718 compared to forging and casting , 2016 .

[53]  A. A. Zadpoor,et al.  Additively manufactured metallic pentamode meta-materials , 2017 .

[54]  Bianca Maria Colosimo,et al.  In situ monitoring of selective laser melting of zinc powder via infrared imaging of the process plume , 2018 .

[55]  A A Zadpoor,et al.  Failure mechanisms of additively manufactured porous biomaterials: Effects of porosity and type of unit cell. , 2015, Journal of the mechanical behavior of biomedical materials.

[56]  Chia-Ying Lin,et al.  Structural and mechanical evaluations of a topology optimized titanium interbody fusion cage fabricated by selective laser melting process. , 2007, Journal of biomedical materials research. Part A.

[57]  L. Hitzler,et al.  On the Anisotropic Mechanical Properties of Selective Laser-Melted Stainless Steel , 2017, Materials.

[58]  H. Wadley,et al.  Mechanical metamaterials at the theoretical limit of isotropic elastic stiffness , 2017, Nature.

[59]  S. M. Ahmadi,et al.  Isolated and modulated effects of topology and material type on the mechanical properties of additively manufactured porous biomaterials. , 2018, Journal of the mechanical behavior of biomedical materials.

[60]  A A Zadpoor,et al.  Mechanics of additively manufactured porous biomaterials based on the rhombicuboctahedron unit cell. , 2016, Journal of the mechanical behavior of biomedical materials.

[61]  A. A. Zadpoor,et al.  Statistical shape and appearance models of bones. , 2014, Bone.

[62]  A. A. Zadpoor,et al.  Multiscale modeling of fatigue crack propagation in additively manufactured porous biomaterials , 2018, International Journal of Fatigue.

[63]  M. Savalani,et al.  Microstructure and mechanical properties of selective laser melted magnesium , 2011 .

[64]  Galina Kasperovich,et al.  Improvement of fatigue resistance and ductility of TiAl6V4 processed by selective laser melting , 2015 .

[65]  Fabrizio Scarpa,et al.  Double‐Negative Mechanical Metamaterials Displaying Simultaneous Negative Stiffness and Negative Poisson's Ratio Properties , 2016, Advanced materials.

[66]  H Weinans,et al.  Additively manufactured biodegradable porous magnesium. , 2017, Acta biomaterialia.

[67]  E. Thomas,et al.  Micro‐/Nanostructured Mechanical Metamaterials , 2012, Advanced materials.

[68]  T. Sercombe,et al.  Heat treatment of Ti‐6Al‐7Nb components produced by selective laser melting , 2008 .

[69]  R. Misra,et al.  Surface nanotopography-induced favorable modulation of bioactivity and osteoconductive potential of anodized 3D printed Ti-6Al-4V alloy mesh structure , 2018, Journal of biomaterials applications.

[70]  Mariana Calin,et al.  Manufacture by selective laser melting and mechanical behavior of commercially pure titanium , 2014 .

[71]  Ma Qian,et al.  Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition , 2015 .

[72]  Howon Lee,et al.  Ultralight, ultrastiff mechanical metamaterials , 2014, Science.

[73]  Yigil Cho,et al.  Finite element analysis for mechanical response of Ti foams with regular structure obtained by selective laser melting , 2015 .

[74]  Mohsen Badrossamay,et al.  Further studies in selective laser melting of stainless and tool steel powders , 2007 .

[75]  Amir A. Zadpoor,et al.  Additive Manufacturing of Biomaterials, Tissues, and Organs , 2016, Annals of Biomedical Engineering.

[76]  Andrea Ehrmann,et al.  Three-Dimensional (3D) Printing of Polymer-Metal Hybrid Materials by Fused Deposition Modeling , 2017, Materials.

[77]  Antonio Domenico Ludovico,et al.  Experimental investigation and statistical optimisation of the selective laser melting process of a maraging steel , 2015 .

[78]  M. Larosa,et al.  Cranial reconstruction: 3D biomodel and custom-built implant created using additive manufacturing. , 2014, Journal of cranio-maxillo-facial surgery : official publication of the European Association for Cranio-Maxillo-Facial Surgery.

[79]  Sujit Das,et al.  Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components , 2016 .

[80]  P. Sheng,et al.  Dark acoustic metamaterials as super absorbers for low-frequency sound , 2012, Nature Communications.

[81]  Amir A. Zadpoor,et al.  Rationally designed meta-implants: a combination of auxetic and conventional meta-biomaterials , 2018 .

[82]  Konrad Wissenbach,et al.  Ductility of a Ti‐6Al‐4V alloy produced by selective laser melting of prealloyed powders , 2010 .

[83]  H Weinans,et al.  Fatigue performance of additively manufactured meta-biomaterials: The effects of topology and material type. , 2018, Acta biomaterialia.

[84]  A. Alú,et al.  Controlling sound with acoustic metamaterials , 2016 .

[85]  Di Wang,et al.  Evaluation of topology-optimized lattice structures manufactured via selective laser melting , 2018 .

[86]  Jean-Pierre Kruth,et al.  Optimization of Scan Strategies in Selective Laser Melting of Aluminum Parts With Downfacing Areas , 2014 .

[87]  L. Murr,et al.  Comparison of the microstructures and mechanical properties of Ti–6Al–4V fabricated by selective laser melting and electron beam melting , 2016 .