Additive manufacturing of Nitinol is a promising field, as it can circumvent the challenges associated with its conventional production processes and unlock unique advantages. However, the accompanying surface features such as powder adhesions, spatters, ballings, or oxide discolorations are undesirable in engineering applications and therefore must be removed. Plasma electrolytic polishing (PeP) might prove to be a suitable finishing process for this purpose, but the effects of post-processing on the mechanical and functional material properties of additively manufactured Nitinol are still largely unresearched. This study seeks to address this issue. The changes on and in the part caused by PeP with processing times between 2 and 20 min are investigated using Nitinol compression springs manufactured by Laser Beam Melting. As a benchmark for the scanning electron microscope images, the differential scanning calorimetry (DSC) measurements, and the mechanical load test cycles, conventionally fabricated Nitinol springs of identical geometry with a medical grade polished surface are used. After 5 min of PeP, a glossy surface free of powder adhesion is achieved, which is increasingly levelled by further polishing. The shape memory properties of the material are retained without a shift in the transformation temperatures being detectable. The decreasing spring rate is primarily attributable to a reduction in the effective wire diameter. Consequently, PeP has proven to be an applicable and effective post-processing method for additively manufactured Nitinol.

Aircraft design must be lightweight and cost-efficient on the condition of aircraft certification. In addition to standard load cases, human-induced loads can occur in the aircraft interior. These are crucial for optimal design but difficult to estimate. In this study, a simple bipedal spring-mass model with roller feet predicted human-induced loads caused by human gait for use within an end-to-end design process. The prediction needed no further experimental data. Gait movement and ground reaction force (GRF) were simulated by means of two parameter constraints with easily estimable input variables (gait speed, body mass, body height). To calibrate and validate the prediction model, experiments were conducted in which 12 test persons walked in an aircraft mock-up under different conditions. Additional statistical regression models helped to compensate for bipedal model limitations. Direct regression models predicted single GRF parameters as a reference without a bipedal model. The parameter constraint with equal gait speed in experiment and simulation yielded good estimates of force maxima (error 5.3%), while equal initial GRF gave a more reliable prediction. Both parameter constraints predicted contact time very well (error 0.9%). Predictions with the bipedal model including full GRF curves were overall as reliable as the reference.