Optimal print parameters for additively manufacturing 316L stainless steel using selective laser melting (SLM) at Cal Poly had previously been identified. In order to further support the viability of the current settings, tensile material characteristics were needed. Furthermore, reliable performance of the as-printed material had to be demonstrated. Any influence on the static performance of parts in the as-printed condition inherent to the SLM manufacturing process itself needed to be identified. Tensile testing was conducted to determine the properties of material in the as-printed condition. So as to have confidence in the experimental results, other investigations were also conducted to validate previous assumptions. Stereological relative density measurements showed that the as-printed material exhibited relative density in excess of 99%. Optical dimensional analysis found that the as-printed tensile specimens met ASTM E8 dimensional requirements in 14 out of 15 parts inspected. Baseline tensile tests indicated that the yield stress of the as-printed material is 24% higher than a cold-rolled alternative, while still achieving comparable ductility. The location of a tensile specimen on the build plate during the print was not found to have a significant effect on its mechanical properties. Theoretical behavior of notched tensile specimens based on finite element models matched experimental behavior in the actual specimens. Unique fracture behavior was found in both the unnotched reference and the most severe notch after microscopic inspection, and a root cause was proposed. Finally, extrapolating from previous studies and observing that experimental results matched theoretical models, it was determined that features inherent to SLM parts were not detrimental to the static performance of the as-printed material.

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Conventionally manufactured stents are available in uniform sizes and straight forms. These standard products are not suitable for all patients and research indicates that this is the reason for migration of stents in the vessel, and tubular structure in general, after deployment. The occurrence of migration makes readmission into hospital and the removal of the deployed stent necessary. This thesis develops a method which results in patient-customized stents which can be manufactured through additive manufacturing. These individualized stents intent to offer the same advantages of conventional stents while mitigating the disadvantages. The work’s core part is thedesign of a stent based on the geometric information through a medical scan. It converts the relevant areas from the medical scan data which is in the DICOM format to the STL file format. After cleaning and further processing, the shape will be the base for the design process of a stent using CAD software. Additionally, it also gives insight into the subjacent technologies such as medical scanning, additive manufacturing, choice of material and necessary further processing steps. A process chain from scanning, data transformation, 3D printing and post processing is described.The developed method delivers a reliable model and results in a fully individualized stent. In the current stage, it involves manual work since the representation of data in the steps is different. Further suggestions for steps to automate the process and an estimation of economic efficiency is given. / Det finns konventionellt tillverkade stenter i likformiga storlekar och raka former. Dem här standardprodukter är inte lämpliga för alla patienter och forskning tyder på att detta är orsaken till migrationen av stenter i blodkärl efter placering. Förekomsten av migration skapa återtagande på sjukhus och avlägsnande av den placerade stenten är nödvändig. Den här avhandlingen utvecklar en metod som resulterar i patient anpassade stenter som kan varatillverkad genom additiv tillverkning. Dessa individualiserade stenter avser att erbjuda samma fördelar som konventionella stenter och mildra nackdelarna. Arbetets kärna är designen av en stent baserad på den geometriska informationen baserande på en medicinsk bildteknik. Det omvandlar relevanta kroppsdelar från det medicinska bildteknik som finns i DICOM-formatet till STLfilformatet. Efter rengöring och vidare bearbetning kommer formen att vara basen för stentens designprocess med CAD-mjukvara. Dessutom ger den också inblick i de underliggande teknikerna som medicinsk bildteknik, tillsatsframställning, materialval och nödvändig vidarebehandling steg. En processkedja från skanning, datatransformation, 3D-utskrift och efterbehandling är beskrivits.Den utvecklade metoden ger en tillförlitlig modell och resulterar i en helt individualiserad stent. I det aktuellt stadium, innebär det manuellt arbete eftersom representationen av data i stegen är annorlunda. Ytterligare förslag till åtgärder för att automatisera processen och en uppskattning av ekonomisk effektivitet är given.

Additive Manufacturing (AM) as a method is on the rise and allow for a high freedom to create unique shapes without being limited by conventional machining methods. The Electron Beam Melting method, developed by Arcam AB in Mölndal, Sweden, use Powder Bed Fusion together with an electron beam and at an elevated temperature (+1000ºC) to lower stress due to thermal gradients. The purpose of this paper is to study the influence of Scan Length during Electron Beam Melting of Alloy 718 in regards to the appearance of shrinkage, porosity, primary carbide precipitation (mainly NbC), primary dendrite width and hardness. Samples built had the dimensions of 10x15xVar mm3 (Height x Depth x Width) with widths ranging from 10 mm in steps of 5 mm up to a maximum of 90 mm. The parameters were set as a single entry within the build project and as such each layer was melted as a single unit. A Light-Optical Microscope (LOM) and a Scanning Electron Microscope (SEM) was used to obtain images for manual counting to calculate the fraction of porosity and NbC-precipitates as well as the columnar grain width. The space between lines of interdendritical precipitation of NbC was used to determine the dendrite arm widths and a series of Hardness Vickers (500g for 15s) indents was performed. An Energy-Dispersive X-Ray Spectroscope (EDS) was used to help identify precipitates and phases. Columnar grain width and the spacing between vertical bands of interdendritical NbC was measured according to ASTM112-13 while porosity and hardness was measured according to ASTM562-11. Both of these only looked at the XZ-plane instead of all three planes. The columnar grain width was measured in the 10 mm, 40 mm and 90 mm samples at a distance of 4 mm from the top and with a slight spread over the sample width according to ASTM112-13 but using only one plane for counting. No significant change to columnar width was found. Primary dendrite arm width was measured on the 10 mm, 40 mm and 90 mm samples at about 5 mm from the top. An average for all samples was found to be 7.82 μm ± 2.89. No significant trend could be found with increased sample width. A total average porosity of 0.33% ± 0.16 was found. Variations between samples were less than the standard deviation. Even though the variations were not high enough to be significant, no obvious trend could be seen in regards to sample width, position on the base plate or heat transfer through the build. The presence of NbC was investigated in all samples with a total average of 0.36% ± 0.23 with variations between sample lengths being within the standard deviation. An insignificant trend could be seen between the smaller samples together with the wider samples having a higher degree of NbC compared to the middle samples. No significant trend could be seen in NbC based on row. Across all samples, the mean hardness was found to be 406.75 HV0.5 ± 16.53. No significant trend could be seen with increased sample width. Based on sample rows no significant trend could be seen.

The overall goal was to understand the capabilities of a dairy based meat alternative. This was done in three phases: 1) the production of a dairy protein gel as a base for a dairy based meat alternative, 2) texturization of the dairy protein gel base to produce a nugget like texture, and 3) a consumer test to determine the acceptability of the dairy based nugget compared to meat and meat alternatives on the market. For phase I, a dairy protein gel base was tested to understand the textural attributes. Milk to whey percentages and level of acidification were examined to determine their effects on instrumental textural attributes of the protein gel. The milk to whey percentages and level of acidification that were tested were 5/95, 10/90, and 15/85, and pH 5.70-5.60, 5.15-5.05, and 4.6-4.5; respectively. The texture was objectively measured using a texture analyzer. The results showed that there was an increase in the hardness, gumminess and chewiness which was associated with an increase of the milk to whey ratio. Also a firmer dairy protein gel was produced using a low pH. A milk to whey percentage of 15/85 and a pH of 4.6-4.5 produced the highest overall instrumental textural attributes, specifically . For phase II, the dairy protein gel composed of a milk to whey ratio of 15/85 and pH of 4.6 was evaluated in the formulation of a dairy based nugget. The grinding of the dairy protein gel was used to determine if different size grinding plates and the presence of a gum can influence the textural attributes of the dairy protein gel. The dairy protein gel base was evaluated by a trained sensory panel to compare to the results of the objective texture analyzer. The dairy protein gel was processed using a meat grinder with a grind size of 3 mm, 6 mm and a blend of 4 parts 6 mm grinded and 1 part 3 mm. The increase in the grind size produced an increased instrumental hardness, springiness, cohesiveness, chewiness and gumminess. The usage of gum in the dairy protein gel system produced a higher instrumental adhesiveness. The sensory results showed that an increase in the grind size increased the sensory attributes; hardness, cohesiveness, chewiness and adhesiveness. The use of gum in the system had no influence on the sensory textural attributes. Both the texture analyzer and trained sensory testing showed a similar trend for the texture attributes. No correlation between the texture analyzer and sensory was found. This was a surprise because literature indicates there are significant correlations between instrumental textural attributes and sensory texture attributes. The lack of correlation may be explained by the variability of the panelists (P-value<0.05) for each sample. For phase III, an acceptability test was performed on untrained consumers of chicken nuggets to determine if the dairy based meat alternative was acceptable compared to meat nuggets and meat alternatives on the market. Texture, flavor, and appearance were evaluated by a consumer panel. The consumers evaluated the dairy based meat alternative and concluded that the appearance, texture and flavor needed improvement. From this research, it was concluded that a dairy based meat alternative can be created to imitate meat and meat alternative textures. By understanding the processing conditions to produce the dairy protein gel base and grinding of the product, an acceptable meat alternative can be produced. Dairy based meat alternative texture attributes were produced from a milk to whey percentage of 15/85 and a pH of 4.6, and a large grind plate of 6 mm with the use of methylcellulose.

The melting behavior of polymers can provide information on their crystallization mechanism. However, the origin of the time-dependent low endotherm, or annealing peak, and the extent of melting-recrystallization-remelting during heating are still debated. The crystallization and subsequent melting behavior of isotactic polystyrene are explored in the context of Stroblâ "s 3-Phase model using differential scanning calorimetry (DSC), small angle X-ray scattering (SAXS), and wide angle X-ray diffraction. DSC experiments confirm the existence of a crystallization time-dependent low endotherm, and melting-recrystallization-remelting processes during heating. SAXS analysis using the correlation function confirms that the lamellar thickness increases with crystallization temperature and is independent of time. The spread between equilibrium melting and crystallization temperatures determined in this work (Tfâ"" = 533K, Tcâ"" = 544K) is much smaller than reported by Strobl et al. (Tfâ"" = 562K, Tcâ"" = 598K). These differences are partially attributed to overestimation in lamellar thicknesses calculated through the interface distribution function. Analysis of diffraction broadening shows that the apparent crystal size decreases with crystallization time, suggesting the formation of smaller/less perfect crystals during secondary crystallization. These results are consistent with observations that the glass transition temperature increases with crystallization time and supports the idea that secondary crystallization leads to increased amorphous conformational constraints. These results also suggest that the upward shift of the annealing peak during secondary crystallization is associated with increased amorphous constraints rather than increased crystal dimensions. The lack of distinction between Tfâ"" and Tcâ"" and the evolution of crystal size during crystallization stand in direct contrast with Stroblâ "s model. / Master of Science

No / This paper presents the results of a recent comprehensive investigation of selective laser melting (slm) of prealloyed gas and water atomised M2 and H13 tool steel powders. The objective of the study was to establish the parameters that control the densification of single and multiple layers with the aim of producing high density parts without the need for infiltration. Powders were processed using continuous wave (CW) CO2 and Nd:YAG lasers. Relationships between alloy composition, powder particle size and shape, flowability, microstructure (phases present, their size, morphology and distribution), track morphology, post scanned density, surface finish and scan conditions (Laser power, spot size and scan speed) are discussed for single track, single layer and multi-layer (up to 25 layers) constructions. Processing with a Nd:YAG laser with powders placed on substrates rather than on a loose powder bed gave more stable builds than with the CO2 laser. Using the Nd:YAG laser densities up to ~90% relative were possible with H13 powder compared with a maximum of ~70% for M2 in multi-layer builds. Maximum density achieved with CW CO2 processing was only ~60%, irrespective of powder composition. The paper compares the processibility of these materials with stainless steel powders processed to higher densities (up to 99% relative) under similar conditions. The results of the work show that a crucial factor for high density processing is melt pool wettability and this is controlled largely by carbon content; low carbon contents producing better wettability, flatter tracks and higher densities. The significance of this observation for the processing high alloy steels by slm will be discussed.

Ultrafast lasers are valuable research and manufacturing tools. The ultrashort pulse duration is comparable to electron-lattice relaxation times, yielding unique interactions with matter, particularly nonlinear absorption, melting, and ablation. The field of ultrafast laser manufacturing is rapidly evolving with advances in related laser technologies. The applications of ultrashort pulse lasers in additive manufacturing aim to fill gaps left by conventional techniques especially on the nano- and micro-scale. Concurrently, uptake of ultrafast fiber lasers for micromachining has increased, and may replace the Ti:Sapphire laser as the ultrafast laser of choice. Both additive and subtractive manufacturing are accomplished with ultrafast lasers which presents the possibility of hybrid, all-in-one devices using a single laser source. As one such combination of laser techniques, ultrashort pulse surface modification of additively manufactured metals is an area of limited investigation. This thesis aims to address the ever-changing landscape of ultrafast laser manufacturing by 1) reviewing ultrafast laser additive manufacturing techniques and recent advancements 2) comparing the design, operation, and micromachining potential of a commercial ultrafast Ti:Sapphire and ultrafast fiber laser, and 3) investigating femtosecond ablation of as-printed additively manufactured Ti-6Al-4V at a range of parameters to test the feasibility of surface feature control. Ultrafast laser additive manufacturing is still in its infancy with mostly niche applications. The ultrafast fiber laser architecture is found to deliver a platform that is easier to operate and maintain and has superior micromachining throughput relative to Ti:Sapphire lasers. In our experimental work, five main surface morphologies are obtained by femtosecond ablation of a rough Ti-6Al-4V surface: laser-induced periodic surface structures (LIPSS), undulating grooves, micro-ripples, grooves, and micro-cavities. Transitions between ablation regimes and evolutions of the surface under increasing pulse energy and number of pulses are observed. These patterns allow for control over the surface geometry without the need for post-printing polishing. / Thesis / Master of Applied Science (MASc) / Ultrafast pulsed lasers of <10 picoseconds pulse duration are commonly used to modify, melt, or ablate materials. As an important research and manufacturing tool, ultrafast lasers and techniques have seen great change in the past two decades. Additive manufacturing has emerged as an area in which ultrafast lasers are becoming increasingly prevalent. To make sense of this continuously evolving landscape, this thesis 1) reviews ultrafast laser additive manufacturing techniques, applications, and advances towards industrial use and commercialisation, 2) compares the setup, operability, and characteristics for two ultrafast laser designs, and 3) investigates the surfaces produced by ultrafast laser irradiation of an additively manufactured titanium alloy part. The surface morphologies that are produced are categorised into five main patterns: laser-induced periodic surface structures, undulating grooves, micro-ripples, grooves, and micro-cavities. Each is a distinct pattern that may allow for tuning of the surface properties with respect to the wettability and biocompatibility.

<p> Levitation melting was used to measure the equilibrium between H2-H2o or CO-C02 gas mixtures and pure Fe or Fe-Cr alloys over the temperature range 1550 - 1750°C. The effects of thermal diffusion on the two types of gases were investigated. First and second order interaction parameters were employed to describe the interaction between oxygen and chromium {up to 25 wt. pct. of Cr.). </p> / Thesis / Master of Science (MSc)