Low Temperature Preparation and Cold Manufacturing Techniques for Femoral Head of Al_2O_3 Ceramic

The hip joint femoral head prosthesis was prepared using the Al2O3 material, which was synthesized by high purity alumina micro-powder and Mg- Zr- Y composite addhitives , the cold manufacturing techniques of lathe turning, grade polishing and the matching size correction of the sintered femoral head were studied. The results showed, after being pressed under 200 MPa cold isostatic pressure and being pre-sintered at 1150℃ , the biscuit＇ s strength can meet the demands of lathe turning ; After being grade polished by SiC micro-powder and diamond abrading agent and being size corrected by special instrument, the femoral head prosthesis of Al2O3 ceramic has good surface degree of finish and articulates tightly with femoral handle.

Ductile and high strength Cu fabricated by solid-state cold spray additive manufacturing

In this work,pure Cu with excellent strength and ductility(UTS of 271 MPa,elongation to fracture of 43.5%,uniform elongation of 30%)was prepared using cold spray additive manufacturing(CSAM),realizing a breakthrough in the field.An in-depth investigation was conducted to reveal the microstructure evolution,strengthening and ductilization mechanisms of the CSAM Cu,as well as the single splats.The results show that the CSAM Cu possesses a unique heterogeneous microstructure with a bimodal grain structure and extensive infinitely circulating ring-mounted distribution of twinning.Based on the single splat observation,the entire copper particle forms a gradient nano-grained(GNG)structure after high-speed impact deposition.The GNG-structured single splat serves as a unit to build the heterogeneous microstructure with bimodal grain distribution during the successive deposition in CSAM.The results also show that CSAM can achieve synergistic strengthening and ductilization by controlling the grain refinement and dislocation density.This work provides potential for CSAM technique in manufacturing various metallic parts with the desired combination of high strength and good ductility without additional post-treatments.

Fast strength-ductility synergistically adjusting of cold spray additive manufactured Cu deposits via electric pulse processing

Electric Pulse Processing(EPP)treatment was innovatively introduced to optimize the strength and ductility of the CSAMed Cu deposits.The results show that EPP is an efficient and fast post-treatment to improve the strength and ductility(within tens of seconds).The larger the pulse current and number of pulses,the better the mechanical properties.Interestingly,this research found that when the heat input determined by pulse current and number of pulses exceeds a certain threshold(pulse current intensity is 2000 A,number of pulses is 10),increasing the number of repeat time could also effectively improve the mechanical properties.A tensile strength of 210 MPa and a ductility of 14.0%could be obtained with reasonable EPP parameters(pulse current intensity is 2000 A,number of pulses is 10,and repeat number is 2),which is similar to those of conventional annealing(e.g.,tensile strength is 272 MPa,elongation is 28.3%).The microstructure evolution analysis shows that EPP can effectively improve the bonding quality between the deposited particles by recrystallization,promote grain growth and the formation of twins,which is the main reason for the improvement of mechanical properties.

Solid-state additive manufacturing and repairing by cold spraying:A review

High-performance metal additive manufacturing （AM） has been extensively investigated in recent years because of its unique advantages over traditional manufacturing processes. AM has been applied to form complex components of Ti, Fe or Ni alloys. However, for other nonferrous alloys such as AI alloys, Mg alloys and Cu alloys, AM may not be appropriate because of its melting nature during processing by laser, electron beam, and/or arc. Cold spraying （CS） has been widely accepted as a promising solid-state coating technique in last decade for its mass production of high-quality metals and alloys, and/or metal matrix composites coatings. It is now recognized as a useful and powerful tool for AM, but the related research work has just started. This review summarized the literature on the state-of-the-art and problems for CS as an AM and repairing technique.

Effect of carrier gas species on the microstructure and compressive deformation behaviors of ultra-strong pure copper manufactured by cold spray additive manufacturing

Cold spray(CS)which has recently become a promising additive manufacturing(AM)technology,was used to fabricate ultra-strong pure copper.In addition,the effects of carrier gas species on the microstructural characteristics,mechanical properties and deformation mechanisms were systemically explored.The CSAM copper manufactured with N_(2) carrier gas reveals a heterogeneous bimodal microstructure consisting of ultra-fine grains at the particle interface and relatively coarse grains in inner particles.With He carrier gas,a homogeneous grain structure consisting of ultra-fine grains in most areas was obtained.Compressive tests showed that N_(2) and He carrier gasses enabled ultra-high yield strengths of 340 and415 MPa,respectively.These values are comparable to severely plastic deformed copper,which has extremely low ductility and shape fidelity.On the other hand,both samples showed a strain-softening phenomenon that does not commonly occur at room temperature.The deformation microstructures revealed that dynamic recovery(DRV)and dynamic recrystallization(DRX)phenomena were generated despite being deformed at room temperature.Based on the above findings,the overall deformation mechanisms according to the carrier gas species in the CSAM copper manufacturing process were discussed.Furthermore,the work hardening and softening behaviors of CSAM Cu are predicted by using a constitutive equation.

Microstructure and Mechanical Properties of Ti–Ta Composites Prepared Through Cold Spray Additive Manufacturing

In this study, an innovative approach was used to fabricate Ti–Ta composite biomaterials through cold spray additive manufacturing followed by a diff usion treatment. The microstructure and mechanical properties of the composites were investigated in detail using field emission scanning electron microscopy, electron backscatter diff raction, 3D X-ray computed tomography, tensile test, nanohardness test and resonance vibration test. The obtained results indicated that the prepared composites have inhomogeneity in their microstructure and composition. A unique microstructure, composed of Ti-rich, Ta-rich and diff usion regions, was evolved in the composites due to incomplete diff usion between Ti and Ta splats. Further, Kirkendall pores were formed in the composites due to uneven diff usion of the two phases(of Ti and Ta) during high-temperature heat treatment. The prepared composites simultaneously showed low elastic modulus and high tensile strength which is required for a good biomaterial. Low elastic modulus was associated with the residual pores and the alloying eff ect of Ta in Ti, while high tensile strength was related to the solid solution strengthening eff ects. The obtained results indicated that the prepared Ti–Ta composites have a great potential to become a new candidate for biomedical applications.

Optimization of cold spray additive manufactured AA2024/Al_(2)O_(3) metal matrix composite with heat treatment

In this study,the effects of annealing and solution aging heat treatment on the microstructure and mechanical properties of cold spray additive manufactured(CSAMed)AA2024/Al_(2)O_(3) composite were investigated.The results showed that both annealing and solution aging enhanced the interfacial bonding between the deposited AA2024 particles in the composite.The tensile properties of CSAMed AA2024/Al_(2)O_(3) composite were significantly improved by 13.8%for ultimate tensile strength and 47.8%for elongation after solution aging.Microstructural examination and fractographic analysis showed that the fracture mechanism between the adjacent AA2024 particles changed from brittle to ductile-dominant mode after heat treatment.However,the interfacial bonding between the AA2024 and Al_(2)O_(3) particles cannot be improved.For the improvement of mechanical properties,the solution aging was slightly better than annealing.In addition,low-temperature annealing greatly reduced the anisotropy of the mechanical properties of CSAMed AA2024/Al_(2)O_(3) composite.