Design of Three-Dimensional Functional Articles via Layer-by-Layer Laser Sintering of Exothermic Powder Mixtures

Abstract

Three-dimensional parts with a wide range of properties were synthesized by combining together self-propagating high-temperature synthesis (SHS) and selective laser sintering (SLS). Different powder mixtures were investigated for producing piezoceramics, ferrites, and the high-temperature superconductor. Changing the structure, volume fraction, phase, and pore-distribution within the composite optimized the physical properties. The optimum regime for laser synthesis and some of their associated electro-physical properties were determined by changing the laser parameters, as well as, by conducting the reactions in an applied dc magnetic field. The mechanical properties and the ability to influence the Shape Memory Effect in synthesized porous NiTi were also studied. Stress-strain, X-ray, scanning electronic microscopy (SEM), and energy dispersive analysis by X-rays (EDAX) characterization data were shown to be dependent on laser irradiation parameters. A comparative study of bone-integration with porous NiTi implants was conducted.

Keywords:

• Combustion
• Complex oxides
• Ferrites
• Implants
• Laser irradiation
• Magnetic field
• Nitinol
• Powder compositions
• Sintering
• SHS
• SLS
• SME
• 3D Parts

ACKNOWLEDGMENTS

This work was supported by the Russian Foundation for Basic Research (Grants Nos. 06-03-32119 and 07-08-12048), Russian Academy of Sciences (Division of Chemistry and Materials Sciences), and Russian Science Support Foundation (Young Drs. Sci. Sub-Programme). Prof. I. P. Parkin thanks the Royal Society/Wolfson trust for a merit award. The Royal Society is thanked for a UK-FSU joint project grant.

Notes

MFA – 0.1 T dc magnetic field applied during SHS–SLS. Slash divided the values obtained on samples after annealing at 1070 K and 1470 K, accordingly.