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Different Approaches for Manufacturing Ti-6Al-4V Alloy with Triply Periodic Minimal Surface Sheet-Based Structures by Electron Beam Melting

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  • Dmitry Khrapov
  • Maria Kozadayeva
  • Kayrat Manabaev
  • Alexey Panin
  • William Sjöström
  • Andrey Koptyug
  • Tatiana Mishurova
  • Sergei Evsevleev
  • Dietmar Meinel
  • Giovanni Bruno
  • David Cheneler
  • Roman Surmenev
  • Maria Surmeneva
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Article number4912
<mark>Journal publication date</mark>29/08/2021
<mark>Journal</mark>Materials
Issue number17
Volume14
Number of pages21
Publication StatusPublished
<mark>Original language</mark>English

Abstract

Targeting biomedical applications, Triply Periodic Minimal Surface (TPMS) gyroid sheet-based structures were successfully manufactured for the first time by Electron Beam Melting in two different production Themes, i.e., inputting a zero (Wafer Theme) and a 200 µm (Melt Theme) wall thickness. Initial assumption was that in both cases, EBM manufacturing should yield the structures with similar mechanical properties as in a Wafer-mode, as wall thickness is determined by the minimal beam spot size of ca 200 µm. Their surface morphology, geometry, and mechanical properties were investigated by means of electron microscopy (SEM), X-ray Computed Tomography (XCT), and uniaxial tests (both compression and tension). Application of different manufacturing Themes resulted in specimens with different wall thicknesses while quasi-elastic gradients for different Themes was found to be of 1.5 GPa, similar to the elastic modulus of human cortical bone tissue. The specific energy absorption at 50% strain was also similar for the two types of structures. Finite element simulations were also conducted to qualitatively analyze the deformation process and the stress distribution under mechanical load. Simulations demonstrated that in the elastic regime wall, regions oriented parallel to the load are primarily affected by deformation. We could conclude that gyroids manufactured in Wafer and Melt Themes are equally effective in mimicking mechanical properties of the bones.