Thomas L. Starr

In this study, micro-computed tomography (CT) is utilized to detect defects of Ti-6Al-4V specimens fabricated by selective laser melting (SLM) and electron beam melting (EBM), which are two popular metal additive manufacturing methods. SLM and EBM specimens were fabricated with random defects at a specific porosity. The capability of micro-CT to evaluate inclusion defects in the SLM and EBM specimens is discussed. The porosity of EBM specimens was analyzed through image processing of CT single slices. An empirical method is also proposed to estimate the porosity of reconstructed models of the CT scan.

Porosity is an inherent attribute in selective laser melting (SLM) and profoundly degrades the build part quality and its performance. This study attempts to understand and characterize the keyhole pores formed during single-track scanning in SLM. First, 24 single tracks were generated using different line energy density (LED) levels, ranging from 0.1 J/mm to 0.98 J/mm, by varying the laser power and the scanning speed. The samples were then scanned by micro-computed tomography to measure keyhole pores and analyze the pore characteristics. The results show a general trend that the severity of the keyhole porosity increases with the increase of the LED with exceptions of certain patterns, implying important individual contributions from the parameters. Next, by keeping the LED constant in another set of experiments, different combinations of the power and the speed were tested to investigate the individual effect. Based on the results obtained, the laser power appears to have a greater effect than the scanning speed on both the pore number and the pore volume as well as the pore depth. For the same LED, the pore number and volume increase with increasing laser power until a certain critical level, beyond which, both the pore number and volume will decrease, if the power is further increased. For the LED of 0.32 J/mm, 0.4 J/mm, and 0.48 J/mm, the critical laser power that reverses the trend is about 132 W, 140 W, and 144 W, respectively.

Titanium dioxide (TiO2)(TiO2) photocatalytic films can be excited only by UV light which is about 4–5% of the overall solar spectrum and the activity under visible light irradiation is very limited. In this study, atomic layer deposition was used to deposit ZrO2ZrO2 -doped TiO2TiO2 films which had better visible light response. X-ray diffraction, electron microscopy and Raman, X-ray photoelectron, and UV-visible spectroscopy were used to characterize the films. The photocatalytic activities were measured by decomposition of stearic acid coating. ZrO2ZrO2 -doped TiO2TiO2 retained the anatase crystal phase when zirconium substitution was below 10%. The doped film with 9:1 Ti:ZrTi:Zr pulse ratio has greater visible light absorption and a bandgap reduction of 0.2eV0.2eV . The photocatalytic decomposition efficiency under visible light irradiation was increased by 50% compared to undoped TiO2TiO2 .

α/β type titanium alloys, such as Ti-6Al-4V and Ti-6Al-7Nb, have been used for orthopedic implant materials because of their combination of biocompatibility, corrosion resistance and mechanical properties. However, toxicity of alloying elements is a concern.In this project, it is proposed to design the new type of titanium alloys composed of non-toxic elements, such as Ti, Al, and Fe with lower modulus of elasticity and greater corrosion resistance. To find the optimal ratio of components in the Ti-Al-Fe system is important. The composition of the alloy determines its properties. Using combinatorial approach the optimal ratio can be found relatively easily.Direct metal deposition (DMD) is a novel precise manufacturing process for fabricating metal parts directly from Computer Aided Design (CAD) solid models. The DMD process allows making several layers of different composition on one substrate. One sample includes several Ti-xAl-yFe alloys at once. This combinatorial library dramatically reduces the time and cost of the investigation.The structure, mechanical and electrochemical properties of each new composition was studied using scanning electron microscopy (SEM) with energy-dispersive X-ray fluorescence analyzer (EDAX ZAF®), and electrochemical polarization method.