Abstract
An approach of sintering 3D metal printed lattices and diamond nickel-coated particles is proposed which can be used for the production of tunnel boring machine (TBM) cutters and mining equipment blades. Nickel-coated diamond particles are mixed with titanium powder and incorporated into a lightweight Ti6Al4V (3D printed) lattice with the help of spark plasma sintering (SPS) method. Effect of Ti6Al4V lattices size, diamond particles size, and nickel coating layer thickness on wear resistance of composites is discussed. Functionally graded lattice (FGL) structures were produced by selective laser melting (SLM) method, representing an increasingly growing additive manufacturing engineering area introduced in material engineering. Impact-abrasive tribo-device (IATD), scanning electron microscopy (SEM), X-ray diffraction (XRD), energy-dispersive spectroscopy (EDS), and optical surface profiler (OSP) were used to characterize samples. An ab initio design of diamond-metal composite is based on the improvement of impact and abrasive wear resistance of Ti6Al4V by adding diamond particles and by applying of gradient lattice structure. The specimen with larger size of the diamond particle and thicker Ni coating has better wear resistance. In addition, ANSYS software simulations were done to analyze the effect of the presence of 3D printed lattice via nonlinear finite element AUTODYN solver under impact test. Diamond-based gradient composite material produced by combined SLM-SPS methods can be applied in applications where resistance against impact-abrasive wear is important.
Highlights
Ti6Al4V is the most applicable titanium alloy that has been extremely used in biomedicine, osteology, aerospace, marine, and additive manufacturing industries due to low density and high mechanical properties
Use of nickel-coated diamond particles was preferable in comparison with pure polycrystalline diamond due to resulting higher homogeneity of distribution of diamond in composite after sintering (Figure 5)
The present study is an attempt to introduce a new approach toward the production of wear resistant materials by the combination of selective laser melting and spark plasma sintering
Summary
Ti6Al4V is the most applicable titanium alloy that has been extremely used in biomedicine, osteology, aerospace, marine, and additive manufacturing industries due to low density and high mechanical properties. Additive manufactured titanium alloys have motivated in deep in vivo corrosion research for recovering fractures of knee and hip bones [1]. Diamond-containing metal matrix composites (MMCs) are made with the help of chemical/physical vapor deposition (CVD/PVD) techniques and they are considered because of their high thermal conductivity and mechanical properties [3]. Selective laser melting/sintering (SLM/SLS) is one of the new additive manufacturing techniques that is applied for production of complex metal shapes, lattice structures, and rapid prototyping. AISI 316L stainless steel, Ti6Al4V titanium, and AlSi10Mg aluminum are three highly demanded metal lattice structures due to high strength to weight ratio.
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