Increase Of Scanning Speed Research Articles

Fibre Laser Treatment of Beta TNZT Titanium Alloys for Load-Bearing Implant Applications: Effects of Surface Physical and Chemical Features on Mesenchymal Stem Cell Response and Staphylococcus aureus Bacterial Attachment

A mismatch in bone and implant elastic modulus can lead to aseptic loosening and ultimately implant failure. Selective elemental composition of titanium (Ti) alloys coupled with surface treatment can be used to improve osseointegration and reduce bacterial adhesion. The biocompatibility and antibacterial properties of Ti-35Nb-7Zr-6Ta (TNZT) using fibre laser surface treatment were assessed in this work, due to its excellent material properties (low Young’s modulus and non-toxicity) and the promising attributes of fibre laser treatment (very fast, non-contact, clean and only causes changes in surface without altering the bulk composition/microstructure). The TNZT surfaces in this study were treated in a high speed regime, specifically 100 and 200 mm/s, (or 6 and 12 m/min). Surface roughness and topography (WLI and SEM), chemical composition (SEM-EDX), microstructure (XRD) and chemistry (XPS) were investigated. The biocompatibility of the laser treated surfaces was evaluated using mesenchymal stem cells (MSCs) cultured in vitro at various time points to assess cell attachment (6, 24 and 48 h), proliferation (3, 7 and 14 days) and differentiation (7, 14 and 21 days). Antibacterial performance was also evaluated using Staphylococcus aureus (S. aureus) and Live/Dead staining. Sample groups included untreated base metal (BM), laser treated at 100 mm/s (LT100) and 200 mm/s (LT200). The results demonstrated that laser surface treatment creates a rougher (Ra value of BM is 199 nm, LT100 is 256 nm and LT200 is 232 nm), spiky surface (Rsk > 0 and Rku > 3) with homogenous elemental distribution and decreasing peak-to-peak distance between ripples (0.63 to 0.315 µm) as the scanning speed increases (p < 0.05), generating a surface with distinct micron and nano scale features. The improvement in cell spreading, formation of bone-like nodules (only seen on the laser treated samples) and subsequent four-fold reduction in bacterial attachment (p < 0.001) can be attributed to the features created through fibre laser treatment, making it an excellent choice for load bearing implant applications. Last but not least, the presence of TiN in the outermost surface oxide might also account for the improved biocompatibility and antibacterial performances of TNZT.

High-speed THz imaging using two-way raster scanning method without dwell time

The resolution and accuracy of terahertz (THz) imaging depend on the scanning distance between raster pixels. Recently, numerous studies have focused on increasing scanning speed and accuracy. The current study presented a high-speed scanning method without dwell time during scanning. A compensation factor for the velocity in a motorized x-y linear stage with a scanning sample was introduced to maintain the high accuracy of image scanning with the proposed method. The THz imaging system consisted of fiber-coupled pulsed photoconductive antenna and motorized x-y linear stage based on THz-time-domain spectroscopy. A validation specimen was fabricated by using copper tape and acrylic plate to compare the image scanning performance of various methods. Reflection mode scanning with 90° incident angles was conducted on the validation sample. The performance of the proposed scanning method without dwell time was evaluated and compared with that of other methods in terms of scanning speed, which is defined as the number of pixels per second; and geometric matching ratio, which uses modal assurance criterion (MAC) to quantify scanning accuracy. Results confirmed that the scanning speed of the proposed method is 328 % faster than that of conventional scanning methods and that the MAC value of the geometric matching ratio is more than 0.994 without any additional equipment installation.

Effect of scanning speeds on electrochemical corrosion resistance of laser cladding TC4 alloy**Project supported by the National Natural Science Foundation of China (Grant Nos. 61475117 and 51471084), the National Key Research and Development Program of China (Grant No. 2017YFB1103604), and the Tianjin Municipal Special Program of Talents Development for Excellent Youth Scholars, China (Grant No. TJTZJHQNBJRC-2-15).

In order to study the effect of scanning speed on the electrochemical corrosion resistance of laser cladding TC4 alloy in artificial seawater, the x-ray diffraction analysis, microstructure of cross-section, microhardness variation, and impedance spectrum have been studied in comparison with the TC4 titanium alloy. The results show that the main phase of cladding coating is α-Ti, and the change of scanning speed has no obvious effect on it; therefore, the supersaturated α-Ti solid solution is formed, and the acicular martensite is obtained. As the scanning speed increases, the microstructure of cladding coating is orthogonal basket-weave, the crystal surface spacing decreases, and the average microhardness of laser cladding TC4 alloy slightly increases. When the scanning speed increases to 10 mm/s, the microhardness is about 14.71% higher than that of the substrate, and the electrochemical corrosion resistance of laser cladding TC4 alloy is also improved, which is about 2.48 times more than the substrate. Grain refinement has a great effect on enhancing the anti-electrochemical corrosion.

Effects of process parameters on the quality aspects of weld-bead in laser welding of NiTinol sheets

ABSTRACTThe effects of process variables, like scan speed and laser power, on the quality of bead-on-plate welding of NiTinol sheets were investigated. The measured quality aspects for the weld-bead profile were bead geometry, changes in microstructure, variation of microhardness value along the weld-bead, extent of oxide contamination during welding, Ti/Ni ratio after welding, changes in tensile strength of the welded samples and corrosion behavior of the welded and parent materials. The laser weld-bead profile changed from the shape of a stemless wineglass to that with a prominent leg. Dimensional aspects of weld-bead geometry showed a decreasing trend with increasing scan speed. However, an increasing trend of the same was observed with power. The Ti/Ni ratio on the top surface after welding was found to decrease with scan speed at a particular power. Oxide contamination during welding followed the same pattern of variation as that of the Ti/Ni ratio. Microhardness values gradually increased from the weld centerline to the base metal. Formation of brittle intermetallic compounds reduced the tensile strength of the material after welding. A dual failure mode for the welded sample was observed, whereas a single mode of failure was detected for the parent material. The corrosion properties of the welded samples were better than that of the parent material.

Experimental study of pulsed laser bending process parameters of 6061 aluminum alloy sheet

The effect of process parameters on pulsed laser bending of 6061 aluminum alloy sheet was investigated experimentally under oblique incidence. The results of single factor experiment showed that the bending angle increased with the increase of duty cycle, frequency, scan times and sheet width, decreased with the increase of scan speed, spot diameter and sheet thickness, and increased first and then decreased with the increase of the distance from the scanning line to the free end. The bending angle of water cooling was smaller than the natural cooling, but the bending angle increment of water cooling exceeded the natural cooling after 55 scans. When the laser incident angle was 15°, the bending angle reached 102.35° after 60 scans under natural cooling condition. The combination of optimal processing parameters and the order of factors affecting the laser bending angle were determined by orthogonal experiment. The order of influencing factors was duty cycle, scan speed, spot diameter, frequency and the distance from the scanning line to the free end.

Parametric study of laser cutting of carbon fibre reinforced polymer (CFRP) and the effect of fibre orientation on cutting quality

ABSTRACTLaser cutting of CFRP was performed using 2 kW fibre laser. A detailed analysis of the effect of various laser processing parameters on the cutting of CFRP was carried out. The present work considers mainly laser power (W), scan speed (mm/min), gas pressure (bar) and duty cycle (%) as the process parameters with average kerf width and heat affected zone (HAZ) as the output parameters. Cutting of the fibres at 90º with respect to fibre orientation was performed. The SEM and EDS analysis were also performed to understand the cut quality, matrix melting, fibre pullout and vaporisation phenomena of the matrix in the heat affected zone (HAZ). Laser cutting of CFRP with a minimum kerf width of around 184 µm was observed for 800 W, 600 mm/min, 3 bar and 25% duty cycle while HAZ in this parameter was around 1561 µm. Kerf width and HAZ directly increase with an increase in laser power, gas pressure and duty cycle, but they reduce with increase in scan speed. SEM images confirm that the CFRP cutting process generates relatively burr-free fibre edges. Matrix recession and delamination (fibre pullout) were identified as the major quality defects occurring in the laser cutting process of CFRP.

Surface wettability and superhydrophobic characteristics of Ni-based nanocomposites fabricated by selective laser melting

Superhydrophobic metallic surfaces have attracted much attention in aeronautical and biomedical applications. In this study, an easy-to-operate one-step selective laser melting (SLM) was adopted to fabricate superhydrophobic surface from TiC/Inconel 718 nanocomposites. The work studied the surface morphology, roughness, wettability and corrosion resistance by SLM with variation of laser processing parameters. The results showed that with the increase of laser scan speed (v), the surface morphology experienced a successive change: relatively smooth surface — micro/nano hierarchical rough surface — cracked surface. The corresponding surface roughness increased from 9.81 μm to 15.06 μm. At a proper v of 600 mm/s, the multi-scaled structure with micro-metallic balls and uniform nano-particles showed superhydrophobicity with the contact angle about 151.5°. The electrochemical measurements showed that the fabricated superhydrophobic surface exhibited excellent anti-corrosion performance that could behave as the barrier for inhibiting the corrosion of composites. The formation mechanisms of the surface morphologies and different wetting behaviors were analyzed.

Wear Resistance and Morphological Characterization of High-power Laser Clad Coatings on Ti-6Al-4V Alloy

Ti-Si binary coatings were cladded on Ti-6Al-4V alloy surface for improvement morphological orientation, microstructure and surface properties. The coatings were developed at 2.1 kW power, laser scanning speed of 1.2, 1.6 and 2.0 m/min, spot diameter of 3 mm and 0.5 overlap ratio. An optical microscope was used to magnify and analyse the microstructural arrangement and a microhardness indenter used to measure microhardness at 100gf for 10 seconds. The indent spacing was maintained at 100 µm between adjacent indents. The phase content of the coatings was analyzed with XRD technique. The coating wear resistance was tested at 10N force loading for 7 minutes using a TRB tribometer and characterized using SEM. Clad coatings were observed to exhibit refinement in microstructure with an increase in laser scanning speed where transformation occurred from equiaxed grains with localized smaller grains to refined grain structure. The highest degree of refinement was observed at 2.0 m/min scanning speed. It was also found that the microhardness property was improved by 2.44, 2.60 and 2.64 times the microhardness of Ti-6Al-4Vat 342.3 HV0.1. It is understood that high microhardness values favor improved wear resistance behavior. XRD analysis on the coatings revealed presence of Ti5Si3, Ti, Si and TiSi2 phases where Ti and Si are in matrix capacity and Ti5Si3 and TiSi2 present as intermetallic phases. The reported improvement in microhardness was attributed to the presence of Ti5Si3 and TiSi2. The action of the laser scanning speed was found to influence the clad height where an increase in laser scanning speed resulted in a decrease in clad height in the order 685.9, 491.4 and 291.5 µm for 1.2 m/min, 1.6 m/min and 2.0 m/min respectively. Wear test indicated that the coatings displayed an improved wear resistance by evidence of little material removal exhibited, compared to the substrate material which was dilapidated by severe adhesive wear and further aggravated by plastic deformation.

EBM-manufactured single tracks of Alloy 718: Influence of energy input and focus offset on geometrical and microstructural characteristics

Electron beam melting-powder bed fusion (EBM-PBF) is an additive manufacturing process, which is able to produce parts in layer-by-layer fashion from a 3D model data. Currently application of this technology in parts manufacturing with high geometrical complexity has acquired growing interest in industry. To recommend the EBM process into industry for manufacturing parts, improved mechanical properties of final part must be obtained. Such properties highly depend on individual single melted track and single layer. In EBM, interactions between the electron beam, powder, and solid underlying layer affect the geometrical (e.g., re-melt depth, track width, contact angle, and track height) and microstructural (e.g., grain structure, and primary dendrite arm spacing) characteristics of the melted tracks. The core of the present research was to explore the influence of linear energy input parameters in terms of beam scanning speed, beam current as well as focus offset and their interactions on the geometry and microstructure of EBM-manufactured single tracks of Alloy 718. Increased scanning speed led to lower linear energy input values (<0.9 J/mm) in an specific range of the focus offset (0–10 mA) which resulted in instability, and discontinuity of the single tracks as well as balling effect. Decreasing the scanning speed and increasing the beam current resulted in higher melt pool depth and width. By statistical evaluations, the most influencing parameters on the geometrical features were primarily the scanning speed, and secondly the beam current. Primary dendrite arm spacing (PDAS) slightly decreased by increasing the scanning speed using lower beam current values as the linear energy input decreased. By increasing the linear energy input, the chance of more equiaxed grain formation was high, however, at lower linear energy input, mainly columnar grains were observed. The lower focus offset values resulted in more uniform grains along the 〈001〉 crystallographic direction.

Laser weld geometry and microstructure of cast Uranium-6 wt% niobium alloy

Laser welding was performed on a U6wt%Nb uranium alloy using a 400 W solid state laser with welding speeds from 20 to 2500 mm/s. This speed range spanned melt pool sizes from traditional welding to surface modification and additive manufacturing. With increasing scan speed, the ratio of weld length relative to depth and width increased, with melt pool lengths being more than 5x greater than the width and 10x greater than the depth at the highest speeds. Keyhole mode welds were shown to occur at low speeds, while conduction mode welds occurred at 700 mm/s or higher as the weld depth dropped off more rapidly than width at higher speeds. Microstructures that form at the boundary between the fusion zone and base metal were observed to have a nonconventional appearance consisting of interpenetrating dark and light contrast phases before cells or dendrites appear. Dendrites with secondary arms form from this boundary in keyhole welds and refine to no visible secondary arms near the weld center. Primary and secondary dendrite arms, where present, were shown to refine in size inversely with cooling rate raised to the 0.465 and 0.375 powers respectively. Dendrites were largely absent from the conduction mode welds at higher speeds, and were replaced by a banded microstructure that appears to form by an oscillatory solidification front mechanism.

Theoretical and experimental investigation of continuous-wave laser scribing on metal thin film: effect of power.

In this paper, the scribing of the metal thin film using a continuous-wave laser is investigated theoretically and experimentally. We propose a reversible relation between incident fluence and ablation width. Microscopic analysis of the results is compared to theoretical expectations. Scribing has been done by focusing a 450nm laser diode beam on 100nm chromium thin film. Beam power and scanning speed are varied in the domains of 0.02-1.0W and 0.05-5mm/s, respectively. The microscopic images of the thin film show that the average ablation width on metal thin film varies slightly by increasing the scanning speed, which was anticipated by theory. Moreover if scanning speed increases, the ablation quality is reduced significantly and is not compensated by increasing incident power. According to microscopic images of the sample, this method could be a good substitute for pulsed-laser scribing in many applications such as making solar cells.

Experimental and Taguchi-Based Grey Approach of Laser Metal Deposition Technique on Nickel-Based Superalloy

Thin sections of Inconel 718 sample was treated with laser-based metal deposition using a CW CO2 laser. The Taguchi-based grey relational approach was incorporated for determining the optimized process characteristics of the laser treatment. Laser scan speed was varied at a constant laser power in order to analyze the effect of cooling rate and the subsequent thermal gradient on the microstructure and other properties of the base alloy. The presence of γ′-(Ni3Al, Ni3Ti) and γ″-Ni3Nb precipitates in the interdendritic boundaries was evidenced in the deposition zone. The increase in laser scan speed to 600 m/min changed the microstructure from coarse to fine grains, and a further increase to maximum laser power of 1.75 kW showed the transformation to still finer dendritic structure. Even though the fine dendritic structure, it also resulted in delamination of bonding layers which could be deleterious. X-ray diffraction spectrum revealed the precipitation of γ-NiCr, γ′-Ni3Al and γ″-Ni3Nb in the γ-Ni matrix and there was no evidence for the transformation of γ″-Ni3Nb to δ-Ni3Nb. It indicated that the selected laser parameter had the least possibility of influence in the formation of intermetallics after treatment. The significant effect of grain refinement improved the hardness by 15–20%. The tensile test on Inconel 718 showed the Ni3Nb precipitate particles initiated the interfacial failure and was encountered with ductile mode of fracture.

A Convenient and High-Efficient Laser Micro-Engraving Treatment for Controllable Preparation of Microstructure on Al Alloy.

Surface microstructure preparation offers a promising approach for overcoming the shortcomings of Al alloy, such as poor friction resistance, low hardness and weak corrosion resistance to corrosive liquid. Though many methods for the surface microstructure preparation of Al alloy have been developed, it is difficult for most of the reported methods to regulate the as-prepared microstructure, meaning that the properties of Al alloy cannot be improved efficiently by the microstructure. Thus, the application of microstructure surface of Al alloy and microstructure preparation technology is severely limited. Aimed at this issue, a simple, convenient, high-efficient, low-cost micro-scale roughness structure construction approach that is suitable for engineering application (laser micro-engraving) was developed. The as-prepared microstructure on Al alloy surface formed by laser micro-engraving was investigated systemically. The morphology and formation mechanism of the microstructure were examined. Meanwhile, the effect of laser parameters on morphology, geometrical dimensions and composition of microstructure was investigated. The results indicate that the morphology of microstructure is affected by the overlap degree of molten pool greatly. When each molten pool does not overlap with others, successive individual pits can be constructed. When each molten pool overlaps with others for one time, successive overlapping pits will form. As the overlap degree of the molten pool further increases (overlapping with others for more than one time), the successive pits can become grooved. Because of the influence of laser beam pulse frequency and scanning speed on the diameter and distance of the molten pools, the morphology and geometrical dimensions of microstructure can vary greatly with laser parameters. As the laser beam scanning speed increases, the geometrical dimensions of as-prepared microstructure reduce significantly. In contrast, with the increase of laser beam pulse frequency, the geometrical dimensions change in a complicated manner. However, the chemical composition of microstructure is slightly affected by laser parameters. More importantly, a relationship model was successfully established, which could be used to predict and regulate the geometrical dimensions of microstructure treated by laser micro-engraving. Controllable preparation of microstructure on Al alloy is realized, leading that specific microstructure can be prepared rapidly and accurately instead of suffering from long-time experimental investigation in the future.

Optimization of processing parameters and establishment of a relationship between microstructure and mechanical properties of SLM titanium alloy

The processing parameters of a selective laser-melted (SLM) Ti6Al4V alloy were systematically optimized for optimal surface roughness and relative density. The relationship between microstructure and mechanical properties were established in the optimal parameter range. The results showed that the optimal laser power and scan speed was 200–250 W and 850–1150 mm/s, respectively. The laser power and scan speed played contradicting roles in the resultant roughness and porosity. An appropriate increase in laser power and decrease in scan speed could reduce the surface roughness and simultaneously improve the density and dimensional accuracy. When the laser power was 200 W, the microstructure varied from equiaxed grains to mixed equiaxed-columnar grains, and then it varied to columnar grains as the scan speed changed from 250 mm/s to 850–1750 mm/s. The acicular structure inside the grains transformed from an α (α′) + β phase to an α′ (α) phase with gradual grain refinement. Some nano-β phase precipitated near the acicular phase. Micro-hardness measurements revealed different values at the top, middle and bottom of the samples with increasing laser power and showed a reduced hardness gap with increasing scan speed. However, the elongation continuously increased with increasing scan speed and reached a maximum value of 7.8% at a scanning speed of 1150 mm/s. Decrease in elongation was observed when the laser power increased to 275 W. These variations in the hardness and mechanical properties were attributed to the combined effects of nano-β phase and grain refinement of acicular α (α′) martensites.

A Simple Model to Predict Machined Depth and Surface Profile for Picosecond Laser Surface Texturing

A simple mathematical model was developed to predict the machined depth and surface profile in laser surface texturing of micro-channels using a picosecond laser. Fabrication of micro-craters with pulse trains of different numbers was initially performed. Two baseline values from the created micro-craters were used to calculate the estimated simulation parameters. Thereafter, the depths and profiles with various scanning speeds or adjacent intervals were simulated using the developed model and calculated parameters. Corresponding experiments were conducted to validate the developed mathematical model. An excellent agreement was obtained for the predicted and experimental depths and surface profiles. The machined depth decreased with the increase of scanning speed or adjacent interval.

Experimental investigation on laser micromilling of SiC microchannels

Silicon carbide (SiC) microchannels show their promising merits in the applications of microchannel heat sink cooling systems, microsensor MOS devices, and UV photodiodes. The fabrication of SiC microchannels is critical for their wide applications. In this study, a laser micromilling method is utilized to process SiC microchannels. A series of SiC microchannels are fabricated using a pulsed fiber laser. Based on the SEM observations and 3D confocal microscope measurements, the formation of microchannels is analyzed. The effects of laser processing parameters, such as laser output power, scanning speed, and scanning times as well as the predetermined microchannel width, on the geometric dimension and surface morphology are systematically assessed. The common recast layer deposited around the laser-scanned areas in the laser micromilling of metallic structures was not found for the SiC microchannels. A transition between triangular and trapezoidal shapes occurred for the laser-micromilled microchannels depending on the processing parameters and predetermined width. The microchannel depth increased monotonically with the laser output power and laser scanning time but decreased with increasing scanning speed. On the contrary, the bottom width of microchannels presented an inverse trend. The surface roughness was dependent on the laser scanning speed, scanning time, as well as predetermined width.

Microstructure simulations of Inconel 718 during selective laser melting using a phase field model

In this study, the microstructure evolution of the Inconel 718 alloy fabricated by selective laser melting (SLM) was investigated by a phase field model. The temperature gradient and the solidification velocity were first calculated from a finite element thermal model of SLM and then used as the input of the phase field model to simulate the microstructure growth with time. The influences of the build height and laser beam scanning speed on the microstructure evolution were studied and evaluated. The results show that the columnar dendritic arm spacing values estimated from the phase field simulations are comparable to experimental and analytical results. With the increase of the build height, the dominated values of thermal gradient and cooling rate decreased first and then slightly increased at the top end of the manufacturing process. The microstructural evolution along the build height agreed well with the experimental test. In addition, with the increase of the laser beam scanning speed, the dominant temperature gradient increased to a certain value and then decreased, and the direction of the maximum temperature gradient tended to be parallel to the part build direction. Moreover, the temperature gradient affects the dendrite growth significantly, a greater temperature gradient resulting in a higher growth speed.

Selective laser melting of titanium parts: Influence of laser process parameters on macro- and microstructures and tensile property

The laser process parameters play an important role in the macro- and microstructures and tensile property of titanium samples fabricated by selective laser melting (SLM). In this study, the effect of laser process parameters on the density, surface morphology, dimensional accuracy, microstructure and tensile property of SLMed Ti6Al4V parts was investigated. With the increase of laser power and decrease of scan speed, the densification increased and the relative density showed reduced sensitivity to laser power under higher laser power (>175 W). The morphology of scan tracks on the top surface changed from clear and uniform mode to disordered mode with the increase of scan speed. The marks of melt flow, molten pool overlap and adhered powder could be observed obviously on the side surface. In the analysis of dimensional accuracy, the size shrinkage effect in the building direction (z-axis) was discussed and the “periphery spreading effect” in horizontal direction (x-axis and y-axis) was presented. Martensite α’ was the main constituent phase in SLMed Ti6Al4V samples. With the increase of scan speed, the width of prior β grains decreased gradually and the formed α’ phase changed into a relatively refined acicular shape. Conclusively, the relationship between microstructure and tensile property was discussed and a relative high tensile property was obtained.

Densification, microstructure evolution and fatigue behavior of Ti-13Nb-13Zr alloy processed by selective laser melting

Ti-13Nb-13Zr alloy was fabricated by selective laser melting (SLM), and the densification, microstructure evolution, nanohardness, tensile strength and fatigue behavior of the alloy were systematically investigated. A narrow, feasible process window (laser power 325 W, scanning speed 1000 mm/s, scanning distance 0.13 mm, and layer thickness 0.03 mm) was accordingly determined. With the increase of scanning speed, the coarse acicular-shaped α′ grains changed to refined acicular-shaped α′ grains and then defect formed in the microstructure. The optimally prepared Ti-13Nb-13Zr sample had a very high hardness of 519.448 HV and tensile strength of 1106.07 MPa, which are superior higher than that prepared by traditional thermomechanical technique (280 ± 15 HV and 732 MPa). Owing to the change of BCC to HCP structure ([111] β→ [1-21-3] α′), the accumulation of dislocations and the finer grains, the SLM-processed samples exhibited higher fatigue strength than that the alloy processed by cast and was commensurate with the cast Ti-6Al-4 V. Moreover, the influences of phase transition on fatigue behavior have been discussed carefully.

P01.091 A robust method for rapidly simulating TTFields distributions within patient-specific computational head models

Tumor Treating Fields (TTFields) are delivered to the brain through two pairs of transducer arrays placed on the patient’s scalp. TTFields distribution in the brain depends on the array’s position, patient anatomy and the electric properties of the tissues and tumor. We aim to create realistic computational patient models in order to understand how field distribution influences disease progression. However, preparation of such models is a highly time consuming task. In addition, in clinical scenarios, MRI acquisition time is often reduced by increased slice spacing, limited field of view, or increased scan speed, leading to difficulties in creating automated models. Our method is designed to enable model creation under those restrictions. It does so by using a realistic head model of a healthy individual used as a deformable template with which the patient model is derived. A highly detailed healthy head model serves as a deformable template from which patient models are created. The first step is pre-processing, involving denoising and background noise reduction, as well as super-resolution algorithms when needed. To create the patient model, the tumor is first segmented manually and masked, leaving only healthy tissues in the MRI, which is then registered to the template space to yield the transformation from patient space to template space. The template is then deformed into the patient space using the inverse transformation, and the tumor is placed back creating a full patient model. Next, automatic identification of landmarks on the patient’s head is used to position the transducer arrays on the head, which are then introduced into the model. Finally, boundary conditions are set, and field distribution is simulated using Finite Differences Time Domain (FDTD) method (Sim4Life V3.0, ZMT-Zurich). We have simulated TTFields distribution of 317 patients treated with TTFields as part of the EF-14 trial. Our method is optimized for accurate contouring of tissues highly influencing the distribution of electric field (Scalp, skull, CSF, ventricles), and it is robust, having the ability to give sufficient results even when MRI data quality is low. Thus enabling a study correlating the spatial distribution of TTFields and patient outcome. Our process for rapidly creating patient models presents a breakthrough that enables the first study in which the spatial distribution of therapeutic electric fields correlates with patient outcome. In the future this method can be used for clinical studies investigating other clinical indications of large datasets.