Experimental and Computational Analyses of Structural and Mechanical Deviations in Magnesium Alloy Manufacturing with Selective Laser Melting

2021 
Currently, the potential use of selective laser melting (SLM) technology to fabricate and optimise the performance of human bone implants with functionally graded scaffold (FGS) structures has drawn an increasing amount of attention. Magnesium alloy is a high-quality light metal that shows impressive potential in bioengineering; thus, it is chosen in this study. However, the defects that occur in magnesium during manufacturing may generate unexpected mechanical differences between the products and the ideal products, so there is a need to determine an efficient way to model actual products. In this article, samples were manufactured with different laser energy densities and subjected to compression experiments. The formation of spherical defects was analysed according to the principle of additive manufacturing. Hence, based on the observed characteristics, finite element (FE) models with different geometries were built, and changes in the stress distribution during compression were discussed. By comparing the mechanical properties obtained from compression tests and FE modelling, the simulation accuracy of each model was also estimated, from which the model that highlighted the stacking relationship was notable. Moreover, the expanded Hertzian contact stress theorem verified the influence of spherical defects on the compressive behaviour of the sample. The accuracy of the FE results was obviously improved by rectifying the equivalent bearing area.
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