Leibniz Universität Hannover
Additive manufacturing processes such as laser powder bed fusion (PBF-LB) offer a high degree of design freedom compared with conventional machining or casting processes and are becoming increasingly important in lightweight and biomedical applications. As the high specific strength and good biocompatibility of magnesium alloys result in many promising implant applications for the material, for example bone grafts, the production of magnesium components using laser additive processes has great potential. Magnesium powder are hard to be processed reliably using PBF-LB because the oxide layer has a high melting point of approximately 2800 °C. Therefore, the laser must apply high power to break up the oxide layer. As the boiling point of the underlying metallic magnesium is only approximately 1100 °C, the magnesium evaporates and individual particles are whirled up from the melt pool, causing the particles to disrupt the process. This poses a challenge for the production of high-quality components made of magnesium alloys using PBF-LB. To address this challenge, new magnesium alloys were developed within the present study specifically for the PBF-LB process and produced using the gravity die casting process. It could be shown that the oxidation rate can be reduced by alloying with strontium, thereby reducing the oxide layer thickness. Using zinc and calcium as additional alloying elements alongside strontium, a biocompatible alloy with enhanced mechanical properties was developed using gravity die casting. The alloy ZJX200 (2 wt.-% Zn, 0.5 wt.- % Sr, 0.5 wt.-% Ca) showed the most promising mechanical properties of the alloys tested. Such a magnesium alloy could potentially be processed with lower laser power by PBF-LB to further reduce evaporation and could serve as a material for complex three-dimensional structures, for example, bone implants customized to the needs of a patient.
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