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<p>Powder bed fusion laser beam (PBF-LB) is one of the widely used additive manufacturing (AM) processes for the fabrication of layered (discontinuous) functionally graded material (FGM) based functional prototypes. However, little has been reported on layered-composition gradient-based FGM processed by PBF-LB for customizing the tensile characteristics required for biomedical applications. In this study, a multilayer FGM was designed and fabricated (as per ASTM E8) using a composition gradient strategy comprising a 17-4 precipitate-hardened (PH) stainless steel (SS) (base layer, 1.33&#xa0;mm), a Ni-625 (middle layer, 1.33&#xa0;mm), and a Ti-6Al-4V (top layer, 1.33&#xa0;mm) processed by PBF-LB. The graded architecture was designed to achieve mechanical stiffness compatibility with human cortical bone, based on Young’s modulus (<i>E</i>), to mitigate stress-shielding effects. The fabrication was carried out using a fiber laser-based PBF-LB setup (laser power 300W, wavelength 1070&#xa0;nm, Class IV). A Taguchi-based design of experiments was employed to investigate the influence of process parameters, including laser energy density (LED), infill strategy for middle layer (solid, octet-truss, and Weaire Phelan lattice), and hatch distance (HD), each at 03 levels. The results suggest that the infill strategy for PBF-LB is the most significant parameter (at the 95% confidence level) affecting the <i>E</i> of fabricated FGM. Among the investigated configurations, the solid infill structure exhibited an <i>E</i> of 13.349&#xa0;GPa, which closely matches the range reported for human cortical bone (12.2-20.5&#xa0;GPa), indicating its suitability for load-bearing biomedical applications. The results were further supported by thermokinetic simulations (based on melt-pool analysis, solidification rate, and phase volume fractions) and morphological characterization (SEM/EDS, grain size No., and porosity analysis).</p>

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Investigations on Layered-Composition Gradient-Based Functionally Graded Material Processed by Powder Bed Fusion-Laser Beam for the Customization of Tensile Behavior in Biomedical Applications

  • 期刊论文

  • 发表日期：

    2026年7月20日

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  • Bharat Kalia,
  • Rupinder Singh,
  • B. S. Pabla

摘要

Powder bed fusion laser beam (PBF-LB) is one of the widely used additive manufacturing (AM) processes for the fabrication of layered (discontinuous) functionally graded material (FGM) based functional prototypes. However, little has been reported on layered-composition gradient-based FGM processed by PBF-LB for customizing the tensile characteristics required for biomedical applications. In this study, a multilayer FGM was designed and fabricated (as per ASTM E8) using a composition gradient strategy comprising a 17-4 precipitate-hardened (PH) stainless steel (SS) (base layer, 1.33 mm), a Ni-625 (middle layer, 1.33 mm), and a Ti-6Al-4V (top layer, 1.33 mm) processed by PBF-LB. The graded architecture was designed to achieve mechanical stiffness compatibility with human cortical bone, based on Young’s modulus (E), to mitigate stress-shielding effects. The fabrication was carried out using a fiber laser-based PBF-LB setup (laser power 300W, wavelength 1070 nm, Class IV). A Taguchi-based design of experiments was employed to investigate the influence of process parameters, including laser energy density (LED), infill strategy for middle layer (solid, octet-truss, and Weaire Phelan lattice), and hatch distance (HD), each at 03 levels. The results suggest that the infill strategy for PBF-LB is the most significant parameter (at the 95% confidence level) affecting the E of fabricated FGM. Among the investigated configurations, the solid infill structure exhibited an E of 13.349 GPa, which closely matches the range reported for human cortical bone (12.2-20.5 GPa), indicating its suitability for load-bearing biomedical applications. The results were further supported by thermokinetic simulations (based on melt-pool analysis, solidification rate, and phase volume fractions) and morphological characterization (SEM/EDS, grain size No., and porosity analysis).