Directed energy deposition (DED) parameters were determined for near-β alloy Ti-55511 by employing statistical design of experiments (DOE) methods. Parameters resulting in fully dense freeform deposits were identified using two sequential DOEs. Single laser tracks were printed with several laser power, traverse rate, and powder feed rate settings in an initial DOE to identify promising build parameters. Capture efficiency and effective deposition rate were used to characterize and rank the single track deposits. The best parameters were then used to print solid cube with various X-Y and Z-overlaps (different hatch spacing, HS, and layer thickness, ZS) in a second DOE. Suitable deposition parameters were selected based on cube density and microstructure and were used to fabricate larger tensile samples for mechanical testing. Multiple parameter sets were found to provide dense Ti-55511 deposits with acceptable mechanical properties and parametric models showed statistical significance.

The study focuses on a novel porous TiNi-based material for ophthalmic orbital implants which was produced by self-propagating high-temperature synthesis (SHS) and, after proper surface modification, possesses a specific microstructure of its surface pores, which makes it attractive for biomedical use in implants. After preparation via SHS, the obtained porous TiNi material was etched in acidic environment, to get rid of its surface Ti2Ni secondary-phase particles. This was found to improve the material’s surface morphology, adding micro-roughness to its macro-rough pores. As a result, cell growth tests conducted on the material demonstrated improved cell adhesion and growth kinetics on such a porous material with improved roughness. Finally, the material was tested in vivo as an ophthalmic orbital implant, demonstrating good biocompatibility, good degree of biointegration with surrounding eyeball tissues, and no signs of rejection after as long as 180 days. Thus, the novel porous TiNi-based material shows promise for its use in ophthalmic implantology, for instanse for manufacturing musculoskeletal stumps of the eyeball after evisceration, as it is biocompatible, has a high tissue-implant integration potential and demonstrates reduced risks of exposure and rejection of the implant.

A two-way coupled model between polydisperse particle phases with compressible gases and a density-based coupling implicit solution method combining the third-order MUSCL with QUICK spatial discretization scheme and the second-order temporal discretization scheme are constructed based on the discrete-phase model (DPM) and the stochastic wander model (DRWM) in the Eu-lerian-Lagrangian framework in conjunction with a unitary particulate source (PSIC) approach and the SST k-ω turbulence model. The accuracy of the numerical prediction method is verified using previous supersonic nozzle gas-solid two-phase flow experiments. Numerical simulation of two-phase jet of dry powder extinguishing agent gas with pilot-type supersonic nozzle was carried out to analyze the influence of geometrical parameters such as length ratio rL and area ratio rA of main nozzle on the two-phase flow field as well as on the jet performance indexes such as particle mean velocity vp,a, velocity inhomogeneity Φvp, particle dispersion Ψp, particle mean acceleration ap,a and so on. By analyzing the parameters, we indicate the requirements for the combination of jet performance metrics for different flame types such as penetrating, spreading, and dispersing.

TiC particles were prepared from Ti and C powders, and TiC-reinforced Cu-based composites were prepared by powder metallurgy with SPS sintering. The effects of SPS sintering temperature and TiC particle reinforcement phase content on the electrical and mechanical properties of Cu-based composites were investigated. The reinforcement of TiC particles by thermal mismatching at increasing sintering temperature has a significant strengthening effect on the composites, but the high temperature causes softening of the Cu matrix and the growth of grains reduces the properties of the composites. In this study, the effects of porosity and density on the composite properties were not significant.

Chromium (Cr) metal has garnered significant attention in alloy systems owing to its exceptional properties, such as high melting point, low density, and superior oxidation and corrosion resistance. However, its processing capabilities are hindered by the high Ductile-Brittle Transition Temperature (DBTT). Recently, powder bed fusion-laser beam for metals (PBF-LB/M) has emerged as a promising technique, offering the fabrication of net shapes and precise control over crystallographic texture. Nevertheless, research investigating the mechanism underlying crystallographic texture development in pure Cr via PBF-LB/M still needs to be conducted. This study explores the impact of scan speed on relative density and crystallographic texture. At the optimal scan speed, an increase in grain size attributed to epitaxial growth was observed, resulting in the formation of cubic texture. Consequently, a reduction in High Angle Grain Boundaries (HAGB) was achieved, suppressing defects such as cracks and enhancing relative density up to 98.1%. Furthermore, with increasing densification, Vickers hardness also exhibited a corresponding increase. These findings underscore the efficacy of PBF-LB/M for processing metals with high DBTT properties.

Swarf of aluminum alloy with high corrosion resistance and ductility was successfully converted into fine hydroreactive powders via its ball milling with silver powder and either lithium chloride or gallium. The later substances significantly intensified particle size reduction, while silver formed ‘cathodic’ sites (Ag, Ag2Al) promoting Al corrosion in aqueous saline solutions with hydrogen generation. The diffraction patterns, microphotographs, and elemental analysis results demonstrated partial aluminum oxidation in the samples and their contamination with tungsten carbide from milling balls. Those effects were responsible for obtaining hydrogen yields lower than expected. For AlCl3 solution at 60 °C, Al–LiCl–Ag, Al–LiCl, Al–Ga–Ag, and Al–Ga composites delivered (84.6±0.2), (86.8±1.4), (80.2±0.5), and (76.7±0.7)% of the expected hydrogen respectively. Modification with Ag promoted Al oxidation thus providing higher hydrogen evolution rates. The samples with Ag were tested in CaCl2 solution as well, for which the reaction proceeded much slower. At a higher temperature (80 °C) after 3 h of experiment, the hydrogen yields for Al–LiCl–Ag and Al–Ga–Ag powders were (46.7±2.1) and (31.8±1.9)%. The tested Ag-modified composite powders were considered promising for hydrogen generation and had a potential for further improvement to provide higher performance.

Controlling injection parameters is paramount when it comes to producing high-quality green parts using powder injection molding. This work combines experimental and numerical approaches to study the impact of injection parameters on mold in-cavity pressure and on the overall quality of green parts produced by low-pressure powder injection molding. The properties of two low-viscosity feedstocks (formulated from a water-atomized stainless-steel powder and wax-based binder system) were measured and implemented in an Autodesk Moldflow numerical model to quantify the molding pressures, which were finally validated using experimental real-scale injections. The results confirmed that an increase in mold temperature, an increase in feedstock temperature, and a decrease in solid loading decrease the mold in-cavity pressure, which was correlated with the feedstock viscosity. As a key result, real-scale injections confirmed that a minimum flow rate was required to avoid atypical high in-cavity pressure leading in several visual defects such as weld lines, flow marks, cracks, sinks, and incomplete filling. Due to differences in its thermal transfer properties, this flow rate threshold value decreases as the feedstock solid loading increases. For injection speeds higher than this value, the injection pressure measured experimentally was linearly correlated with the injection flow rate.

Aluminum matrix nanocomposites have been the subject of much attention due to their extraordinary mechanical properties and thermal stability. This research focuses on producing and characterizing an aluminum matrix reinforced with silicon carbide (SiC) nanometric particles. The conventional powder metallurgy route was used to produce the nanocomposites, and the dispersion and mixing process was carried out by ultrasonication. The conditions of the dispersion and the volume fraction of the SiC were evaluated in the production of the nanocomposites. Microstructural characterization was carried out using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD). Mechanical characterization was carried out using hardness and tensile tests. The dispersion agent was investigated, and isopropanol leads to better dispersion with fewer agglomerates. Increasing the volume fraction of the reinforcement improves the hardness of the nanocomposites. However, greater agglomeration of the reinforcement is observed for larger volume fractions. The greatest increase in hardness (77% increase compared to the hardness of the Al matrix) is obtained with 1.0 vol % of SiC, corresponding to the sample with the best dispersion. The mechanical characterization through tensile tests attests to the effect of the reinforcement on the Al matrix. The main strengthening mechanisms identified were the load transfer, the texture hardening, Orowan strengthening, and the increase in the density of dislocations in the nanocomposites.

Vit-106 is a promising zirconium-based alloy with high glass-forming ability and belongs to the so-called bulk metallic glasses (BMG). Workpieces with a size of around one centimeter in all three dimensions can be obtained from a BMG alloy by casting. However, further increasing the cast size decreases the cooling rate and thus induces crystallization. Selective laser melting (SLM) is a well-known technique to overcome the size limitations for BMGs because a workpiece is built by the addition of multiple melt portions where the cooling rate is kept above the critical one. Currently, BMG parts obtained by SLM suffer from partial crystallization. The present work studies the influence of SLM process parameters on partial crystallization of Vit-106 by metallography and the influence of the microstructure on mechanical properties by microhardness and wear resistance testing. Submicron crystalline inclusions are observed in an amorphous matrix of Vit-106 alloy obtained by SLM. The size and the concentration of the inclusions can be controlled by varying the laser scanning speed. It is shown that submicron crystalline inclusions formed in the amorphous matrix during SLM can favorably affect microhardness and wear resistance.

Polymeric composites such as Poly-ether-ether-ketone (PEEK)/carbon fiber (CF) have been widely utilized due to outstanding performances such as high specific strength and specific modulus. The PEEK/CF components via powder-bed fusion additive manufacturing usually show brittle fracture behaviors induced by their poor interfacial affinity and inner voids. These defects are strongly associated with powder packing quality upon deposition. The particle dynamic model has been widely employed to study the interactions of particle motions. Powder property, bulk material property, and interfacial features of composite powders are key factors in the particle dynamic model. In this work, an efficient and systematic material evaluation is developed for composite powders to investigate their deposition mechanism. The discrete element method is utilized to simulate the dynamic behaviors of PEEK/CF composite powders. The powder properties, bulk material properties, and interfacial features of powders are calibrated and justified by experimental measurement, numerical simulation, and design of experiments. The particle dynamic model can well explain the powder flow behaviors and interactions. It reveals that the addition of short CF particles can assist the flow of PEEK powders and improve the packing quality of the composite powders.

Reactive powder concrete (RPC) is a modern form of cementitious material. Major components include cement with a very low water-to-binder (w/b) ratio, steel fibres, superplasticizers, and very fine additives used in place of coarse aggregate, and very little water. The primary goal of this study is to examine the impact of immersion in sulfuric acid on compressive strength and to evaluate the impact of curing procedures on the preparation of RPC with high characteristics. The experimental work includes 4 mixes, which are prepared using 30 mm hooked-end steel fibers with a ratio of 0.4 by volume, silica fume and metakaolin with a ratio of 25% of cement weight. Compressive and indirect tensile strengths, ultrasonic velocity, and bulk density tests were conducted on the RPC that was prepared to evaluate its qualities. The results showed that heat curing resulted in a greater increase in strength than water curing did, and that mechanical properties improved with increasing SF more than MK additions. Heat-cured RPC demonstrated greater resistance to sulfuric acid immersion tests on compressive strength compared to water-cured RPC.

(1) Background: The research on the potential of regional food products, known for their rich bio-active compound content, could enhance human health in local populations. This is especially pertinent amid the Covid-19 pandemic and global trade disruptions; (2) Methods: The current study evaluated the physico-chemical composition using standard methods, antioxidant activity via DPPH, ABTS, FRAP, and CUPRAC methods, sorption capacity (at 10°C, 25°C, and 40°C with water activity ranging from 0.1 to 0.9) through the static-gravimetric method, and monolayer moisture content (MMC) calculated using the BET model; (3) Results: The approximate physi-co-chemical composition of laboratory-produced quince powder is as follows: proteins - 1.27g, carbohydrates - 75.80g, fats - 0.49g, fibers - 21.50g, ash – 2.31g, and nutritional value – 355.65kcal. Antioxidant activity is confirmed by all methods. The Modified Halsey model is recommended to describe the sorption isotherms with an S-shaped form. The MMC for the adsorption process ranges from 14.41% d.b. to 7.09% d.b., and for the desorption process, it ranges from 13.11% d.b. to 7.80% d.b.; (4) Conclusions: Seasonal and regional foods boast the best nutritional profiles, as they are cultivated and harvested at optimal ripeness in natural sunlight, preserving the essential vitamins and minerals in the food.

The main purpose of the work was to determine the powder composition and properties of iron-based sinters used as a matrix in metallic diamond tools. The FeCuSnNi sinters obtained from a mixture of commercial powders were used for research. The material was subjected to milling in a ball mill and sinter have been performed with the hot-pressing technique in a graphite mold. The physical and mechanical properties of the sinters were tested. The investigations of obtained sinters concerned density, porosity, hardness, oxygen content, static tensile test and analysis of microstructure. The static tensile test was carried out with the use of a universal testing machine UTS-100. The study of the microstructure of sinters was performed using the JSM-7100F scanning electron microscope. The sinters are characterized by a high coefficient of thermal expansion and good mechanical properties. The FeCuSnNi sinter revealed a complex phase structure. Spot chemical analysis revealed the presence of Fe solution, Cu solution and the presence of iron oxides oxides. Nickel atoms were present throughout the sinter volume. The obtained results indicate that the presented material can be used as a matrix of a diamond-metal composite in diamond tools for the processing of natural stones and building materials.

This work deals with the analysis of phase composition of sintered Ti-Al-C composite materials under high voltage electrical discharge. The samples of Ti-Al-C powder composites were tested by SEM, Raman spectroscopy and XRD. It was determined that the treatment of the powder by high voltage electrical discharge (HVED) and further sintering at high temperatures using the method of spark plasma sintering (SPS) encourages the formation of the intermetallic reinforcing phases, carbides and different nanocarbon structures like graphene and fullerenes, as well as pure graphite. Intermetallic phases and nanocarbon structures improve mechanical and physical properties of the composites. By using experimental methods mentioned above, the phase composition of Ti-Al-C powder composites obtained at different sintering temperatures was determined.

Technical components should be produced sustainably and are subject to growing demands in terms of durability and reliability. To meet these expectations, the development of thermochemical processes is auspicious. Titanium alloys, which have a comparatively high gas solubility, allow temporary hydrogen (H) loading, often called thermo hydrogen treatment (THT). THT causes lattice deformation and reduces the β transformation temperature. These effects enable an adjustment of the microstructure, which improves the mechanical properties as compared to those produced conventionally. Furthermore, the process is applicable to complex geometries that cannot be surface hardened by mechanical surface treatment techniques. The investigation presented intends to realize a local microstructure gradient in additively via laser-powder bed fusion (L-PBF) manufactured cylindrical Ti–6Al–4V specimens by changing the distribution and morphology of strengthening precipitates as well as the β grain size depending on the distance to the surface, which should improve the material fatigue properties. To evaluate the mechanical properties of such THT-induced microstructure gradients, the resulting change in fatigue life in the LCF and HCF range was determined by stress-controlled cyclic deformation tests. Besides, the resulting microstructure was characterized by means of XRD and TEM. In addition to the additively manufactured and thermo hydrogen treated cylindrical specimens, conventionally produced tube-like specimens were thermo hydrogen treated and examined. For the THT-induced microstructure gradients, numerically simulated H concentration profiles as well as experimentally determined hardness profiles were used for the evaluation of the THT process. The study shows that H-loading at 500°C and H-degassing at 750°C, followed by aging at 550°C, allows the establishment of a microstructure gradient that shows an 8% improvement in fatigue properties compared to a reference condition without THT. The reason for this improvement is an increased volume fraction secondary alpha phase in the near-surface area of the specimens. Moreover, the results show that the process is applicable a tube-like specimen with varying wall thicknesses.

Alectinib hydrochloride is an anticancer medication used for the first-line treatment of non-small cell lung cancer. Although it has been approved for medical use ten years ago, and three polymorphs of this substance were proposed based on X-ray diffraction patterns, their crystal structures remained unknown to date. The main problem was preparation of high quality single crystals due to very low solubility of the salt. Herein we report on molecular and crystal structure of form I of alectinib hydrochloride as obtained by powder X-ray diffraction data from laboratory source. The refinement revealed that the nitrogen atom of the morpholinyl ring is protonated. The chloride anion interacts with the H(N) atoms of the morpholine and benzo[b]carbazole rings to form infinite H-bonded chains.

This study utilises NaOH to treat composite cementitious materials containing aeolian sand and zeolite powders, which were used to replace 50% of the cement in aeolian-sand concrete (ASC). The mechanical properties of treated ASC considerably improved, especially when the NaOH dosage was 4% by mass. After curing this sample (denoted as AAZC-4) for 28 d, its compressive strength improved by 17.2% and its split tensile was increased by 16.3%. Potassium feldspar and montmorillonite in zeolite powder and SiO2 in the sand were decomposed by OH− and combined with other elements to generate various silicate gels and A-type potassium zeolite crystals inside the concrete. Microscopic examination showed that the gels and crystals intertwined to fill the pores, decreasing (increasing) the percentage of large (small) pores, thus optimising the pore structure. This substantially improved the mechanical properties of ASC. Freeze–thaw salt-intrusion tests showed that the extent of mass loss, degree of damage and loss of compressive strength of AAZC-4 were similar to those of ordinary concrete but were reduced by 36.8%, 19% and 52.1%, respectively, compared with those of ASC. Therefore, AAZC-4 has sustainable working performance in the chloride ion permeable environment in cold and arid areas.

The objective of this study is to evaluate how two varying amounts of sepiolite-based powder, infused with indigo extract, affect the appearance and durability of a water-based white primer. To examine the influence of this eco-friendly pigment on the coatings' overall appearance, assessments were performed for color, gloss, and surface roughness. Additionally, the coatings were investigated through optical and electron microscopic observations, to evaluate the distribution of the pigment within the polymer matrix. The effect of the pigment on the coating's durability was assessed through accelerated tests, including exposure in a salt spray chamber and a UV-B chamber. These tests aimed to evaluate the emergence of defects and changes in the appearance of the samples over time. Furthermore, the impact of different quantities of sepiolite-based powder on the coating's ability to act as a barrier was assessed using liquid resistance tests and contact angle measurements. These evaluations aimed to understand how the coating responded to various liquids and its surface properties concerning repellency or absorption. In essence, this study underscores the considerable influence of the eco-friendly pigment, demonstrating its capacity to introduce unique color and texture variations to the paint. Moreover, the inclusion of the pigment has enhanced the coating's color stability, its ability to act as a barrier, and overall durability when exposed to harsh environments.

Molybdenum tailings powder (MTs) is an industrial waste that contains more than 85% contents of SiO2, Al2O3, CaO, and Fe2O3. Therefore, MTs has the potential pozzolanic activity and can be used as a mineral admixture in cementitious materials. In order to understand the influence of MTs as an admixture on the cement hydration process, the hydration heat and hydration kinetics of the composite cementitious materials (CCMs) were investigated by an isothermal calorimeter and the Krstulovic-Dabic model. Furthermore, the influences of fly ash (FA), slag (SL) and MTs on hydration heat at the same content were compared and analyzed. Results show that proper amount of MTs can promote the hydration of CCMs. When the content of MTs is not more than 15%, the second exothermic peak of CCMs appears earlier and the peak heat release increases. However, when the content of MTs exceeds 15%, the second exothermic peak of CCMs is delayed and the peak heat release decreases. The cumulative heat release of CCMs gradually decreases with an increasing content of MTs. When the replacement of MTs, FA, and SL is 15% respectively, the addition of MTs enhances the second exothermic peak of CCMs compared to FA and SL. The final heat release of MTs is higher than that of FA, but lower than that of SL. The hydration process of CCMs undergoes three stages: nucleation and crystal growth (NG), interactions at phase boundaries (I), and diffusion (D). The incorporation of MTs shortens the NG stage and I stage.

Effects of oxygen content on microstructure and creep property of FGH96 superalloy were investigated. When oxygen content increased from 135ppm to 341ppm, prior particle boundary (PPB) rose from degree 2 to degree 3, and the size of γ′ phase on PPB enlarged from 1.07μm to 1.27μm, and MC carbide size grew from 77.4nm to 104.0nm. Meanwhile, the steady creep rate accelerated form 4.34×10-3 h-1 to 1.87×10-2 h-1, and the creep rupture life shortened from 176h to 94h, and the creep rupture mode transferred from intergranular and transgranular mixed fracture to along PPB fracture. During creep, the micro-twins formation and gliding will be restrained by ∑3 boundaries. FGH96 superalloy with higher oxygen content contains less ∑3 boundaries and its micro-twins cross slipped instead of single direction slip in lower oxygen content superalloy. Consequently, specimen with higher oxygen content creeped faster and raptured earlier.

The ultrasonic vibration assisted pressing process can improve the fluidity, the uneven distribution of density and particle size of WC-Co powder. However, the microscopic mechanism of ultrasonic vibration on the powder remains unclear. In this paper, WC and Co particles are simulated by three-dimensional spherical models of two particle sizes with the aide of the secondary development of Python. At the same time, the forming process of powder at mesoscale is simulated in the virtue of the finite element analysis software ABAQUS. The influence of vibration amplitude on the fluidity, the filling density and the stress distribution of WC-Co powder is investigated when the ultrasonic vibration is applied to the conventional pressing process. From simulation results, the ultrasonic vibration amplitude has great influences on the density of the compact. With the increase of the ultrasonic amplitude, the compact density also increases gradually. At the initial stage of the compaction, the particles move violently under the action of ultrasonic vibration, the fluidity is obviously enhanced, the arch bridge effect between particles is destroyed, the fine particles quickly fill the pores between the large particles, which increase the density, and the residual stress in the billet decreases after the compaction. From the experimental results, the size distribution of the billet is more uniform, the elastic aftereffect is reduced, the dimensional instability is improved, and the density curves obtained by experiment and simulation are within a reasonable error range.

Abstract Octreotide is the first synthetic peptide hormone, consisted of eight amino acids, that mimics the activity of somatostatin, a natural hormone in the body. During the past decades, advanced instrumentation and crystallographic software established X-ray Powder Diffraction (XRPD) as a valuable tool for extracting structural information of biological macromolecules. The latter was demonstrated by the successful structural determination of octreotide at a remarkably high d-spacing resolution (1.87 Å) (PDB code: 6vc1). This study focuses on the response of octreotide to different humidity levels and temperatures, with a particular focus on the stability of the polycrystalline sample. XRPD measurements were accomplished employing an Anton Paar MHC-trans humidity-temperature chamber installed within a laboratory X’Pert Pro diffractometer (Malvern Panalytical). The chamber is employed to control and maintain precise humidity and temperature levels of samples during XRPD data collection. Pawley analysis of the collected data sets revealed that the octreotide polycrystalline sample is remarkably stable and no structural transitions were observed. The compound retains its orthorhombic symmetry (space group: P212121, a = 18.57744(4) Å, b = 30.17338(6) Å, c = 39.70590(9) Å, d~ 2.35 Å). However, a characteristic structural evolution in terms of lattice parameters and volume of the unit-cell is reported mainly upon controlled relative humidity variation. In addition, an improvement of signal-to-noise ratio in the XRPD data under a cycle of dehydration/rehydration is reported. These results underline the importance of considering the impact of environmental factors, as humidity and temperature, in the context of structure-based drug design, thereby contributing to the development of more effective and stable pharmaceutical products.

Existing implants used with Total Knee Arthroplasty (TKA), Total Hip Arthroplasty (THA), and other joint reconstruction treatments, have displayed premature failures and frequent needs for revision surgery in recent years, particularly with young active patients who represent more than 55% of all joint reconstruction patients. Bone cement and stress shielding have been identified as the major reasons for premature joint failures. A breakdown of the cement may happen, and revision surgery may be needed because of the aseptic loosening. The significant mismatch of stiffness properties of patient trabecular bones and metallic implant materials in joint reconstruction surgery results in the stress shielding phenomenon. This could lead to significant bone resorption and increased risk of bone fracture and the aseptic loosening of implants. The present project introduces an approach for development of customized cellular structures to match the mechanical properties and architecture of human trabecular bone. It consists of four modules:1- characterization of geometry, microarchitecture, and stiffness properties of patient’s bones; 2- developing customized lattice structures tailored to mimic properties established in module 1; 3 - integration of developed lattice structure into full scale implant design and manufacturing; 4- implementation of the developed technology for use in implants that would overcome most of the issues related to aseptic loosening phenomenon. The present work aims at fulfilling the objectives of module 2 by exploring new designs of customized lattice structures and texture tailored to mimic closely patients’ bone anisotropic properties and that can incorporate an engineered biological press-fit fixation technique. The effects of various lattice design variables on mechanical performance of the structure are examined through systematic experimental plan using statistical design of experiments technique and analysis of variance method. All tested lattice designs were explored under realistic geometrical, biological, and manufacturing constraints. Of the four design factors examined in this study, strut thickness was found to have the highest percent contribution (41%) regarding the structure stiffness, followed by unit cell type, and cell size. Srut shape was found to have the lowest effect with only 11% contribution. The introduced solution offers lattice structure designs that can be adjusted to match bone stiffness distribution and promote bone ingrowth and hence eliminating the phenomenon of stress shielding while incorporating biological press-fit fixation technique.

Laser powder bed fusion can fabricate porous structure through lattices, but it remains a challenge to prepare micropores (

With the ever-growing emphasis on global decarbonization and rapid increases in the power density of electronics equipment in recent years, new methods and lightweight materials have been developed to manage heat load as well as interfacial stresses associated with Coefficient of Thermal Expansion (CTE) mismatch between components. The Al-Si system provides an attractive combination of CTE performance and high thermal conductivity whilst being a very lightweight option. Such materials are of interest to industries where thermal management is a key design criterion, such as aerospace, automotive, consumer electronics, defense, EV and space. This paper will describe the development and manufacture of a family of high-performance hypereutectic Al-Si alloys (AyontEX™) by a powder metallurgy method. These alloys are of particular interest for structural heat sink applications that require high reliability under thermal cycling (CTE of 17μm/(m·°C)) as well as reflective optics and instrument assemblies that require good thermal and mechanical stability (CTE of 13μm/(m·°C)). Critical performance relationships are presented, coupled with the microstructure, physical and mechanical properties of these Al-Si alloys.