Bioaccessibility and reactivity of alloy powders used in powder bed fusion additive manufacturing

Exposure to metal particles via the inhalation route unavoidably takes place at occupational settings during additive manufacturing of metals and alloys. This calls for investigations on possible adverse health effects. This study focuses on virgin and reused powders of three iron- and nickel-based...

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Published inMaterialia Vol. 19; p. 101196
Main Authors Wang, Xuying, Vallabani, N.V. Srikanth, Giboin, Alix, Lundqvist, Johan, Färnlund, Kim, Karlsson, Hanna L., Hedberg, Yolanda S., Odnevall, Inger
Format Journal Article
LanguageEnglish
Published Elsevier B.V 01.09.2021
Subjects
Chemistry
Corrosion
Kemi
Metal and alloys
Microstructure
Powder processing
Rapid prototyping
Powder processing
Rapid prototyping
Metal and alloys
Corrosion
Microstructure
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Abstract Exposure to metal particles via the inhalation route unavoidably takes place at occupational settings during additive manufacturing of metals and alloys. This calls for investigations on possible adverse health effects. This study focuses on virgin and reused powders of three iron- and nickel-based alloy powders (316L, IN718, 18Ni300) widely used in additive manufacturing, and dust powder of 18Ni300 generated during laser melting. Investigations were performed from a physico-chemical and toxicological perspective assessing their bioaccessibility in artificial lysosomal fluid (ALF, simulating lung exposure to respirable particles), corrosion behavior, surface morphology and composition, microstructure, hydrodynamic size distribution in ALF, and in-vitro toxicity towards cultured human lung cells. Less than 1% of the powder mass was dissolved from the passive alloys (316L, IN718) under simulated physiological conditions (pH4.5, 37 °C, 24 h), whereas the 18Ni300 iron-nickel alloy showed an active behavior and dissolved completely. Reused powders of 18Ni300 and IN718 showed no, or only minor, differences in surface oxide composition, metal release pattern, and corrosion behavior compared with virgin powders. After reuse, the 316L powder showed an enrichment of manganese within the outermost surface, an increased corrosion current, increased amounts of released iron and an increased fraction of particles with ferritic microstructure, which increased the extent of particle aggregation. All powders showed low, or negligible, cytotoxic potency and reactive oxygen species formation. Powder bed fusion using laser melting can hence affect the chemical, physical, and surface properties of non-fused powders, which, if reused, could influence the properties of the printed part. [Display omitted]
AbstractList Exposure to metal particles via the inhalation route unavoidably takes place at occupational settings during additive manufacturing of metals and alloys. This calls for investigations on possible adverse health effects. This study focuses on virgin and reused powders of three iron- and nickel-based alloy powders (316L, IN718, 18Ni300) widely used in additive manufacturing, and dust powder of 18Ni300 generated during laser melting. Investigations were performed from a physico-chemical and toxicological perspective assessing their bioaccessibility in artificial lysosomal fluid (ALF, simulating lung exposure to respirable particles), corrosion behavior, surface morphology and composition, microstructure, hydrodynamic size distribution in ALF, and in-vitro toxicity towards cultured human lung cells. Less than 1 % of the powder mass was dissolved from the passive alloys (316L, IN718) under simulated physiological conditions (pH 4.5, 37°C, 24 h), whereas the 18Ni300 iron-nickel alloy showed an active behavior and dissolved completely. Reused powders of 18Ni300 and IN718 showed no, or only minor, differences in surface oxide composition, metal release pattern, and corrosion behavior compared with virgin powders. After reuse, the 316L powder showed an enrichment of manganese within the outermost surface, an increased corrosion current, increased amounts of released iron and an increased fraction of particles with ferritic microstructure, which increased the extent of particle aggregation. All powders showed low, or negligible, cytotoxic potency and reactive oxygen species formation. Powder bed fusion using laser melting can hence affect the chemical, physical, and surface properties of non-fused powders, which, if reused, could influence the properties of the printed part.
Exposure to metal particles via the inhalation route unavoidably takes place at occupational settings during additive manufacturing of metals and alloys. This calls for investigations on possible adverse health effects. This study focuses on virgin and reused powders of three iron- and nickel-based alloy powders (316L, IN718, 18Ni300) widely used in additive manufacturing, and dust powder of 18Ni300 generated during laser melting. Investigations were performed from a physico-chemical and toxicological perspective assessing their bioaccessibility in artificial lysosomal fluid (ALF, simulating lung exposure to respirable particles), corrosion behavior, surface morphology and composition, microstructure, hydrodynamic size distribution in ALF, and in-vitro toxicity towards cultured human lung cells. Less than 1% of the powder mass was dissolved from the passive alloys (316L, IN718) under simulated physiological conditions (pH4.5, 37 °C, 24 h), whereas the 18Ni300 iron-nickel alloy showed an active behavior and dissolved completely. Reused powders of 18Ni300 and IN718 showed no, or only minor, differences in surface oxide composition, metal release pattern, and corrosion behavior compared with virgin powders. After reuse, the 316L powder showed an enrichment of manganese within the outermost surface, an increased corrosion current, increased amounts of released iron and an increased fraction of particles with ferritic microstructure, which increased the extent of particle aggregation. All powders showed low, or negligible, cytotoxic potency and reactive oxygen species formation. Powder bed fusion using laser melting can hence affect the chemical, physical, and surface properties of non-fused powders, which, if reused, could influence the properties of the printed part. [Display omitted]
ArticleNumber 101196
Author Wang, Xuying
Färnlund, Kim
Hedberg, Yolanda S.
Lundqvist, Johan
Giboin, Alix
Odnevall, Inger
Karlsson, Hanna L.
Vallabani, N.V. Srikanth
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  organization: Institute of Environmental Medicine, Karolinska Institute, Stockholm SE-171 77, Sweden
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  surname: Giboin
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  surname: Färnlund
  fullname: Färnlund, Kim
  organization: Amexci AB, Gammelbackavägen 2, Karlskoga SE-691 51, Sweden
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  givenname: Hanna L.
  surname: Karlsson
  fullname: Karlsson, Hanna L.
  organization: Institute of Environmental Medicine, Karolinska Institute, Stockholm SE-171 77, Sweden
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  givenname: Yolanda S.
  orcidid: 0000-0003-2145-3650
  surname: Hedberg
  fullname: Hedberg, Yolanda S.
  email: yhedberg@uwo.ca
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  givenname: Inger
  orcidid: 0000-0003-2206-0082
  surname: Odnevall
  fullname: Odnevall, Inger
  email: ingero@kth.se
  organization: KTH Royal Institute of Technology, School of Engineering Sciences in Chemistry, Biotechnology and Health, Department of Chemistry, Division of Surface and Corrosion Science, Drottning Kristinas v. 51, Stockholm SE-10044, Sweden
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Keywords Powder processing
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Metal and alloys
Corrosion
Microstructure
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Snippet Exposure to metal particles via the inhalation route unavoidably takes place at occupational settings during additive manufacturing of metals and alloys. This...
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StartPage 101196
SubjectTerms Chemistry
Corrosion
Kemi
Metal and alloys
Microstructure
Powder processing
Rapid prototyping
Title Bioaccessibility and reactivity of alloy powders used in powder bed fusion additive manufacturing
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