During the hot pressing of pure titanium and different carbon steels in a temperature range of $\vartheta$ = 950–1050 $°\mathrm{C}$, a compound layer up to d_L≈10 $\mu \mathrm{m}$ thick is formed at the titanium–steel interface. With a higher carbon content of the used steel, the layer thickness increases. The carbon concentration within the layer is in the range of stoichiometry for TiC. Apart from TiC, no other phases can be detected by X-ray diffraction (XRD) measurements inside the formed layer. The calculation of the activation energy for the TiC layer formation is Q = 126.5–136.7 $\mathrm{kJ}$ mol⁻¹ and is independent of the carbon content of the steel. The resulting microstructure has a grain size gradient, wherein the mechanical properties, such as hardness and Young‘s modulus, are almost constant. Statistical analysis using Response Surface Methodology (RSM) indicates that the carbon content of the steel has the most significant influence on layer thickness, followed by annealing temperature and annealing time. By selecting the appropriate carbon steel and the subsequent removal of the steel, it is possible to produce targeted TiC layers on titanium substrates, which holds enormous potential for this material in wear-intensive applications.

One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145° included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective.

Polyetheretherketone is a promising material for implants due to its good mechanical properties and excellent biocompatibility. Its accessibility to a wide range of applications is facilitated by the ability to process it with an easy-to-use manufacturing process such as fused filament fabrication. The elimination of disadvantages associated with the manufacturing process, such as a poor surface quality, is a main challenge to deal with. As part of the mass finishing process, centrifugal disc finishing has demonstrated good results in surface optimization, making it a promising candidate for the post-processing of additively manufactured parts. The objective of this study is to identify the key parameters of the centrifugal disc finishing process on the waviness of additively manufactured PEEK specimens, which has not been investigated previously. The waviness of the specimen was investigated by means of confocal laser scanning microscopy (CLSM), while weight loss was additionally tracked. Six parameters were investigated: type, amount and speed of media, use of compound, amount of water and time. Type of media, time and speed were found to significantly influence waviness reduction and weight loss. Surface electron microscopy images demonstrated the additional effects of deburring and corner rounding. Results on previous studies with specimens made of metal showed similar results. Further investigation is required to optimize waviness reduction and polish parts in a second post-processing step.

Additive manufacturing (AM), particularly laser powder bed fusion (L-PBF), provides unmatched design flexibility for creating intricate steel structures with minimal post-processing. However, adopting L-PBF for high-performance applications is difficult due to the challenge of predicting microstructure evolution. This is because the process is sensitive to many parameters and has a complex thermal history. Thin-walled geometries present an added challenge because their dimensions often approach the scale of individual grains. Thus, microstructure becomes a critical factor in the overall integrity of the component. This study focuses on applying cellular automata (CA) modeling to establish robust and efficient process–structure relationships in L-PBF of 316L stainless steel. The CA framework simulates solidification-driven grain evolution and texture development across various processing conditions. Model predictions are evaluated against experimental electron backscatter diffraction (EBSD) data, with additional quantitative comparisons based on texture and morphology metrics. The results demonstrate that CA simulations calibrated with relevant process parameters can effectively reproduce key microstructural features, including grain size distributions, aspect ratios, and texture components, observed in thin-walled L-PBF structures. This work highlights the strengths and limitations of CA-based modeling and supports its role in reliably designing and optimizing complex L-PBF components.