Developments in selective laser melting (SLM) have enabled the fabrication of periodic cellular lattice structures characterized by suitable properties matching the bone tissue well and by fluid permeability from interconnected structures. These multifunctional performances are significantly affected by cell topology and constitutive properties of applied materials. In this respect, a diamond unit cell was designed in particular volume fractions corresponding to the host bone tissue and optimized with a smooth surface at nodes leading to fewer stress concentrations. There were 33 porous titanium samples with different volume fractions, from 1.28 to 18.6%, manufactured using SLM. All of them were performed under compressive load to determine the deformation and failure mechanisms, accompanied by an in-situ approach using digital image correlation (DIC) to reveal stress–strain evolution. The results showed that lattice structures manufactured by SLM exhibited comparable properties to those of trabecular bone, avoiding the effects of stress-shielding and increasing longevity of implants. The curvature of optimized surface can play a role in regulating the relationship between density and mechanical properties. Owing to the release of stress concentration from optimized surface, the failure mechanism of porous titanium has been changed from the pattern of bottom-up collapse by layer (or cell row) to that of the diagonal (45°) shear band, resulting in the significant enhancement of the structural strength.

The material of Ti–6Al–4V has been widely applied in various industries, such as automobile, aerospace, and medical due to its high specific strength, superior thermal stability and strong corrosion resistance. In the recent decades, selective laser melting (SLM) has become an attractive method to fabricate Ti–6Al–4V parts, thanks to its significant advantages in low material consumption, the high degree of freedom in design, low carbon footprint, etc. Predictability of SLM material fatigue properties is especially important for the safety-critical structures under dynamic load cases. The present research is aimed at evaluating the low cycle fatigue (LCF) performance of SLM Ti–6Al–4V under high loading states. LCF tests were performed for as-built and annealed SLM Ti–6Al–4V. Comparison between LCF properties of SLM Ti–6Al–4V and the wrought Ti–6Al–4V was also made. It was found that as-built SLM Ti–6Al–4V demonstrated a comparable LCF performance with the wrought material. The LCF life of as-built SLM Ti–6Al–4V was longer than that of wrought Ti–6Al–4V at lower strain amplitudes. However, the wrought Ti–6Al–4V had better LCF performance at higher strain amplitudes. The results revealed that the porosity in the as-built SLM material exerted much more impact on the degradation of the material at high strain amplitudes. Annealing deteriorated the LCF performance of SLM Ti–6Al–4V material due to the formation of coarser grains. The cyclic Ramberg–Osgood and the Basquin–Coffin–Manson models were fitted to depict the cyclic stress–strain and the strain–life curves for the SLM Ti–6Al–4V, based on which the LCF performance parameters were determined. In addition, the fatigue fracture surfaces were observed by using scanning electron microscopy (SEM), and the results indicated that fatigue cracks originated from the surface or subsurface defects.

Additional structures are usually adopted to support the overhanging structures in order to resist the deformation of parts. Improper geometric design of the support structures may result in a sharp deterioration in the surface quality and a failure of manufacture, which affects the expansion in the use of selective laser melting (SLM) technology. In this research, cuboids were added into the conventional block support for a better heat dissipation. The Taguchi method was used to analyze the effect of the geometric design of this support on the part’s deformation and surface roughness. It was found that solid pieces or cuboids as support structures can reduce the deformation. However, their effects are weaker than those of teeth structures which decrease the deformation by more reliable connections. It is interesting that narrowing the gap between the cuboids and overhang can weaken the strength of teeth structures and then increases the deformation of part. In general, the distance between every two adjacent walls of support and the gap between the cuboids and the overhang have the greatest influence on the part’s deformation and surface quality respectively.

Aiming at the problems of Doppler-induced error and slow measurement rate in frequency-swept interferometry, a novel dynamic clearance measuring method is proposed. By combining frequency-swept and frequency-fixed interferometry, and using fusion processing of interferometric signals, this method not only can eliminate the Doppler-induced error, but also can give the dynamic clearance value at each sampling point. To verify this method, an all fiber-optic measurement system was constructed, and experiments under 500 Hz triangular and 4 kHz sinusoidal vibrations were carried out. Experimental results show that the dynamic clearance can be reconstructed accurately.

A fast real-time demodulation method based on the coarsely sampled spectrum is proposed for transient signals of fiber optic extrinsic Fabry-Perot interferometers (EFPI) sensors. The feasibility of phase demodulation using a coarse spectrum is theoretically analyzed. Based on the coarse spectrum, fast Fourier transform (FFT) algorithm is used to roughly estimate the cavity length. According to the rough estimation, the maximum likelihood estimation (MLE) algorithm is applied to calculate the cavity length accurately. The dense wavelength division multiplexer (DWDM) is used to split the broadband spectrum into the coarse spectrum, and the high-speed synchronous ADC collects the spectrum. The experimental results show that the system can achieve a real-time dynamic demodulation speed of 50 kHz, a static measurement root mean square error (RMSE) of 0.184 nm, and a maximum absolute and relative error distribution of 15 nm and 0.005% of the measurement cavity length compared with optical spectrum analyzers (OSA).

To realize accurate dynamic axial clearance measurement in high-speed rotating machinery using basic Frequency-swept interferometry (FSI), a novel algorithm of Doppler error suppression is proposed. In this algorithm, we first extract the incremental phase of the FSI signal by Hilbert transform and use it to construct a virtual clearance variation. Then, using the periodic characteristics of rotor rotation, optimized initial clearance can be obtained. Eventually, the dynamic axial clearance at each sampling point can be recovered with the optimized initial clearance and the Doppler error is greatly suppressed. The feasibility of this method is tested and verified by both simulation and experiment. For a 4 kHz rotation simulating target located at 5 mm away, the experimental results show that the dynamic clearance measurement error is less than 2.057 µm, which meets the measurement accuracy required for most high-speed rotating machinery.