Filippo Zanini

Filippo Zanini
University of Padova | UNIPD · Department of Management and Engineering

Master of Engineering

About

66
Publications
19,732
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968
Citations
Additional affiliations
January 2014 - December 2016
University of Padova
Position
  • PhD Student

Publications

Publications (66)
Article
Full-text available
Local fiber alignment in fiber-reinforced thermoplastics is governed by complex flows during the molding process. As fiber-induced material anisotropy leads to non-homogeneous effective mechanical properties, accurate prediction of the final orientation state is critical for integrated structural simulations of these composites. In this work, a dat...
Article
X-ray computed tomography (CT) is an advanced non-destructive measuring technique that enables holistic three-dimensional measurements of outer as well as inner geometries and micro-scale features. In the field of fiber-reinforced polymeric (FRP) materials, CT can overcome the limitations of conventional methods typically based on time-consuming an...
Article
Multiaxial fatigue tests were carried out on plain and notched specimens extracted from EN-GJS-600-3 pearlitic DCI heavy-section castings. Two notches of different severities were combined for the determination of mode I and mode III critical distances, along with the related intrinsic fatigue strengths. SEM and CT clearly showed that fatigue crack...
Article
Metal additive manufacturing (AM) technologies can produce complex components with unique and controlled lattice architectures and advantageous strength-to-weight properties, for which there is increasing interest by important industrial sectors, including aerospace, automotive and biomedical. One critical open issue of metal AM products is related...
Article
Full-text available
This work aims at enabling the fabrication of a new generation of prosthetic components with enhanced mechanical behaviour and an extended lifetime. Cobalt‑chromium lattice structures manufactured using laser powder bed fusion are analysed to quantify the influence of microstructural anisotropy and geometrical deviations on stiffness prediction. Re...
Article
Full-text available
The present work investigates cellular materials that can be potentially used as a replacement of solid implants owing to their mechanical properties and biocompatibility. More specifically, titanium alloy (Ti6Al4V) cellular materials of three different topologies were considered to study the effect of the degree of irregularity. Cubic regular, cub...
Article
In some fatigue critical scenarios, like those arising in cast or additively manufactured components, the fatigue damage mechanisms prevailing in plain and notched components might be different. This could hinder the applicability of the theory of critical distances (TCD), which postulates that the critical distance L can be inferred from a plain a...
Article
Full-text available
Channels manufactured by laser powder bed fusion have an inherent process-induced dross formation and surface texture that require proper characterization for design and process optimization. This work undertakes surface texture characterization of AlSi10Mg channels of nominal diameter sizes ranging from 1 mm to 9 mm using X-ray computed tomography...
Article
Full-text available
The tensile response of chiral auxetic cellular structures was experimentally and computationally studied. The auxetic cellular structures with two different chiral geometries (tetrachiral and hexachiral) were fabricated using laser powder bed fusion (LPBF) technology from two different materials (aluminium alloy AlSi10Mg and stainless steel AISI 3...
Article
Porous metal lattice structures have a very high potential in biomedical applications, setting as innovative new generation prosthetic devices. Laser powder bed fusion (L-PBF) is one of the most widely used additive manufacturing (AM) techniques involved in the production of Ti6Al4V lattice structures. The mechanical and failure behavior of lattice...
Article
Full-text available
We present pore-scale simulations of two-phase flows in a reconstructed fibrous porous layer. The three-dimensional microstructure of the material, a fuel cell gas diffusion layer, is acquired via X-ray computed tomography and used as input for lattice Boltzmann simulations. We perform a quantitative analysis of the multiphase pore-scale dynamics,...
Article
Full-text available
Metal additive manufacturing (MAM) of mould components is associated with cost-intensive post-process finishing operations, which are currently one of the main drawbacks preventing wider industrial adoption of MAM. This work analyses the current possibilities and limitations of MAM for plastic injection moulding tool applications, demonstrating the...
Article
Full-text available
X-ray computed tomography is one of the most promising measurement techniques for the dimensional evaluation of industrial components. However, the inherent complexity of this technology also involves important challenges. One of them is to develop surface determination algorithms capable of providing measurement results with better accuracy in any...
Article
Laser powder bed fusion (LPBF) is a robust metal additive manufacturing technique for generation of complex geometries using a high-energy laser beam. NiTi is a promising material for porous biomaterials applications. The use of LPBF for such applications is justified by the complex architecture of porous biomaterials and by the current difficultie...
Article
Full-text available
Solute transport and reaction in porous electrodes at high Schmidt numbers - Volume 896 - Dario Maggiolo, Francesco Picano, Filippo Zanini, Simone Carmignato, Massimo Guarnieri, Srdjan Sasic, Henrik Ström
Article
Ti6Al4V alloy can be successfully used to fabricate complex near-net-shape industrial products and prosthetic components with enhanced biocompatibility by means of additive manufacturing (AM) technologies. Post-processing machining of such components are still necessary steps; however, the different machinability that characterizes AM products affe...
Preprint
Full-text available
We present pore-scale simulations of two-phase flows in a reconstructed fibrous porous layer. The three dimensional microstructure of the material, a fuel cell gas diffusion layer, is acquired via X-ray computed tomography and used as input for lattice Boltzmann simulations. We perform a quantitative analysis of the multiphase pore-scale dynamics a...
Article
The surgical treatment of urinary incontinence is often performed by adopting an Artificial Urinary Sphincter (AUS). AUS cuff represents a fundamental component of the device, providing the mechanical action addressed to urethral occlusion, which can be investigated by computational approach. In this work, AUS cuff is studied with reference to both...
Article
Ti6Al4V scaffolds were printed by Direct Ink Writing of a water-based polymeric ink. Different geometries were fabricated in terms of filament size (250 μm, 400 μm and 800 μm) and filament distance (half, same and double the filament size). The designed and actual porosity (total, open and closed), the linear and volumetric shrinkage as well as the...
Article
Clogging of venting slots in injection molds is a common maintenance problem caused by the degradation and the accumulation of gaseous and volatiles by‐products of polymer melting. In this work, the effect of laser‐induced periodic surface structures on the self‐cleaning properties of venting slots is investigated. The degradation of poly(ethylene...
Conference Paper
Full-text available
X-ray computed tomography (CT) has recently started to be used for evaluating the surface topography of metal parts produced by additive manufacturing (AM). Differently from conventional contact and optical measuring techniques, CT enables non-destructive measurements of both internal and difficult-to-access AM surfaces, including typical complex m...
Conference Paper
Full-text available
X-ray computed tomography (CT) is and advanced measuring technique capable of performing holistic dimensional verification of both internal and external threaded elements. The contactless and non-destructive nature of CT measurements makes them suited for evaluating also screw threads and threaded features that are internal, small in size, or made...
Article
X-ray computed tomography (CT)has recently started to be used for evaluating the surface topography of metal parts produced by additive manufacturing (AM). In particular, CT can overcome the main limitations of contact and optical measuring techniques, as CT enables non-destructive measurements of both internal and difficult-to-access surfaces, inc...
Article
Manufacturing technologies deliver products that can suffer from various defects, one of which is internal porosity. Pores are present in most of the parts produced by, e.g., casting, additive manufacturing, and injection molding and can significantly affect the performance of the final products. Due to technological and economic limits, typically...
Article
Scale is a key issue in soil studies. The idea that a sample must be of adequate size to embody a specific physical property comes from the representative elementary volume (REV) concept that defines minimum sample size for consistent results. Other approaches to describe soil spatial heterogeneity rely on the fractal dimension concept (FDC), which...
Article
Porous structures have great potential in the biomedical field because, compared to traditional fully dense implants, prostheses with a porous structure show reduced stress shielding and improved osseo-integration. Selective Laser Melting (SLM) made possible to obtain metallic cellular materials with highly complex structures characterized by a wid...
Conference Paper
Full-text available
X-ray computed tomography (XCT) allows performing non-destructive measurements of fibers in fiber-reinforced polymeric materials. The accurate evaluation of fiber orientation and fiber length distribution is particularly useful as these factors have a strong influence on physical and mechanical properties of such materials. XCT data is already succ...
Article
Full-text available
X-ray computed tomography (CT) is a non-destructive measuring technique that allows performing measurements of outer as well as inner geometries and features. This work addresses the application of CT in the field of fiber-reinforced polymers, which are increasingly used in industry to manufacture products with enhanced mechanical properties and li...
Article
Full-text available
Surface topographies of metal additively manufactured components are inherently characterized by the presence of complex surface characteristics that are not accessible by contact or optical measuring techniques. Micro X-ray computed tomography is capable of measuring non-accessible surfaces and micro-scale surface features, including undercuts. In...
Conference Paper
Full-text available
Additive manufacturing technologies allow the production of highly complex parts. The surface topography of such parts often presents micro-scale and freeform-shaped re-entrant features. These features cannot be measured completely using optical or tactile techniques, without sectioning the sample. Therefore, X-ray computed tomography has recently...
Article
Full-text available
Additive manufacturing technologies allow the production of highly complex parts. The surface topography of such parts often presents micro-scale and freeform-shaped re-entrant features. These features cannot be measured completely using optical or tactile techniques, without sectioning the sample. Therefore, X-ray computed tomography has recently...
Conference Paper
Full-text available
Additive manufacturing (AM) technologies are rapidly expanding in industrial domains that were typically dominated by conventional manufacturing technologies. For example, AM technologies are starting to be used to produce metal threaded products, including dental implants. Threaded joints are extensively used in many industrial applications and ac...
Conference Paper
Full-text available
Components produced by additive manufacturing (AM) technologies are typically characterized by complex surface topographies, including the presence of micro-scale and freeform-shaped re-entrant features. Such surfaces can be external or internal. The most commonly used techniques for topography measurements (i.e. contact probing and optical techniq...
Conference Paper
Additively manufactured parts are characterized by metrological challenges and complexities, due to several reasons, including the inherent presence of internal defects and complex surface topography. Micro X-ray computed tomography is currently used to perform dimensional evaluations, porosity analysis and, more recently, surface topography measur...
Article
Full-text available
Severe fiber breakage occurs in injection molding, affecting the mechanical performance of discontinuous fiber-reinforced composites. Accurate measurement of the residual fiber length distribution is crucial to experimentally investigate the physics of fiber breakage. This work proposes an automatic glass fiber length measurement method, based on t...
Conference Paper
Full-text available
Additively manufactured metal parts are inherently characterized by surface topographies that are challenging to be measured due to several complexities, including: presence of undercuts and non-totally melted powder particles. Micro X-ray computed tomography has recently started to be considered as an alternative technique for topographical measur...
Conference Paper
Full-text available
Up to date, several different approaches are proposed in standards and guidelines to determine the spatial resolution and the focal spot size of micro X-ray sources. From a metrological point of view, the precise measurement of the focal spot is essential, as this is one of the main factors determining the uncertainty of computed tomography dimensi...
Article
Full-text available
Micro manufacturing using micro direct metal deposition was successfully implemented on NiTi powder alloy. Micro direct metal deposition was optimized through a set of process parameters and designed experiments to improve the geometrical accuracy and repeatability of micro fabrication. Scanning electron microscopy and micro X-ray computed tomograp...
Article
Rapid heat cycle molding (RHCM) of reinforced thermoplastics is increasingly used in order to obtain high surface quality on structural parts. In this work, the effect of RHCM on both microstructure and ultimate tensile strength of polypropylene reinforced with 30 wt% long glass fibers was investigated. Micro X-ray computed tomography was employed...
Article
Full-text available
Porous electrodes are pivotal components of Vanadium Redox Flow Batteries, which influence the power density, pressure drop losses, activation overpotentials, limit current density, bulk and contact resistance, and ohmic losses. The quantification of the fluid-mechanic efficiency of porous electrodes based on their real geometry is a useful measure...
Article
Abstract Selective laser melting (SLM) is a net-shape AM technology to produce metal parts also for load-carrying applications. The present work is aimed at investigating the fatigue performance of the biomedical titanium Grade 23 (aka Ti-6Al-4V ELI) AMed via SLM. Low and high cycle fatigue tests are carried out on samples that received a low tempe...
Article
Full-text available
Hip joint replacements have been successfully used in the field of orthopaedic medicine for over fifty years. Whilst clinical studies have shown encouraging long-term clinical performance, failure of these devices due to wear still occurs. The laboratory determination of wear rate is an important part of the pre-clinical validation of prostheses. T...
Article
Full-text available
Additively manufactured parts are characterized by metrological challenges and complexities, due to several reasons, including the inherent presence of internal defects and complex surface topography. Micro X-ray computed tomography is currently used to perform dimensional evaluations, porosity analysis and, more recently, surface topography measur...
Article
The gas transport parameters, diffusivity and air-filled porosity are crucial for soil aeration, microbial activity and greenhouse gas emission, and directly depend on soil structure. In this study, we analysed the effect of long-term tillage and irrigation practices on the surface structure of an arable soil in New Zealand. Our hypothesis was that...
Article
Full-text available
In recent years, x-ray computed tomography has been successfully applied as an innovative coordinate measurement technology for dimensional metrology. An important characteristic to be evaluated when testing the metrological performances of computed tomography systems is the metrological structural resolution for dimensional measurements, which des...
Conference Paper
Full-text available
Additive Manufacturing (AM) of metals is rapidly emerging as an innovative production technology. Nevertheless, the quality of metal AM products is still affected by high variability in product performance, for example due to the inherent presence of unwanted internal porosity. X-ray computed tomography (CT) has proven to be an advanced measuring t...
Conference Paper
Full-text available
Dental implants are commonly used as replacement of tooth roots to support dental prosthetics. A successful implant therapy can be complicated by biological and/or mechanical factors. Tight dimensional tolerances are required to ensure a correct fit between implant, abutment and screw. In this context, verifying the quality of the assembly becomes...
Article
Full-text available
X-ray computed tomography (CT) is increasingly used in dimensional metrology. However, several influencing factors affect CT dimensional measurements. In particular, significant deviations can be observed between CT and tactile measurements especially when measuring parts with rough surfaces. The dependence of such deviations from surface morpholog...
Article
Full-text available
Wear is currently quantified as mass loss of the bearing materials measured using gravimetric methods. However, this method does not provide other information, such as volumetric loss or surface deviation. In this work, we validated a technique to quantify polyethylene wear in three different batches of ultrahigh-molecular-polyethylene acetabular c...
Article
Full-text available
More than 60.000 hip arthroplasty are performed every year in Italy. Although Ultra-High-Molecular-Weight-Polyethylene remains the most used material as acetabular cup, wear of this material induces over time in vivo a foreign-body response and consequently osteolysis, pain, and the need of implant revision. Furthermore, oxidative wear of the polye...
Article
Full-text available
Fully dense titanium alloy implants have long been used for the replacement and stabilization of damaged bone tissue. Nevertheless, they can cause stress shielding which brings to a loss of bone mass. Additive manufacturing (AM) allows obtaining highly porous cellular structures with a wide range of cell morphologies to tune the mechanical properti...
Article
Full-text available
The paper presents the evaluation of the drillability characteristics of the Ti6Al4V titanium alloy produced through the Additive Manufacturing (AM) technology called Direct Metal Laser Sintering (DMLS). Holes of 1.6mm diameter were drilled on a 5-axis high-precision micro-milling machine under dry cutting conditions at varying cutting speed and fe...
Article
Full-text available
A new methodology for normal and quasi-tangential pulsed laser profiling of grinding wheels is proposed, with laser path planning calculated according to a pre-specified angle of incidence and radial laser progression or predicted single-pass incision depth. Though tangential laser profiling has previously been investigated, few works have addresse...
Article
Full-text available
This study focuses on the comparison of porosity testing methods for the quality assessment of selective laser melted parts. Porosity is regarded as important quality indicator in metal additive manufacturing. Various destructive and non-destructive testing methods are compared, ranging from global to local observation techniques and from quick low...