This study presents a methodology to fabricate Ti6Al4V cylindrical compacts with a highly porous core and dense shell with the purpose to mimic the bone microstructure. Compacts with different core diameters were obtained by conventionally press and sintering. Large pores were created with the aid of pore formers. Sintering kinetics was determined by dilatometry, whereas characterization was performed by X-ray computed tomography. Also, permeability was evaluated on the 3D microstructure and the mechanical strength was evaluated by compression tests. Results indicated that sintering is constraint by the different densification rates of the porous and dense layers. Nonetheless, defectless compacts were obtained due to neck bonding between Ti6Al4V particles. Large pores were located in the designed core with similar pore size distribution. Permeability increased following a power law as a function of the pore volume fraction. Stiffness of bilayer components was driven by the porous core, meanwhile, the strength resulted from the combination of both layers. Bilayer materials obtained showed a permeability and mechanical properties, as well as admissible strain (σy /E) similar to those of human bones.

Porous structured metallic implants are preferable as bone graft substitutes due to their faster tissue integration mediated by bone in-growth and vascularization. The porous scaffolds/ implants should also mimic the graded structure of natural bone to ensure a match of mechanical properties. This article presents a method to design graded porous structured acetabular implant and identifies the suitable parameters for manufacturing the model through additive manufacturing. The design method is based on slice-wise modification to ensure continuity of gradation. Modification of the slices was achieved through the binary image processing route. A geodesic dome type design was adopted for developing the acetabular cup model from the graded porous structure. The model had a solid shell with the target porosity and pore size gradually changing from 65% and 950 µm, respectively, in the inner side to 75% and 650 µm, respectively, towards the periphery. The required dimensions of the unit structures, and the combinations of pore structure and strut diameter to obtain the target porosity and pore size were determined analytically. Suitable process parameters were identified to manufacture the model by Direct Metal Laser Sintering (DMLS) using Ti6Al4V powder after carrying out a detailed experimental study to minimize the variation of surface roughness and warping over different build angles of the strut structures. A dual contour scanning was implemented to simplify the scan strategy. The minimum diameter of struts that could be manufactured using the selected scanning strategy and scanning parameters was found to be 375 µm. Finally, the model was built and from the micro-CT data, the porosities and pore sizes were found to be closely conforming to the designed values. The stiffness of the structures, as found from compression testing, was also found to be well matching with that of human trabecular bone. Further, the structure exhibited compliant bending-dominated behavior under compressive loading.

Dental implant fracture is closely connected to the stress buildup surrounding the implant system during static loading. In areas where the cross section of the implant rapidly changes or where the geometry of the implant system has discontinuities, stress concentrations arise. Therefore, the implant's design is crucial in preventing early failure of the implant system, including fracture, screw loosening, and increased leakage, in addition to reducing stresses at the implant-abutment interface. In the current work, three-dimensional (3D) models of mechanically connected Ti6Al4V implant systems in various dimensions were constructed. Finite Element Analysis (FEA) was used to conduct a stress study of the created implants under actual acting forces static loading conditions in accordance with ISO 14801. In the created models, design elements including implant screw type, thickness, and taper angle of abutment were modified in order to increase the longevity of the implants. The results show that the equivalent stress level is dramatically reduced from 596.22 MPa to 212.72 MPa in the implant model, which exhibit more homogeneous stress pattern under static loading conditions. Furthermore, the relatively smoother stress transmission observed in this model holds promise for the development of new implants capable of withstanding the forces encountered in the oral environment.

Stainless steel 316L (SS316L) and titanium-alloy Ti6AL4V exhibit properties for bio-medical applications; however their tribocorrosion associated with metallosis is still a major concern. Therefore smoothing DLC coatings aiming for the improvement of tri-bocorrosion and cell viability of stainless steel 316L (SS316L) and titanium-alloy Ti6AL4V with and without DLC coatings were compared. The motivation was due to many papers detailing metallosis caused by metal debris in the body's soft tissues. Nowadays, metallosis is responsible for almost of prosthesis replacement surgeries. DLC coatings were produced using the Plasma Enhanced Chemical Vapor Deposition (PECVD) technique; acetylene gas was used as a carbon precursor, and silane gas produced an amorphous silicon interface between the DLC coating and metal substrate. A combined setup of techniques thoroughly evaluated the coatings considering chemical composition, coatings adhesion at a metallic substrate, scratch resistance, and tribocorrosion susceptibility. The cytotoxicity and genotoxicity of metallic samples with and without DLC coatings were analyzed, considering cell viability and its correlation with coatings’ chemical composition

This paper provides an overview of the new CPAM Project on Additive Manufacturing (AM) in design and simulation, focusing on topology & lattice structure optimization for a light-weighting advantage. This industry/academia collaboration project aims to utilize existing hardware and software tools, and investigate the practical limits of the technologies, providing eventual guidelines for general use. This will provide a solid foundation for the practical use of metal AM optimized solid and latticed structures especially for Ti6Al4V parts. Two case studies are demonstrated here, one a purely topology optimized design, and one also incorporating lattice optimized design, both from Ti6Al4V and load-bearing components, to be utilized in the Nelson Mandela University (NMU) Eco-Car Project in competition, late in 2018. This paper presents the Design for Additive Manufacturing (DfAM) process, the challenges met iro applying a DfAM design mindset, and a unique final voxel-based smoothing step finishing off the design process. Detailed structural integrity assessment of these parts are included - the question remains: can Additive Manufacturing help win the race?

In this study, TiO2 nanostructured coatings on Ti-6A-4V alloys were fabricated by two methods: H2O2 oxidation and RF sputtering. In the annealing temperature range of 25 C - 500 C, there were the peaks at 35, 37, 40 and 52 corresponding to {100}, {002}, {101} and {102} crystal planes of hcp structure of α-Ti. At the annealing temperature of 600 C, there was the presence of peaks corresponding to crystal planes of anatase and rutile TiO2. The relative intensities of anatase and rutile phases of the sample fabricated by RF sputtering were 3.62 and 10.25 %, respectively; while those of the sample fabricated by H2O2 oxidation were 21.27 and 3.20 %, respectively (The relative intensity of α-Ti phase was 100 %). The results investigated the peak shift of α-Ti phase in TiO2/Ti-6Al-4V nanostructured coatings fabricated by the two methods which was reasonably explained from the difference in the thermal expansion coefficients of Ti alloy and TiO2 components, as well as the difference in the ratio of anatase to rutile phases.

Ti and Ti alloys are materials usually used in contact with hard tissue for applications such as artificial joints and dental implants. Ti6Al4V is a very common alloy used for dental implants, owing to its good mechanical properties and corrosion resistance. Nevertheless, because of uncertainties regarding the toxicity of vanadium and its influence on the human body, other Ti alloys containing no vanadium and retaining suitable properties are used. In this work Ti6Al4V and Ti6Al7Nb were oxidized in a water solution of calcium acetate (Ca(CH3COO)2) and calcium glycerophosphate (Ca(PO4CH(CH2OH)2) by Plasma Electrolytic Oxidation (PEO) for 20 minutes and then were hydrothermally treated (HTT) in water (pH=7) and in potassium hydroxide (KOH) solution (pH=11) for 2 hours at 200°C in a pressurized reactor. The surface morphologies, elemental composition and phase components were characterized by Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS) and X-Ray Diffraction (XRD), respectively. The surface roughness was measured by Atomic Force Microscope (AFM) and thickness measurements were made by SEM and thickness gauge. Also, corrosion tests were made to evaluate the corrosion behavior of the two alloys. The aim of this study is to compare two viable Ti alloys, Ti6Al4V and Ti6Al7Nb, and to attain on their surface hydroxyapatite (HA) coating improving the osseointegration, as it simulates a human bone.

Ti6Al4V samples obtained by selective laser melting were subjected to acid treatment, chemical oxidation in hydrogen peroxide solution and subsequent thermochemical treatment. The effect of temperature and time of acid etching of Ti6Al4V samples on surface roughness, morphology, topography and chemical and phase composition after the thermochemical treatment was studied. The surfaces were characterized using scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray diffraction and contact profilometry. Pore and protrusion sizes were measured. Acid etching modified the elemental composition and surface roughness of the alloy. Temperature had a greater influence on the morphology, topography and surface roughness of samples than time. Increases in roughness values were observed when applying successive chemical oxidation and thermochemical treatment compared to the values observed on surfaces with acid etching. After the thermochemical treatment, the samples with acid etching at a temperature of 80 °C showed a multiscale topography. In addition, a network-shaped structure was obtained on all surfaces, both on their protrusions and pores previously formed during the acid etching.

Enhancement of mechanical properties by using TiN/TiCN/TiC multilayer thin films deposited on commercially pure cast Titanium (CP-Ti), Ti6Al4V and silicon (Si) substrates via magnetron sputtering technique was investigated in this study. The structural, chemical and mechanical properties of the coatings were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), nanoindentation and scratch test. Results of the XRD analysis showed reflections corresponded to FCC (1 1 1) cubic and polycrystalline structure for TiN/TiCN/TiC films. XPS analysis revealed formation of titanium nitride, titanium carbonitride and titanium carbide in the coatings. According to SEM images, the coatings demonstrated dense cross-sectional morphology and columnar structure as well as good adhesion to the substrate with a thickness of 1.77 μm deposited on silicon (1 0 0). Scratch and nanoindentation test results showed the best mechanical behavior for the coated Ti6Al4V substrate material with the 19.96 GPa hardness and 25 N critical load values, because of its higher hardness and toughness of substrate in compared to Cp-Ti substrate.

Enhancement of mechanical properties by using TiN/TiCN/TiC multilayer thin films deposited on commercially pure cast Titanium (CP-Ti), Ti6Al4V and silicon (Si) substrates via magnetron sputtering technique was investigated in this study. The structural, chemical and mechanical properties of the coatings were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), nanoindentation and scratch test. Results of the XRD analysis showed reflections corresponded to FCC (1 1 1) cubic and polycrystalline structure for TiN/TiCN/TiC films. XPS analysis revealed formation of titanium nitride, titanium carbonitride and titanium carbide in the coatings. According to SEM images, the coatings demonstrated dense cross-sectional morphology and columnar structure as well as good adhesion to the substrate with a thickness of 1.77 μm deposited on silicon (1 0 0). Scratch and nanoindentation test results showed the best mechanical behavior for the coated Ti6Al4V substrate material with the 19.96 GPa hardness and 25 N critical load values, because of its higher hardness and toughness of substrate in compared to Cp-Ti substrate.

The potential of the Additive Manufacturing technologies is impeded by the surface finish obtained on the as-manufactured material. Therefore, the influence of various surface treatments, commonly applied to space hardware, on the mechanical properties of three selected metallic alloys (SS316L, AlSi10Mg, Ti6Al4V) prepared by using Selective Laser Melting (SLM) and Electron Beam Melting (EBM) additive manufacturing processes have been investigated. Within this study, SLM using EOS M400 and EOS M280 equipment and in addition EBM using an ARCAM Q20 machine have been applied for sample manufacturing. A half-automated shot-peening process followed by a chemical and/or electrochemical polishing or Hirtisation® process has been applied in order to obtain lower surface roughness compared to their as-received states. Special emphasize has been taken on their tensile, fatigue, and fracture toughness properties. In addition, their stress corrosion cracking (SCC) behaviour including microstructural analysis using HR-SEM have been investigated.

This paper reports on the production and mechanical properties of Ti6Al4V micro-lattice structures, with strut thickness nearing the single-track width of the laser-based powder bed fusion (LPBF) system used. Besides providing new information on the mechanical properties and manufacturability of such thin-strut lattices, this paper also reports on the in-situ deformation imaging of micro-lattice structures with 6 unit cells in every direction. LPBF lattices are of interest for medical implants, due to the possibility of creating structures with an elastic modulus close to that of the bones and small pore sizes which allow effective osseointegration. In this work four different cubes were produced by laser powder bed fusion and subsequently analyzed using microCT, compression testing and one selected lattice was subjected to in-situ microCT imaging during compression. The in-situ imaging was performed at 4 steps during yielding. The results indicate that mechanical performance (elastic modulus and strength) correlate well with actual density and that this performance is remarkably good, despite the high roughness and irregularity of the struts at this scale. In-situ yielding is visually illustrated.

Ti64 alloy plays a significant role in the biomedical applications such as bioimplants for its excellent biocompatibility. Its usage can be further extended by improving the surface hardness and wear resistance. In this respect, laser surface glazing (LSG), an advanced surface modification technique, is very useful which can produce thin hardened surface layer and strong metallurgical bonding. Investigation of temporal and spatial temperature distributions of laser glazed surface of materials are essential because temperature plays significant role in achieving required surface properties. Therefore, in this study, a 3D Finite element analysis has been developed to perform transient thermal analysis of LSG for Ti64 alloy. The model investigated temperature distribution, depth of modified zone and heating and cooling. The results show that the peak temperature is attained 2095 K for 300 W laser power, 0.2 mm beam width and 0.15 ms residence time. Since this temperature is above the melting point (1933 K) of Ti64 alloy, the melt depth is calculated 22.5 μm. Furthermore, from the simulation results, the average heating and cooling rates are estimated 1.19×10⁷ Ks^-1 and 2.71×10⁶ Ks^-1 respectively which indicate the presence of hard phases in the modified zone.