In situ synthesized TiB-TiN reinforced Ti6Al4V alloy composite coatings: microstructure, tribological and in-vitro biocompatibility

3D printed silicon nitride, alumina, and hydroxyapatite ceramic reinforced Ti6Al4V composites - Tailored microstructures to enhance bio-tribo-corrosion and antibacterial properties

This study utilized directed energy deposition (DED) as a metal additive manufacturing (AM) technique to create ceramic-reinforced composites of Ti6Al4V (Ti64) with hydroxyapatite (HA), alumina (Al2O3), and silicon nitride (Si3N4). The resulting composites had tailored microstructures designed to improve bio-tribological and antibacterial properties simultaneously. A total of 5-wt % ceramic reinforcement were used in Ti64 in four different composites - (1) only Si3N4 (5S), (2) only Al2O3 (5A), (3) 3 wt % Si3N4 and 2 wt% HA (32SH) and (4) 3 wt % Al2O3 and 2 wt% HA (32AH). Microstructural observations revealed that martensite transformation between α and β-Ti in composites resulted in compressive residual stress at the matrix. Coherency is observed between the ceramic particles and Ti64 matrix, preventing cracking, debonding, or porosity. Vicker's hardness of the composite samples increases by 50% over the Ti64 matrix. Various strengthening mechanisms are discussed in detail, representing the reason behind the reduction of compound wear in 5S and 5A composites. Si3N4-added composites demonstrated an antibacterial response against gram-positive Staphylococcus aureus. The multifunctional performance of ceramic-reinforced Ti64 composites makes them suitable for articulating biomedical devices such as femoral heads in hip implants.

Research Progress of Laser Cladding on the Surface of Titanium and Its Alloys

Titanium (Ti) and its alloys have been widely employed in aeronautical, petrochemical, and medical fields owing to their fascinating advantages in terms of their mechanical properties, corrosion resistance, biocompatibility, and so on. However, Ti and its alloys face many challenges, if they work in severe or more complex environments. The surface is always the origin of failure for Ti and its alloys in workpieces, which influences performance degradation and service life. To improve the properties and function, surface modification becomes the common process for Ti and its alloys. The present article reviews the technology and development of laser cladding on Ti and its alloys, according to the cladding technology, cladding materials, and coating function. Generally, the laser cladding parameters and auxiliary technology could influence the temperature distribution and elements diffusion in the molten pool, which basically determines the microstructure and properties. The matrix and reinforced phases play an important role in laser cladding coating, which can increase the hardness, strength, wear resistance, oxidation resistance, corrosion resistance, biocompatibility, and so on. However, the excessive addition of reinforced phases or particles can deteriorate the ductility, and thus the balance between functional properties and basic properties should be considered during the design of the chemical composition of laser cladding coatings. In addition, the interface including the phase interface, layer interface, and substrate interface plays an important role in microstructure stability, thermal stability, chemical stability, and mechanical reliability. Therefore, the substrate state, the chemical composition of the laser cladding coating and substrate, the processing parameters, and the interface comprise the critical factors which influence the microstructure and properties of the laser cladding coating prepared. How to systematically optimize the influencing factors and obtain well-balanced performance are long-term research issues.

Biocompatibility and corrosion evaluation of niobium oxide coated AZ31B alloy for biodegradable implants

Biodegradable magnesium (Mg) based implants have considerable interest in the biomedical field as their use nullifies the necessity for implant removal surgery and avoids the long-standing adverse reaction of permanent bioimplants. The degradation resistance and biocompatibility of the Mg alloys can be improved by coating them with a suitable thin film. Here, thin films of niobium and niobium oxide were developed on the AZ31B Mg alloy by sputtering technique and their biocompatibility and corrosion resistance was examined. X-ray diffraction (XRD) and Transmission electron microscope (TEM) techniques confirmed the crystallinity of the thin films. Subsequently, scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) techniques were employed to evaluate the morphology and chemical composition of the thin film surfaces, respectively. Thin-film coated Mg alloys revealed good corrosion resistance compared to their uncoated bare counterparts in simulated body fluid (SBF). The contact angle study was performed on the coated specimens to investigate their wettability which revealed their hydrophobic character. The cell viability studies on thin-film coated specimens exhibited significant cell proliferation, and cell morphological studies showed good cell attachment and growth. The in vitro MTT assay on mouse osteoblast precursor cells (MC3T3-E1) indicated that the Nb-based coatings are cytocompatible and promote cell proliferation.

Advanced Surface Modification for 3D-Printed Titanium Alloy Implant Interface Functionalization

With the development of three-dimensional (3D) printed technology, 3D printed alloy implants, especially titanium alloy, play a critical role in biomedical fields such as orthopedics and dentistry. However, untreated titanium alloy implants always possess a bioinert surface that prevents the interface osseointegration, which is necessary to perform surface modification to enhance its biological functions. In this article, we discuss the principles and processes of chemical, physical, and biological surface modification technologies on 3D printed titanium alloy implants in detail. Furthermore, the challenges on antibacterial, osteogenesis, and mechanical properties of 3D-printed titanium alloy implants by surface modification are summarized. Future research studies, including the combination of multiple modification technologies or the coordination of the structure and composition of the composite coating are also present. This review provides leading-edge functionalization strategies of the 3D printed titanium alloy implants.

Designing high-temperature oxidation-resistant titanium matrix composites via directed energy deposition-based additive manufacturing

Composite material development via laser-based additive manufacturing offers many exciting advantages to manufacturers; however, a significant challenge exists in our understanding of process-property relationships for these novel materials. Herein we investigate the effect of input processing parameters towards designing an oxidation-resistant titanium matrix composite. By adjusting the linear input energy density, a composite feedstock of titanium-boron carbide-boron nitride (5 wt% overall reinforcement) resulted in a highly reinforced microstructure composed of borides and carbides and nitrides, with variable properties depending on the overall input energy. Crack-free titanium-matrix composites with hardness as high as 700 ± 17 HV_0.2/15 and 99.1% relative density were achieved, with as high as a 33% decrease in oxidation mass gain in the air relative to commercially pure titanium at 700 °C for 50 h. Single-tracks and bulk samples were fabricated to understand the processing characteristics and in situ reactions during processing. Our results indicate that input processing parameters can play a significant role in the oxidation resistance of titanium matrix composites and can be exploited by manufacturers for improving component performance and high temperature designs.

Biotribocorrosion of 3D-Printed silica-coated Ti6Al4V for load-bearing implants

Laser-based 3D Printing was utilized to deposit a silica (SiO₂) coating on the surface of Ti6Al4V (Ti64) alloy for implementation onto articulating surfaces of load-bearing implants. The surface laser melting (SLM) technique was implemented in 1, and 2 laser passes (1LP and 2LP) after SiO₂ deposition to understand the influence of remelting on the coating's hardness and tribological performance. It was observed that compositional and microstructural features increased the cross-sectional hardness. Wear rate was observed to decrease from 2.9×10^-4 in the Ti64 to 5.2 ×10^-6, 3.8×10^-6, and 2.1×10^-7 mm³/Nm for the as-processed or zero laser-pass (0LP), 1LP, and 2LP, respectively. Coated samples displayed a positive shift in open-circuit potential (OCP) during linear wear by displaying a 368, 85, and 613 mV increase compared to Ti64 for 0LP, 1LP, and 2LP, respectively. Our results showed promising tribological performance of SiO₂ coated Ti6Al4V for articulating surfaces of load-bearing implants.

First Principle Study of TiB2 (0001)/γ-Fe (111) Interfacial Strength and Heterogeneous Nucleation

TiB₂/316L stainless steel composites were prepared by selective laser melting (SLM), and the adhesion work, interface energy and electronic structure of TiB₂/γ-Fe interface in TiB₂/316L stainless steel composites were investigated to explore the heterogeneous nucleation potential of γ-Fe grains on TiB₂ particles using first principles. Six interface models composed of three different stacking positions and two different terminations were established. The B-terminated-top 2 site interface ("B-top 2") was the most stable because of the largest adhesion work, smallest interfacial distances, and smallest interfacial energy. The difference charge density and partial density of states indicated that a large number of strong Fe-B covalent bonds were formed near the "B-top 2" interface, which increased the stability of interface. Fracture analysis revealed that the bonding strength of the "B-top 2" interface was higher than that of the Fe matrix, and it was difficult to fracture at the interface. The interface energy at the Ti-poor position in the "B-top 2" interface model was smaller than that of the γ-Fe/Fe melt, indicating that TiB₂ had strong heterogeneous nucleation potency for γ-Fe.

TiB Nanowhisker Reinforced Titanium Matrix Composite with Improved Hardness for Biomedical Applications

Titanium and its alloys have been employed in the biomedical industry as implants and show promise for more broad applications because of their excellent mechanical properties and low density. However, high cost, poor wear properties, low hardness and associated side effects caused by leaching of alloy elements in some titanium alloys has been the bottleneck to their wide application. TiB reinforcement has shown promise as both a surface coating for Ti implants and also as a composite reinforcement phase. In this study, a low-cost TiB-reinforced alpha titanium matrix composite (TMC) is developed. The composite microstructure includes ultrahigh aspect ratio TiB nanowhiskers with a length up to 23 μm and aspect ratio of 400 and a low average Ti grain size. TiB nanowhiskers are formed in situ by the reaction between Ti and BN nanopowder. The TMC exhibited hardness of above 10.4 GPa, elastic modulus above 165 GPa and hardness to Young’s modulus ratio of 0.062 representing 304%, 170% and 180% increases in hardness, modulus and hardness to modulus ratio, respectively, when compared to commercially pure titanium. The TiB nanowhisker-reinforced TMC has good biocompatibility and shows excellent mechanical properties for biomedical implant applications.

Naturally architected microstructures in structural materials via additive manufacturing

Despite recent advances in our understanding of the unique mechanical behavior of natural structural materials such as nacre and human bone, traditional manufacturing strategies limit our ability to mimic such nature-inspired structures using existing structural materials and manufacturing processes. To this end, we introduce a customizable single-step approach for additively fabricating geometrically-free metallic-based structural composites showing directionally-tailored, location-specific properties. To exemplify this capability, we present a layered metal-ceramic composite not previously reported exhibiting significant directional and site-specific dependence of properties along with crack arrest ability difficult to achieve using traditional manufacturing approaches. Our results indicate that nature-inspired microstructural designs towards directional properties can be realized in structural components using a novel additive manufacturing approach.

Influence of in situ ceramic reinforcement towards tailoring titanium matrix composites using laser-based additive manufacturing

Increasing performance requirements of advanced components demands versatile fabrication techniques to meet application-specific needs. Composite material processing via laser-based additive manufacturing offers high processing-flexibility and limited tooling requirements to meet this need, but limited information exists on the processing-property relationships for these materials as well as how to exploit it for application-specific needs. In this study, Ti/B₄C+BN composites are developed for high-temperature applications by designed-incorporation of ceramic reinforcement (5 wt% total) into commercially-pure titanium to form combined particle and in situ reinforcing phases. We combine both B₄C (limited reactivity with matrix) and BN (high reactivity with matrix) reinforcements to understand the processing characteristics, in situ phase formations, and combinatorial effect of the multiphase microstructures on thermomechanical properties and high-temperature oxidation resistance. Combined reinforcement in this new composite material leads to superior yield strength and wear resistance in comparison to the other compositions and matrix, as well as comparable oxidation characteristics to commercially-developed high temperature titanium alloys, alleviating the need for multiple rare-earth alloying elements that significantly raises costs for manufacturers. Tubular structures are fabricated to demonstrate the ease of site-specific composition and dimensional tolerancing using this method. Our results indicate that tailored ceramic reinforcement in titanium via laser-based AM could lead to significantly enhanced engineering structures, particularly for developing higher temperature titanium-based materials.

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

Additive manufacturing (AM) is a new paradigm for the design and production of high-performance components for aerospace, medical, energy, and automotive applications. This review will exclusively cover directed energy deposition (DED)-AM, with a focus on the deposition of powder-feed based metal and alloy systems. This paper provides a comprehensive review on the classification of DED systems, process variables, process physics, modelling efforts, common defects, mechanical properties of DED parts, and quality control methods. To provide a practical framework to print different materials using DED, a process map using the linear heat input and powder feed rate as variables is constructed. Based on the process map, three different areas that are not optimized for DED are identified. These areas correspond to the formation of a lack of fusion, keyholing, and mixed mode porosity in the printed parts. In the final part of the paper, emerging applications of DED from repairing damaged parts to bulk combinatorial alloys design are discussed. This paper concludes with recommendations for future research in order to transform the technology from “form” to “function,” which can provide significant potential benefits to different industries.

Influence of boron nitride reinforcement to improve high temperature oxidation resistance of titanium

Influence of boron nitride (BN) addition in commercially pure titanium (Cp-Ti) was characterized for their microstructural variation, hardness and oxidation kinetics. Feedstock powders Cp-Ti with 3 wt.% BN (3BN) and 6 wt.% BN (6BN) were prepared by roller mill followed by additive manufacturing using laser engineered net shaping (LENS™). Rate of oxidation was measured from thermogravimetric analysis (TGA) at 1000°C for 50 h. Average instantaneous parabolic constants (k _p ) for Cp-Ti, 3BN and 6BN were 41.2±12.0, 28.6±2.8 and 18.2±9.2 mg²·cm^-4·h^-1, respectively. Cp-Ti displayed acicular α-Ti microstructure. After TGA, large equiaxed grains along with TiO₂ formation at the grain boundaries was observed, which increased the hardness. With BN addition, plate-like TiN and needle-like TiB secondary phases were also observed. Hardness for Cp-Ti, 3BN and 6BN were 256.9, 424.0 and 548.3 HV_0.2, respectively. Overall, a small addition of BN was effective in improving the oxidation resistance of Cp-Ti.

Microstructural Modeling and Strengthening Mechanism of TiB/Ti-6Al-4V Discontinuously-Reinforced Titanium Matrix Composite

A novel modeling method was proposed to provide an improved representation of the actual microstructure of TiB/Ti-6Al-4V discontinuously-reinforced titanium matrix composite (DRTMC). Based on the Thiessen polygon structure, the representative volume element (RVE) containing the complex microstructures of the DRTMC was first generated. Thereafter, by using multiple user-defined subroutines in the commercial finite element software ABAQUS, the application of asymmetric mesh periodic boundary conditions on the RVE was realized, and the equivalent elastic modulus of the DRTMC was determined according to the homogenization method. Through error analyses on the experimental and calculated results regarding the equivalent elastic parameters of the DRTMC, the rationality of generating the DRTMC finite element model by using the present method was validated. Finally, simulations based on four types of network-like models revealed that the present simplifications to the particle shape of the reinforcement phase had less of an influence on the overall composite strength. Moreover, the present study demonstrates that the DRTMC enhancement is mainly attributed to the matrix strengthening, rather than the load-transferring mechanism. The strengthening influences of the distribution forms of the reinforcement phases, including their distribution density and orientation, were studied further. It was found that both the higher distribution density and limited distribution orientation of the particles would increase the probability of overlapping and merging between particles, and; therefore, higher strength could be yielded when the volume fraction of the reinforcement phase reached a certain threshold. Owing to the versatility of the developed methods and programs, this work can provide a useful reference for the characterization of the mechanical properties of other composites types.

Additive manufacturing of biomaterials

Biomaterials are used to engineer functional restoration of different tissues to improve human health and the quality of life. Biomaterials can be natural or synthetic. Additive manufacturing (AM) is a novel materials processing approach to create parts or prototypes layer-by-layer directly from a computer aided design (CAD) file. The combination of additive manufacturing and biomaterials is very promising, especially towards patient specific clinical applications. Challenges of AM technology along with related materials issues need to be realized to make this approach feasible for broader clinical needs. This approach is already making a significant gain towards numerous commercial biomedical devices. In this review, key additive manufacturing methods are first introduced followed by AM of different materials, and finally applications of AM in various treatment options. Realization of critical challenges and technical issues for different AM methods and biomaterial selections based on clinical needs are vital. Multidisciplinary research will be necessary to face those challenges and fully realize the potential of AM in the coming days.

Nanoscale size effect in in situ titanium based composites with cell viability and cytocompatibility studies

Novel in situ Metal Matrix Nanocomposite (MMNC) materials based on titanium and boron, revealed their new properties in the nanoscale range. In situ nanocomposites, obtained through mechanical alloying and traditional powder metallurgy compaction and sintering, show obvious differences to their microstructural analogue. A unique microstructure connected with good mechanical properties reliant on the processing conditions favour the nanoscale range of results of the Ti-TiB in situ MMNC example. The data summarised in this work, support and extend the knowledge boundaries of the nanoscale size effect that influence not only the mechanical properties but also the studies on the cell viability and cytocompatibility. Prepared in the same bulk, in situ MMNC, based on titanium and boron, could be considered as a possible candidate for dental implants and other medical applications. The observed relations and research conclusions are transferable to the in situ MMNC material group. Aside from all the discussed relations, the increasing share of these composites in the ever-growing material markets, heavily depends on the attractiveness and a possible wider application of these composites as well as their operational simplicity presented in this work.

Articulating Biomaterials

This chapter examines the importance of surface characteristics such as microstructure, composition, crystallographic texture, and surface free energy in achieving desired biocompatibility and tribological properties thereby improving in vivo life of artificial articulating implants. Current implants often fail prematurely due to inadequate mechanical, tribological, biocompatibility, and osseointegration properties, apart from issues related to design and surgical procedures. For long-term in vivo stability, artificial implants intended for articulating joint replacement must exhibit long-term stable articulation surface without stimulating undesirable in vivo effects. Since the implant's surface plays a vital and decisive role in their response to biological environment, and vice versa, surface modification of implants assumes a significant importance. Therefore, overview on important surface modification techniques, their capabilities, properties of modified surfaces/implants are presented in the chapter. The clinical performance of surface modified implants and new surfaces for potential next-generation articulating implant applications are discussed at the end.