Laser processing of in situ TiN/Ti composite coating on titanium

Wear performance of Ti-based alloy coatings on 316L SS fabricated with the sputtering method: Relevance to biomedical implants

BACKGROUND

This investigation was conducted to encapsulate 316L SS with a Ti-based alloy coating.

OBJECTIVE

The aim was to fabricate a coating using TiN, TiO2, and TiCoCr powders on 316L SS through the physical vapor deposition (PVD) sputtering process.

METHODS

The powders were consecutively coated on 316L SS through the PVD sputtering process with coating durations of 30, 60, and 90 min. Further microhardness, surface roughness, microabrasion, and adhesion strength tests were also carried out.

RESULTS

A 60% improvement in abrasion resistance was observed in TiCoCr-coated samples compared to the uncoated substrate. The X-ray diffraction results confirmed the optimal formation of Ti alloy coatings with corresponding orientation over the SS substrates. Moreover, TiCoCr with a 90 min coating duration had much better surface characteristics than TiO2 and TiN.

CONCLUSION

The 90 min coating duration should be optimal for coating in steel for bio-implants.

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.

Study on the Preparation of Network Ti-N/Ti Composites by Nitridation of Ti Powders

Composite structure design is an important way to improve reinforcement strengthening efficiency. The dispersion of the external reinforcement is often not uniform enough, however, and it is agglomerated in the matrix, which cannot uniformly and effectively bear the load. The interconnected reinforcement network prepared by the in-situ self-growth method is expected to obtain higher material properties. In this paper, the TiN shell was formed on the surface of Ti powder by the in-situ nitriding method, and then the network TiN/Ti composites were prepared by sintering. In the control group, TiN was dispersed by mechanical ball milling, and it was found that TiN powder was coated on the surface of Ti particles, and the sintered TiN/Ti composites formed a discontinuous structure with a great deal of TiN agglomeration. A uniform TiN nitride layer of 5~7 μm was formed on the surface of Ti powder by the in-situ nitriding method, and a connected TiN network was formed in the sintered Ti-N/Ti composites. The composites prepared by nitriding have higher compressive strength, hardness, and plasticity. The hardness of the Ti-N/Ti composite is 685.7 HV and the compressive strength is 1468.5 MPa. On this basis, the influence of the connected TiN structure on the material properties was analyzed, which provided theoretical guidance for the structural design of the network structure-reinforced titanium matrix composites.

Titanium Nitride Coated Implant Abutments: From Technical Aspects And Soft tissue Biocompatibility to Clinical Applications. A Literature Review

PURPOSE

To review the most up to date scientific evidence concerning the technical implications, soft tissue biocompatibility, and clinical applications derived from the use of titanium nitride hard thin film coatings on titanium alloy implant abutments.

MATERIALS AND METHODS

A review was performed to answer the following focused question: "What is the clinical reliability of nitride coated titanium alloy abutments?". A MEDLINE search between 1980 and 2021 was performed for investigations pertaining to the clinical use of nitride coated titanium alloy implant abutments (TiN) in case reports, case series, and short- and long-term non/randomized controlled clinical trials. Literature analysis led to addition evaluation of research related to the technical and biological aspects, as well as the physicochemical characteristics of TiN hard thin film coatings and their impact on titanium abutment biocompatibility, mechanical properties, macroscopic surface topography, and optical properties. Therefore, preclinical data from biomechanical and in vitro investigations were also considered as inclusion criteria.

RESULTS

The limited number of clinical investigations published made a systematic review and meta-analysis not possible, therefore a narrative review was conducted. TiN coatings have been applied to dental materials and instruments to improve their clinical longevity. Implant abutments are coated with titanium nitride to mask the titanium oxide surface and enhance its surface characteristics providing the TiN abutment surface with a low friction coefficient and a very high chemical inertness. TiN coating is suggested to reduce early bacterial colonization and biofilm formation and enhance fibroblast cell proliferation, attachment and adhesion when compared to Ti controls. Additionally, studies indicate that hard thin film coatings enhance the mechanical properties (hardness and wear resistance) of titanium alloy and appears as a yellow color when deposited on the titanium alloy substrate. To date, clinical investigations show that nitride coated titanium abutments provide promising short-term clinical outcomes.

CONCLUSIONS

Published research on nitride-coated abutments is still limited, however, the available biomedical research, mechanical engineering tests, in vitro investigations, and short-term clinical trials have, to date, reported promising mechanical, biological, and esthetic outcomes.

Review on Preparation Technology and Properties of Refractory High Entropy Alloys

Refractory high entropy alloys have broad application prospects due to their excellent comprehensive properties in high temperature environments, and they have been widely implemented in many complex working conditions. According to the latest research reports, the preparation technology of bulk and coating refractory high entropy alloys are summarized, and the advantages and disadvantages of each preparation technology are analyzed. In addition, the properties of refractory high entropy alloys, such as mechanical properties, wear resistance, corrosion resistance, oxidation resistance, and radiation resistance are reviewed. The existing scientific problems of refractory high entropy alloys, at present, are put forward, which provide reference for the development and application of refractory high entropy alloys in the future, especially for plasma-facing materials in nuclear fusion reactors.

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.

Nature-inspired materials and structures using 3D Printing

Emulating the unique combination of structural, compositional, and functional gradation in natural materials is exceptionally challenging. Many natural structures have proved too complex or expensive to imitate using traditional processing techniques despite recent advances. Recent innovations within the field of additive manufacturing (AM) or 3D Printing (3DP) have shown the ability to create structures that have variations in material composition, structure, and performance, providing a new design-for-manufacturing platform for the imitation of natural materials. AM or 3DP techniques are capable of manufacturing structures that have significantly improved properties and functionality over what could be traditionally-produced, giving manufacturers an edge in their ability to realize components for highly-specialized applications in different industries. To this end, the present work reviews fundamental advances in the use of naturally-inspired design enabled through 3DP / AM, how these techniques can be further exploited to reach new application areas, and the challenges that lie ahead for widespread implementation. An example of how these techniques can be applied towards a total hip arthroplasty application is provided to spur further innovation in this area.

3D Printing in alloy design to improve biocompatibility in metallic implants

3D Printing (3DP) or additive manufacturing (AM) enables parts with complex shapes, design flexibility, and customization opportunities for defect specific patient-matched implants. 3DP or AM also offers a design platform that can be used to innovate novel alloys for application-specific compositional modifications. In medical applications, the biological response from a host tissue depends on a biomaterial's structural and compositional properties in the physiological environment. Application of 3DP can pave the way towards manufacturing innovative metallic implants, combining structural variations at different length scales and tailored compositions designed for specific biological responses. This study shows how 3DP can be used to design metallic alloys for orthopedic and dental applications with improved biocompatibility using in vitro and in vivo studies. Titanium (Ti) and its alloys are used extensively in biomedical devices due to excellent fatigue and corrosion resistance and good strength to weight ratio. However, Ti alloys' in vivo biological response is poor due to its bioinert surface. Different coatings and surface modification techniques are currently being used to improve the biocompatibility of Ti implants. We focused our efforts on improving Ti's biocompatibility via a combination of tantalum (Ta) chemistry in Ti, the addition of designed micro-porosity, and nanoscale surface modification to enhance both in vitro cytocompatibility and early stage in vivo osseointegration, which was studied in rat and rabbit distal femur models.

Hydroxyapatite reinforced Ti6Al4V composites for load-bearing implants

Titanium has been used in various biomedical applications; however, titanium exhibits poor wear resistance, and its bioinert surface slows osseointegration in vivo. In this study, directed energy deposition (DED)-based additive manufacturing (AM) was used to process hydroxyapatite (HA) reinforced Ti6Al4V (Ti64) composites to improve biocompatibility and wear resistance simultaneously. Electron micrographs of the composites revealed dense microstructures where HA was observed at the β-phase grain boundaries. Hardness increased by 57% and 71% for 2 and 3 wt.% HA in Ti64 composites, respectively. XRD analysis revealed no change in the phases with the addition of HA, when compared to the control. Tribological studies displayed an increase in contact resistance (CR) due to an in situ formed HA-based tribofilm, reduction in wear rate when testing in Dulbecco's Modified Eagle Medium (DMEM) with a ZrO₂ counter wear ball, <1% wear ball volume loss, and suppression of cohesive shear failure of the Ti matrix. Histomorphometric analysis from a rat distal femur study revealed an increase in the osteoid surface over the bone surface (OS/BS) for 3 wt.% HA composite over the control Ti64 from 9 ± 1% to 14 ± 1%. Additionally, from push-out testing, the shear modulus was observed to increase from 17 ± 3 MPa for control Ti64 to 32 ± 5 MPa for the 3 wt.% HA composite after 5-weeks in vivo. The present study demonstrates that the addition of HA in Ti64 can simultaneously improve bone tissue-implant response and wear resistance.

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.

Additively Manufactured Ti6Al4V-Si-Hydroxyapatite composites for articulating surfaces of load-bearing implants

Directed-energy deposition (DED)-based additive manufacturing (AM) was explored for composite development using silicon (Si) and hydroxyapatite (HA) in Ti-6Al-4V (Ti64) matrix for articulating surfaces of load-bearing implants. Specifically, laser engineered net shaping (LENS™), a commercially available DED-based AM technique, was used to fabricate composites from premixed-feedstock powders. The AM'd composites proved to not only improve upon Ti64's mechanical properties but also produced an in-situ Si-based tribofilm during tribological testing that minimized wear induced damage. Additionally, it was found that with the introduction of Si, titanium silicides and vanadium silicides were formed; allowing for 114% increased hardness, decreased coefficient of friction (COF) and a reduction of wear rate of 38.1% and 48.7%, respectively. The produced composites also displayed a positive shift in open-circuit potential (OCP) during linear wear, along with a reduction in the change of OCP from idle to linear wear conditions. Additionally, contact resistance (CR) values increased with a maximum value of 1500 ohms due to the formation of Si-based tribofilm on the wear surface. Such composite development approach using DED-based AM can open up the possibilities of innovating next-generation implants that are designed and manufactured via multi-material AM.

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.

Direct Fabrication of Bimetallic Ti6Al4V+Al12Si Structures via Additive Manufacturing

Ti6Al4V+Al12Si compositionally graded cylindrical structures were fabricated on a Ti6Al4V substrate using laser engineered net shaping (LENS™) process. LENS™ fabricated materials had two regions of Ti6Al4V+Al12Si compositions, a pure Al12Si, and a pure Ti6Al4V area. Microstructural changes were affected by both laser power and compositional variations. In addition, TiSi₂ and Ti₃Al phase formations were also identified in low and high laser power processed Ti6Al4V+Al12Si sections, respectively. Moreover, the high laser power processed Ti6Al4V+Al12Si section showed the highest hardness value of 685.6 ± 10.6 HV_0.1, which was caused due to the formation of new intermetallic phases. This high hardness section exhibited brittle failure modes during compression tests, while the pure Al12Si sections showed ductile deformation. The maximum compressive strengths of Ti6Al4V+Al12Si compositionally graded material was 507.8 ± 52.0 MPa. Our results show that compositionally gradient bulk structures of Ti6Al4V and Al12Si can be directly manufactured using additive manufacturing, however, performances can vary significantly based on process parameters and compositional variations.

Clinical significance of three-dimensional printed biomaterials and biomedical devices

Three-dimensional printing (3DP) is becoming a standard manufacturing practice for a variety of biomaterials and biomedical devices. This layer-by-layer methodology provides the ability to fabricate parts from computer-aided design files without the need for part-specific tooling. Three-dimensional printed medical components have transformed the field of medicine through on-demand patient care with specialized treatment such as local, strategically timed drug delivery, and replacement of once-functioning body parts. Not only can 3DP technology provide individualized components, it also allows for advanced medical care, including surgical planning models to aid in training and provide temporary guides during surgical procedures for reinforced clinical success. Despite the advancement in 3DP technology, many challenges remain for forward progress, including sterilization concerns, reliability, and reproducibility. This article offers an overview of biomaterials and biomedical devices derived from metals, ceramics, polymers, and composites that can be three-dimensionally printed, as well as other techniques related to 3DP in medicine, including surgical planning, bioprinting, and drug delivery.

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.

Laser processed calcium phosphate reinforced CoCrMo for load-bearing applications: Processing and wear induced damage evaluation

To mitigate shortcomings in current biomedical CoCrMo alloy, composites of CoCrMo with calcium phosphate (CaP) were envisioned. CoCrMo alloy was reinforced with CaP to enhance the wear resistance of the alloy. A powder based direct energy additive manufacturing technique of Laser Engineered Net Shaping (LENS™) was used for processing of CoCrMo alloy with 1% and 3% (by weight) of CaP in the form of hydroxyapaptite. Addition of CaP was found to stabilize the ε (hcp) phase along with the more common γ (fcc) phase of the CoCrMo alloy, and the microstructure showed discontinuous chromium carbide phase. The resultant composite showed hardness similar to the base material, however, there was significant increase in the wear resistance of the alloy due to the addition of CaP. During wear testing, a tribo-layer or a tribofilm was found to develop on the surface. This led to the reduction in the leaching of Co and Cr ions during wear testing. The tribofilm was found to be dependent on the wear distance, and made the CoCrMo-CaP composites an in situ self-protecting system. The overall coefficient of friction of the CoCrMo-CaP composite was found to increase but was more stable with the wear distance as compared to the CoCrMo alloy with no CaP addition.

STATEMENT OF SIGNIFICANCE

Co-based alloys, an ideal choice for biomedical load-bearing implants, show low wear rates along with low coefficient of friction (COF) and good resistance to corrosive media. However, significant material loss can occur in vivo due to wear and/or corrosion of CoCrMo over long periods of time. Release of metal ions in the human body over time leads to medical complications such as metallosis, which can often require a revision surgery that can adversely affect the quality of life for the patient. We hypothesize that metal ion release from CoCrMo alloys can be reduced during articulation using an in situ formed inorganic tribofilm, and our results validate our hypothesis in calcium phosphate reinforced CoCrMo composites.

Nano- and micro-tribological behaviours of plasma nitrided Ti6Al4V alloys

Plasma nitriding of the Ti-6Al-4V alloy (TA) sample was carried out in a plasma reactor with a hot wall vacuum chamber. For ease of comparison these plasma nitrided samples were termed as TAPN. The TA and TAPN samples were characterized by XRD, Optical microscopy, FESEM, TEM, EDX, AFM, nanoindentation, micro scratch, nanotribology, sliding wear resistance evaluation and in vitro cytotoxicity evaluation techniques. The experimental results confirmed that the nanohardness, Young's modulus, micro scratch wear resistance, nanowear resistance, sliding wear resistance of the TAPN samples were much better than those of the TA samples. Further, when the data are normalized with respect to those of the TA alloy, the TAPN sample showed cell viability about 11% higher than that of the TA alloy used in the present work. This happened due to the formation of a surface hardened embedded nitrided metallic alloy layer zone (ENMALZ) having a finer microstructure characterized by presence of hard ceramic Ti₂N, TiN etc. phases in the TAPN samples, which could find enhanced application as a bioimplant material.