Fabrication of low-cost beta-type Ti–Mn alloys for biomedical applications by metal injection molding process and their mechanical properties

Influence of intermetallic phase (TiFe) on the microstructural evolution and mechanical properties of as-cast and quenched Ti-Mo-Fe alloys

This study presents the phase analysis, microstructural characteristics, and mechanical property evaluation of the as-cast and quenched Ti-15Mo-xFe alloys with high iron content ranging from 4 to 12 weight percent. All the four alloys were produced in a vacuum-arc melting furnace. Heat treatment in the form of solution treatment was performed in a muffle furnace at a temperature of 1100 °C, with 1-h holding time and the samples were rapidly quenched in ice-brine. X-ray diffractometer (XRD) was used to analyses the phases present in each alloy whereas the optical microscope (OM) was employed to track the microstructural evolution and percentage porosity. The mechanical properties of the alloys were evaluated using a tensile test and compression test method while the micro-Vickers hardness measurements were conducted to evaluate hardness of the alloys. The XRD patterns of as-cast showed peaks belonging to the β and α″ phases and intermetallic B2 TiFe phases. The as quenched XRD peaks illustrated β phase only and Fe·Ti·O2 phases. The as-cast OM micrographs revealed equiaxed β grains, substructures, dendritic structure, and pores forming around the grain boundaries. The quenched OM showed only β equiaxed grains with pores throughout the grain boundaries. The tensile properties such as ultimate tensile strength (UTS) and elastic modulus (E) of as-cast TMF0 were 264 MPa and 79 GPa respectively and these properties changed upon quenching to 411 MPa and 66 GPa respectively. The elastic modulus of TMF1 in as-cast condition was 74 GPa. The UTS and E of TMF1, TMF2, and TMF3 in as-cast and quenched conditions were not recorded due to the fragility of the samples that failed prior to yielding any useful data. The compressive strength in as-cast and in quenched condition decreased with an increase in Fe content. The micro-Vickers hardness in as-cast and quenched conditions showed a similar trend with hardness increasing slightly upon quenching for TMF0, TMF1, and TMF3 alloys but slightly decreased in the case of TMF2. The fracture surfaces of all the as-cast and quenched alloys were comprised of ductile and brittle fracture.

Biomedical Applications of Titanium Alloys: A Comprehensive Review

Titanium alloys have emerged as the most successful metallic material to ever be applied in the field of biomedical engineering. This comprehensive review covers the history of titanium in medicine, the properties of titanium and its alloys, the production technologies used to produce biomedical implants, and the most common uses for titanium and its alloys, ranging from orthopedic implants to dental prosthetics and cardiovascular devices. At the core of this success lies the combination of machinability, mechanical strength, biocompatibility, and corrosion resistance. This unique combination of useful traits has positioned titanium alloys as an indispensable material for biomedical engineering applications, enabling safer, more durable, and more efficient treatments for patients affected by various kinds of pathologies. This review takes an in-depth journey into the inherent properties that define titanium alloys and which of them are advantageous for biomedical use. It explores their production techniques and the fabrication methodologies that are utilized to machine them into their final shape. The biomedical applications of titanium alloys are then categorized and described in detail, focusing on which specific advantages titanium alloys are present when compared to other materials. This review not only captures the current state of the art, but also explores the future possibilities and limitations of titanium alloys applied in the biomedical field.

Process Development of a Generative Method for Partial and Controlled Integration of Active Substances into Open-Porous Matrix Structures

A special generative manufacturing (AM) process was developed for the partial integration of active ingredients into open-porous matrix structures. A mixture of a silver-containing solution as an antibacterial material with an alginate hydrogel as a carrier system was produced as the active ingredient. The AM process developed was used to introduce the active ingredient solution into an open-porous niobium containing a β-titanium matrix structure, thus creating a reproducible active ingredient delivery system. The matrix structure had already been produced in a separate AM process by means of selective laser melting (SLM). The main advantage of this process is the ability to control porosity with high precision. To determine optimal surface conditions for the integration of active ingredients into the matrix structure, different surface conditions of the titanium substrate were tested for their impact on wetting behaviour of a silver-containing hydrogel solution. The solution-substrate contact angle was measured and evaluated to determine the most favourable surface condition. To develop the generative manufacturing process, an FDM printer underwent modifications that permitted partial application of the drug solution to the structure in accordance with the bioprinting principle. The modified process enabled flexible control and programming of both the position and volume of the applied drug. Furthermore, the process was able to fill up to 95% of the titanium matrix body pore volume used. The customised application of drug carriers onto implants as a drug delivery system can be achieved via the developed process, providing an alternative to established methods like dip coating that lack this capability.

Effect of Mn on the Properties of Powder Metallurgy Ti-2.5Al-xMn Alloys

Titanium alloys are the ideal material for a wide range of structural applications, but their high cost compared to other metals hinders their adoption. Powder metallurgy and cheap alloying elements can be used to create new Ti alloys. In this study, the simultaneous addition of Al and Mn is considered to manufacture and characterise ternary Ti-2.5Al-Mn alloys obtained via pressing and sintering by varying the Mn content (1-10 wt.%). It is found that the addition of the alloying elements reduces compressibility. Consequently, the amount of porosity increases (8.5 → 10.8%) with the amount of Mn as the alloys were processed under the same conditions. The progressive addition of Mn refines the classical lamellar microstructure and, eventually, transforms it into an equiaxed β-grain structure with acicular α grains. The microstructural changes lead to continuous increases in strength (ultimate tensile strength: 694 → 851 MPa) and hardness (225 → 325 HV30) with an associated loss of ductility (elongation to failure: 13.9 → 1.0%). However, the obtained ternary Ti-2.5Al-Mn alloys have similar or better overall mechanical behaviour than most of the binary Ti-Mn alloys obtained through a variety of manufacturing methods.

Recent Advances in Processing of Titanium and Titanium Alloys through Metal Injection Molding for Biomedical Applications: 2013-2022

Metal injection molding (MIM) is one of the most widely used manufacturing processes worldwide as it is a cost-effective way of producing a variety of dental and orthopedic implants, surgical instruments, and other important biomedical products. Titanium (Ti) and Ti alloys are popular modern metallic materials that have revamped the biomedical sector as they have superior biocompatibility, excellent corrosion resistance, and high static and fatigue strength. This paper systematically reviews the MIM process parameters that extant studies have used to produce Ti and Ti alloy components between 2013 and 2022 for the medical industry. Moreover, the effect of sintering temperature on the mechanical properties of the MIM-processed sintered components has been reviewed and discussed. It is concluded that by appropriately selecting and implementing the processing parameters at different stages of the MIM process, defect-free Ti and Ti alloy-based biomedical components can be produced. Therefore, this present study could greatly benefit future studies that examine using MIM to develop products for biomedical applications.

New ternary powder metallurgy Ti alloys via eutectoid and isomorphous beta stabilisers additions

A group of new ternary Ti alloys bearing eutectoid and isomorphous beta stabilising elements was created to be manufactured through the conventional powder metallurgy route. The effect of the simultaneous addition of the same amount of Mn and Nb on the manufacturability, properties, and hardening behaviour was investigated. The ternary alloys are composed of the α-Ti and β-Ti phases and have a lamellar microstructure resulting from the slow cooling upon sintering. However, the size of the equiaxed α grains and of the α + β lamellae is monotonically reduced, especially the interlamellar spacing, as the amount of alloying elements increases. Due to their physical properties, Mn enhances and Nb hinders densification during sintering resulting in a decreasing trend of the relative density with the alloying elements content. Consequently, the resistance to plastic deformation increases (UTS, 514-726 MPa), the ductility decreases (elongation, 13.2-2.6%), and the fracture mode changes from intergranular to transgranular. The new ternary alloys share the same hardening mechanism, but the amount of deformation after necking is, generally, higher for lower amounts of Mn and Nb.

Effect of Milling Parameters on the Development of a Nanostructured FCC–TiNb15Mn Alloy via High-Energy Ball Milling

In this work, a blend of Ti, Nb, and Mn powders, with a nominal composition of 15 wt.% of Mn, and balanced Ti and Nb wt.%, was selected to be mechanically alloyed by the following two alternative high-energy milling devices: a vibratory 8000D mixer/mill® and a PM400 Retsch® planetary ball mill. Two ball-to-powder ratio (BPR) conditions (10:1 and 20:1) were applied, to study the evolution of the synthesized phases under each of the two mechanical alloying conditions. The main findings observed include the following: (1) the sequence conversion evolved from raw elements to a transitory bcc-TiNbMn alloy, and subsequently to an fcc-TiNb15Mn alloy, independent of the milling conditions; (2) the total full conversion to the fcc-TiNb15Mn alloy was only reached by the planetary mill at a minimum of 12 h of milling time, for either of the BPR employed; (3) the planetary mill produced a non-negligible Fe contamination from the milling media, when the highest BPR and milling time were applied; and (4) the final fcc-TiNb15Mn alloy synthesized presents a nanocrystalline nature and a partial degree of amorphization.

Ti-9Mn β-type alloy exhibits better osteogenicity than Ti-15Mn alloy in vitro

Ti-9Mn and Ti-15Mn were prepared using an arc furnace in order to understand their osteogenic behavior as a biomedical implant. Ti-9Mn surface showed a significantly lower contact angle value (41%) as compared with the Ti-15Mn surface. The higher Ra and lower hydrophilicity values of Ti-9Mn alloy as compared with Ti-15Mn alloy indicates that Ti-9Mn can have better osteoconductive properties. ALP activity of the osteoblast cells on the Ti-9Mn alloy was elevated by 45% on day 7 and 20% on day 14 as compared to the Ti-15Mn alloy that reflects faster induction of osteoblast phenotypes of MG63 cells. Filopodia and lamellipodia structures were spread more on the Ti-9Mn specimens as compared to the Ti-15Mn alloy. Cell viability on Ti-9Mn alloy increased by 25% and 32%, respectively after 7 and 14 days of culture as compared to Ti-15Mn alloy. On day 14 of culture, the relative expression of RUNX2, COL1, and OC on Ti-9Mn alloy were elevated by 35%, 21%, and 30% respectively than the Ti-15Mn alloy. Ti-9Mn alloy also exhibited an inductive effect on the cell proliferation, and upregulation in the expression of ALP, RUNX2, and OC that is, the genes related to osteoblastic differentiation. Hence, the present in vitro results suggest that Ti-9Mn can be a preferred implant material than the Ti-15Mn alloy.

Antibacterial Ti-Mn-Cu alloys for biomedical applications

Titanium alloys are common biomedical materials due to their biocompatibility and mechanical performance. However, titanium alloys are expensive and, unless surface treated, generally cannot prevent surgical infections related to bacteria which can damage the integrity of the implant. In this study, new titanium alloys were developed via powder metallurgy and the addition of manganese and copper, respectively, aiming to limit the manufacturing costs and induce new functionality on the materials including antibacterial response. The addition of manganese and copper to titanium significantly changes the behaviour of the Ti-Mn-Cu alloys leading to the successful stabilization of the beta titanium phase, great refinement of the typical lamellar structure, and achievement of materials with low level of porosity. Consequently, it is found that the mechanical performance and the antibacterial efficacy are enhanced by the addition of a higher amount of alloying elements. The manufactured Ti-Mn-Cu alloys fulfil the requirements for structural biomedical implants and have antibacterial response making them potential candidates for permanent medical implants.

Ternary Ti alloys functionalised with antibacterial activity

Prosthesis bacterial infection occurring during surgery is a rising health issue. Pathogenic bacterial infection causes inflammation, interferes with the healing process, inhibits osteogenesis and, eventually, leads to implant failure. These issues can be tackled either by applying coatings or developing multifunctional (i.e. structural and antibacterial) materials. In this work, β eutectoid bearing functionalised Ti alloys were designed and manufactured via the cost-effective press and sinter powder metallurgy route. The systematic analysis of the ternary Ti–xCu–yMn alloys shows that the mechanical properties proportionally increase with the amount of alloying elements added. All the ternary Ti–xCu–yMn alloys have strong antibacterial activity against Escherichia coli with respect to the negative control (i.e. pure Ti). Our study demonstrates that ternary Ti–xCu–yMn alloys are promising candidates for structural prostheses functionalised with antibacterial capability.

Evaluation of Ti-Mn Alloys for Additive Manufacturing Using High-Throughput Experimental Assays and Gaussian Process Regression

Compositionally graded cylinders of Ti-Mn alloys were produced using the Laser Engineered Net Shaping (LENS™) technique, with Mn content varying from 0 to 12 wt.% along the cylinder axis. The cylinders were subjected to different post-build heat treatments to produce a large sample library of a-b microstructures. The microstructures in the sample library were studied using back-scattered electron (BSE) imaging in a scanning electron microscope (SEM), and their mechanical properties were evaluated using spherical indentation stress-strain protocols. These protocols revealed that the microstructures exhibited features with averaged chord lengths in the range of 0.17-1.78 mm, and beta content in the range of 20-83 vol.%. The estimated values of the Young's moduli and tensile yield strengths from spherical indentation were found to vary in the ranges of 97-130 GPa and 828-1864 MPa, respectively. The combined use of the LENS technique along with the spherical indentation protocols was found to facilitate the rapid exploration of material and process spaces. Analyses of the correlations between the process conditions, several key microstructural features, and the measured material properties were performed via Gaussian process regression (GPR). These data-driven statistical models provided valuable insights into the underlying correlations between these variables.

Development of novel Ti-Mo-Mn alloys for biomedical applications

Due to excellent biocompatibility and corrosion resistance, the application of titanium alloys in orthopedic and dental implants has been increasing since the 1970s. However, the elasticity of these alloys as measured by their Young’s modulus is still about two to four times higher than that of human cortical bone. The most widely used titanium alloy for biomedical applications is Ti-6Al-4V, however, previous studies have shown that the vanadium used in this alloy causes allergic reactions in human tissue and aluminum, also used in the alloy, has been associated with neurological disorders. To solve this problem, new titanium alloys without the presence of these elements and with the addition of different elements, usually beta-stabilizers, are being developed. Manganese is a strong candidate as an alloying element for the development of new beta-type titanium alloys, due to its abundance and low cytotoxicity. In this study, Ti-10Mo-5Mn, Ti-15Mo-2.5Mn and Ti-15Mo-5Mn alloys were prepared in an arc furnace, which resulted in an alloy structure clearly showing the predominance of the beta phase with a body-centered cubic crystalline structure. The observed microstructure confirmed the results on the structural characterization of alloys. Measurement of the indirect cytotoxicity of the alloys showed that the extracts of the studied alloys are not cytotoxic for fibroblastic cells.

Probing Nanoscale Phase Separation at Atomic Resolution within β-Type Ti-Mn Alloy: A Potential Candidate for Biomedical Implants

Biocompatible β-type Ti alloys with high ultimate tensile strength (UTS) and yield strength are potential candidates for certain orthopedic and cardiovascular implants. Aiming for these applications, Ti alloy with 14 wt % Mn (Ti-14 Mn) as β-stabilizer was processed through thermomechanical treatment along with solutionizing and quenching, followed by 95% cold rolling, which resulted in ultrahigh UTS and yield strength. 3-[4,5-Dimethylthiazol-2-yl]-2,5-diphenyltetrazolimbromide assay with different cell lines suggests efficient cell growth on alloy surface without compromising biocompatibility. Cell adhesion and spreading assay show that cells are not only able to attach to the alloy surface but also able to spread and grow with normal morphology, which projects this material as a potential candidate for biomedical application. Previous studies on binary β-type Ti alloy systems treated with the above-mentioned processing route confirm the presence of nanoscale phase separation, which enhances its mechanical properties. To discover the same phenomena in the alloy of the present study, bright-field and high-resolution transmission electron microscopy (HRTEM) imaging experiments were performed and nanoscale contrast-modulated lamella regions were observed. Geometrical phase analysis on complex-valued exit wave, reconstructed using focal series HRTEM images, demonstrates that the lamella is a result of d-spacing modulation. Ab initio calculation indicates that d-spacing modulation with the same crystal structure occurs due to composition modulation and was proved by scanning transmission electron microscopy imaging coupled with quantitative energy-dispersive X-ray spectroscopy. Correlating contrast, strain, and composition modulation confirms nanoscale phase separation, which is the first report of this phenomenon in Ti-Mn alloy system.

Mechanical properties and microstructure of Ti-Mn alloys produced via powder metallurgy for biomedical applications

Titanium and especially its alloys are highly employed materials in biomedical applications because of their balanced mechanical properties and biocompatibility. Ti-Mn alloys (1, 5, and 10 wt%. Mn) were produced by powder metallurgy as a potential alternative material for biomedical applications. Two sets of samples were produced, one set as-sintered and the other was beta (β) forged. For the as-sintered samples with a content of up to 10 wt% Mn, the tensile strength ranged from 606 to 1070 MPa. On the other hand, for the β forged alloys the tensile strength ranged from 728 to 1224 MPa and the maximum value was for Ti-5Mn. Forged Ti-5Mn exhibits a good balance of mechanical properties such as ultimate tensile strength (1224 MPa), elongation (4.6%) and Vickers hardness (415 HV). The purely elastic properties of the Ti-10Mn alloy is attributed to the effects of the omega (ω) phase, the formation of which is due to the high amount of beta stabiliser added to Ti.

Porous Titanium Scaffolds Fabricated by Metal Injection Moulding for Biomedical Applications

Biocompatible titanium scaffolds with up to 40% interconnected porosity were manufactured through the metal injection moulding process and the space holder technique. The mechanical properties of the manufactured scaffold showed a high level of compatibility with those of the cortical human bone. Sintering at 1250 °C produced scaffolds with 36% porosity and more than 90% interconnected pores, a compressive yield stress of 220 MPa and a Young's modulus of 7.80 GPa, all suitable for bone tissue engineering. Increasing the sintering temperature to 1300 °C increased the Young's modulus to 22.0 GPa due to reduced porosity, while reducing the sintering temperature to 1150 °C lowered the yield stress to 120 MPa, indicative of insufficient sintering. Electrochemical studies revealed that samples sintered at 1150 °C have a higher corrosion rate compared with those at a sintering temperature of 1250 °C. Overall, it was concluded that sintering at 1250 °C yielded the most desirable results.

Selective laser melted titanium alloys for hip implant applications: Surface modification with new method of polymer grafting

A significant number of hip replacements (HR) fail permanently despite the success of the medical procedure, due to wear and progressive loss of osseointegration of implants. An ideal model should consist of materials with a high resistance to wear and with good biocompatibility. This study aims to develop a new method of grafting the surface of selective laser melted (SLM) titanium alloy (Ti-6Al-4V) with poly (2-methacryloyloxyethyl phosphorylcholine) (PMPC), to improve the surface properties and biocompatibility of the implant. PMPC was grafted onto the SLM fabricated Ti-6Al-4V, applying the following three techniques; ultraviolet (UV) irradiation, thermal heating both under normal atmosphere and UV irradiation under N₂ gas atmosphere. Scanning electron microscopy (SEM), 3D optical profiler, energy-dispersive X-ray spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), and Fourier transform infrared spectroscopy (FTIR) were used to characterise the grafted surface. Results demonstrated that a continuous PMPC layer on the Ti-6Al-4V surface was achieved using the UV irradiation under N₂ gas atmosphere technique, due to the elimination of oxygen from the system. As indicated in the results, one of the advantages of this technique is the presence of phosphorylcholine, mostly on the surface, which reveals the existence of a strong chemical bond between the grafted layer (PMPC) and substrate (Ti-6Al-4V). The nano-scratch test revealed that the PMPC grafted surface improves the mechanical strength of the surface and thus, protects the underlying implant substrate from scratching under high loads.

A review of biocompatible metal injection moulding process parameters for biomedical applications

Biocompatible metals have been revolutionizing the biomedical field, predominantly in human implant applications, where these metals widely used as a substitute to or as function restoration of degenerated tissues or organs. Powder metallurgy techniques, in specific the metal injection moulding (MIM) process, have been employed for the fabrication of controlled porous structures used for dental and orthopaedic surgical implants. The porous metal implant allows bony tissue ingrowth on the implant surface, thereby enhancing fixation and recovery. This paper elaborates a systematic classification of various biocompatible metals from the aspect of MIM process as used in medical industries. In this study, three biocompatible metals are reviewed-stainless steels, cobalt alloys, and titanium alloys. The applications of MIM technology in biomedicine focusing primarily on the MIM process setting parameters discussed thoroughly. This paper should be of value to investigators who are interested in state of the art of metal powder metallurgy, particularly the MIM technology for biocompatible metal implant design and development.