Search Results (90)

Titanium alloy welded joints are key parts of deep-sea pressure hulls, which are subjected to fatigue loadings in service. In this study, axial fatigue tests, mode I fatigue crack growth tests, and mixed-mode I–II fatigue crack growth tests were conducted on the Ti-6Al-4V ELI titanium alloy welded joint, and its fatigue failure mechanism and crack growth behavior is investigated and compared with the base material. The results show that the S–N curve of Ti-6Al-4V ELI titanium alloy welded joints has a very similar slope as the base material, but its fatigue performance is lower than the base material. However, the welded joints exhibit a higher resistance in the near-threshold region under mode I loading compared to the base material. Scanning electron microscope observation indicates that the fatigue crack mainly initiates from gas pores during welding for the Ti-6Al-4V ELI titanium alloy welded joints. Under mixed-mode I–II loading, the stress intensity factor range component $\mathsf{\Delta }{K}_{\mathrm{I}}$ of welded joints is higher than that of the base material, and an equivalent stress intensity factor range model is proposed to describe the crack growth rate under both mode I and mixed-mode I–II loadings. The new model incorporates a parameter dependent on the mode mixity ratio defined by $\mathsf{\Delta }{K}_{\mathrm{I}\mathrm{I}}/\mathsf{\Delta }{K}_{\mathrm{I}}$ in this paper, and it unifies the crack growth data well under mode I and mixed-mode I–II loadings. The paper indicates that the gas pores during welding are an important factor for the poor fatigue performance of Ti-6Al-4V ELI titanium alloy welded joints. Full article

The present work compares the corrosion performance of additively manufactured (AM) Ti-6Al-4V ELI (Extra-Low Interstitials) alloy manufactured by Laser-Powder Bed Fusion (L-PBF) using virgin powder (Cycle 1/C1 sample) and reused powder feedstock after up to 34 cycles (Cycle 34/C34 sample) of manufacturing. The effect of powder reuse is also evaluated for anodizing and Flash-PEO-coated specimens in Harrison’s (25 °C) and Hanks’ solutions (37 °C), representing simulated atmospheric precipitation and physiological conditions, respectively. Specimens were characterized using common metallographic techniques, X-ray diffraction, scanning electron microscopy and optical profilometry. Corrosion resistance was evaluated using cyclic potentiodynamic polarization (PDP) tests. The oxygen content in the Ti-6Al-4V reaches 0.14 wt.% after 34 cycles (C34) of powder reuse, enhancing its passivity in both Harrison’s and Hanks’ solutions. Both virgin and reused powder builds are susceptible to localized corrosion in Hanks’ solution at potentials above 1.75 V. Melt pool borders are thought to be the preferential sites for localized corrosion, as indicated by Volta potential measurements (ΔV = 100 mV). The number of cycles does not significantly affect the current–voltage responses for anodizing and flash-Plasma Electrolytic Oxidation (Flash-PEO) treatments, although anodizing is slightly more responsive to variations in surface roughness (i.e., real specimen area). Anodizing and Flash-PEO reduce the passive current density by nearly two orders of magnitude. Even after surface treatment, the alloy printed with reused powder revealed better passivity. Flash-PEO coatings yielded significant protection against localized corrosion. This unlocks Flash-PEO processing as a successful protection approach for AM biomedical components. Full article

The fatigue performance of titanium alloys is a critical determinant of the service life and structural integrity for aerospace and marine engineering components. But within the framework of damage tolerance design, resistance to fatigue crack propagation is regarded as a key indicator governing the fatigue performance of these engineering structures. In previous work, while the general fatigue performance of Ti–6Al–4V-0.55Fe alloy has received systematic study, targeted research focusing on its resistance to fatigue crack propagation remains limited. Therefore, in this work, compared with Ti–6Al–4V ELI alloy, the fatigue crack propagation behavior and fracture mechanism of Ti–6Al–4V-0.55Fe alloy with a duplex microstructure were systematically investigated. The results show that when ∆K < 12.75 MPa⋅m^1/2, Ti-6Al-4V-0.55Fe alloy demonstrates superior resistance to fatigue crack propagation. Fractographic analysis indicates that the primary difference between the two alloys lies in the stage of crack initiation and early propagation. This behavior is attributed to the addition of trace Fe, which enhances α/β boundary resistance and thereby retards crack growth. Moreover, crack propagation of TC4-F alloy is also slowed by the increased path length from bypassing the α_p phase. Full article

Ti-6Al-4V ELI (Grade 23) fabricated by Laser Powder Bed Fusion (LPBF) exhibits well-known susceptibility to adhesive wear and tribo-oxidation under dry sliding, yet the tribological consequences of in-process laser remelting remain poorly characterized. This study investigates the influence of an in-layer laser scan strategy (single-scan and double-scan), normal forces in the 5–15 N range, and a sliding speed of 0.10–0.20 m·s⁻¹ on the dry sliding tribological response of additive manufactured Ti-6Al-4V ELI. A full factorial experimental design was carried out and the most significant factors and their contributions to the coefficient of friction, specific wear rate, and contact temperature were identified by a statistical method using a general linear model (GLM). The optimal parameters for both of the scan strategies were predicted using a response surface methodology (RSM). Furthermore, to assess the effect of the laser scan strategy and the in-layer remelting on the local mechanical properties, a microscale and nanoscale indentation was carried out. The results show that the normal load was the dominant factor with a contribution of 89.3% for the coefficient of friction, 54% for the specific wear rate, and 40.5% for the temperature. A significant load–scan strategy interaction that governed the wear behavior was detected. The double-scan strategy exhibited higher wear at 5 N but lower wear at 15 N than the single-scan, a counter-intuitive reversal attributed to the load-threshold tribolayer stabilization promoted by the remelting-induced near-surface microstructural modification. The novelty of this study was the setup of a robust GLM–RSM framework for predictive modeling and optimization of additively manufactured surfaces under tribological loading. Full article

Despite the growing adoption of Ti6Al4V-ELI made by Laser Powder Bed Fusion (LPBF) in tribologically demanding applications, the influence of hybrid nanoparticle additives on its lubrication behavior under starved contact conditions remains insufficiently explored. The tribological performance of Ti6Al4V was investigated under starved boundary-to-mixed lubrication conditions using engine oil modified with Ag-doped TiO₂ nanoparticles. Double-scan LPBF-fabricated discs were tested in a ball-on-disc configuration against AISI 52100 bearing steel using a TRB³ tribometer. Nanolubricants were prepared by dispersing TiO₂ and Ag–TiO₂ nanopowders with different Ag⁺/Ti⁴⁺ ratios (0.5%, 1.5%, and 2.5%) in SAE 10W-40 engine oil at a constant nanoparticle concentration of 0.05 wt%. Comprehensive physicochemical characterization of the nanopowders and nanolubricants was performed through structural, chemical, optical, morphological, rheological, and stability analyses. Tribological experiments were conducted following a full-factorial design combining three normal loads (5–15 N), three sliding speeds (0.10–0.20 m·s⁻¹), and four lubricant formulations. The steady-state coefficient of friction ranged between 0.281 and 0.359, while the specific wear rate varied from 2.81 × 10⁻⁴ to 4.83 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The contact temperature rise remained relatively moderate, within the interval of 1.9–9.4 °C. Among the investigated formulations, the lubricant containing 1.5% Ag–TiO₂ exhibited the lowest friction coefficient, whereas the formulation with the highest Ag content showed improved stability of tribological performance across the investigated operating domain. These results indicate that Ag-modified TiO₂ nanoparticles are consistent with the formation of protective tribofilms and contribute to the stabilization of friction, wear, and thermal behavior under starved lubrication conditions. ANOVA confirmed that sliding speed and the load–lubricant interaction are the dominant factors governing friction and wear, while normal load controls the thermal response. These findings support the use of Ag–TiO₂ nanolubricants as a viable strategy for stabilizing interfacial behavior in LPBF-fabricated titanium components operating under starved lubrication conditions. Full article

This research investigates the effects of electrochemical oxidation on surface properties and corrosion performance of the Ti-6Al-4V ELI alloy intended for biomedical applications. Electrochemical anodization is performed in 1 M H₂SO₄ and 1 M H₃PO₄ electrolytes at applied potentials of 200, 250, and 275 V for 1 min. Morphological characteristics and chemical constitution of the oxide films are investigated by SEM-EDS analysis, while surface roughness, wettability, and microhardness are evaluated using profilometry, contact angle measurements, and Vickers microhardness testing. Electrochemical behavior is assessed by monitoring free potential (OCP) and electrochemical impedance spectroscopy in Ringer solution and Ringer solution containing 40 g/L hydrogen peroxide. Among the investigated conditions, anodization at 200 V for 1 min provides the most favorable surface morphology, producing well-defined and uniformly distributed nanopores while maintaining the structural stability of the oxide layer. Oxidation in 1 M H₂SO₄ leads to a more homogeneous nanoporous structure, higher surface roughness, improved hydrophilicity, and increased microhardness compared to 1 M H₃PO₄ treatment. Electrochemical impedance spectroscopy analysis reveals superior corrosion resistance for all oxidized samples in comparison with the untreated alloy. The oxide layers obtained in sulfuric acid exhibit the highest polarization resistance and electrochemical stability in simulated physiological environments. Full article

Laser Powder Bed Fusion (LPBF) enables the fabrication of complex titanium alloy components with high geometric freedom; however, surface integrity and tribological performance remain critical limitations for sliding-contact applications in biomedical and aerospace systems. In this study, the influence of in-layer laser remelting on the microstructure, surface topography, and dry sliding tribological behavior of LPBF-fabricated Ti-6Al-4V ELI (Grade 23) is systematically investigated. Disc-shaped specimens were produced using single-scan (SS) and double-scan (DS, in-layer remelting) strategies and tested in ball-on-disc configuration against AISI 52100 steel at a constant normal load of 10 N and three sliding speeds of 0.10, 0.15, and 0.20 m·s⁻¹. Microstructural and phase-related characteristics were analyzed by X-ray diffraction combined with Rietveld refinement and Warren–Averbach analysis, revealing that the DS strategy increases retained β-phase fraction (up to 5.2%) and promotes crystallite coarsening relative to the SS condition, without significantly altering bulk hardness. Surface morphology examined by SEM/EDS and AFM revealed a more homogeneous near-surface topography in the DS condition. Tribological results indicate that sliding speed governs steady-state friction and wear, with specific wear rates increasing progressively from 5.13 to 5.44 × 10⁻⁴ mm³·N⁻¹·m⁻¹ for SS and from 6.47 to 7.52 × 10⁻⁴ mm³·N⁻¹·m⁻¹ for DS across the investigated speed range. The DS specimens exhibited higher wear rates than the SS condition across all tested speeds, while steady-state COF values remained comparable between strategies, indicating that remelting-induced microstructural modifications affect material removal mechanisms without proportionally destabilizing the frictional regime. These findings suggest that in-layer laser remelting represents a process-integrated parameter with measurable consequences for surface integrity and tribological performance, though the generalizability of these results warrants validation across broader experimental conditions. Full article

In this work, the deposition of graphene coatings on substrates of an ELI grade Ti-6Al-4V alloy was carried out using the Plasma Enhanced Chemical Vapor Deposition (PECVD) technique. The purpose of this study was to improve the surface properties of the material. The characterization of the material was carried out by non-destructive techniques, such as Raman Spectroscopy and Thermoelectric Potential. A preliminary characterization of Ti substrates was carried out by Raman spectroscopy. Conversely, thermoelectric potential tests were conducted using three distinct tip systems and four different temperature gradients. Lastly, some surface roughness measurements were conducted on all samples, both coated and uncoated. Graphene micro-structured coatings were obtained using a plasma-activated mixture of hydrogen and methane gases with an equimolar feed ratio (1:1 H₂:CH₄) at a temperature of 850 °C and a plasma exposure of 150 Watts and duration of 15 min. Raman spectra verified the presence of uniform micrometric graphene on the surface of Ti substrates. Graphene-coated Ti-6Al-4V ELI substrates exhibited Seebeck coefficient values indicating metallic-like behavior and suitability for thermoelectric sensing. In the eddy current analyses, it was found that low frequencies provided the highest sensitivity for differentiating between samples. An inverse relationship was identified between substrate thickness and phase angle, and a direct relationship with calculated electrical conductivity was also identified. This direct relation is attributed to penetration depth and interactions due to the chemical nature of the substrate and coating. Despite a slight increase in surface roughness after graphene deposition, values remained comparable to the base alloy, preserving compatibility for biomedical integration. Thermoelectric potential measurements revealed enhanced sensitivity to surface morphology and interfacial effects when high-sensitivity probe configurations were employed. These results support potential applications in implantable or wearable temperature sensors, energy harvesting devices, and smart biomedical interfaces. The thickness of the graphene coating was also characterized by SEM, which showed that the films deposited by PECVD are about 1 micron thick. Full article

The present work focuses on the fatigue behaviour of the additively manufactured Ti6Al4V-ELI alloy, which is mainly used for biomedical applications such as implants and prosthetics. It was found that the studied material is characterised by an almost fully dense (relative density higher than 99.97%) microstructure, which consists of needle-like α-Ti lamellae with β-Ti phase on their boundaries. Fatigue tests showed that the lifespan of the Ti6Al4V-ELI alloy produced by laser powder bed fusion within the stress amplitude of 300–400 MPa lies in the range of 10⁶–10⁷ cycles. Scanning electron microscope fractographic images showed that the surface of the studied material plays the most important role in determining the material’s lifetime. The findings of this study contribute to a deeper understanding of the structure–property relationships in terms of extremely damaging fully reversible (tension-compression) fatigue measurements in additively manufactured Ti6Al4V-ELI and support the development of more reliable biomedical components, especially hip joint prostheses. Full article

Bacterial infections and the lack of bioactivity of titanium implants and their alloys remain critical challenges for the long-term performance and clinical success of these devices. These issues arise from the undesirable combination of early microbial adhesion and the limited ability of metallic surfaces to form a bioactive interface capable of supporting osseointegration. To address these limitations simultaneously, this study employed electrical discharge machining (EDM), which enables surface topography modification and in situ incorporation of bioactive ions from the dielectric fluid. Ti-6Al-4V ELI surfaces were modified using two dielectric fluids, a fluorine/phosphorus-based solution (DF1-F) and a calcium/phosphorus-based solution (DF2-Ca), under positive and negative polarities. The recast layer was characterized by SEM and EDS, while bioactivity was evaluated through immersion in simulated body fluid (SBF) for up to 21 days. Antibacterial performance was assessed against Staphylococcus aureus at 6 h and 24 h of incubation. The results demonstrated that dielectric composition and polarity strongly influenced ionic incorporation and the structural stability of the modified layers. The DF2-Ca(+) condition exhibited the most favorable bioactive response, with Ca/P ratios closer to hydroxyapatite and surface morphologies typical of mineralized coatings. In antibacterial assays, Ca/P-containing surfaces significantly decreased S. aureus attachment (>80–90%). Overall, EDM with Ca/P-containing dielectrics enables the fabrication of Ti-6Al-4V surfaces with enhanced mineralization capacity and anti-adhesive effects against Gram-positive bacteria, reinforcing their potential for multifunctional biomedical applications. Full article

In this study, the influence of the electrochemical oxidation process on Ti-Grad 23 alloy (Ti6Al4V ELI) in 1 M H₃PO₄, under applied voltages between 200 and 275 V, at a constant time of 1 min, is analyzed. The structural, morphological, and wettability properties of the TiO₂ anodic layers obtained were investigated by X-ray diffraction (XRD), energy dispersive electron microscopy (SEM-EDS), contact angle measurements, and chemical corrosion. XRD analysis showed the development and intensification of anatase and brookite phases, with increased crystallite size after electrochemical oxidation. SEM/EDS characterization confirmed the formation of an inhomogeneous porous TiO₂ layer, with pore diameters ranging from 98 to 139 nm and a significant increase in oxygen content. Contact angle measurements demonstrate enhanced hydrophilicity for all oxidized samples, with progressively lower values as the applied voltage increased. Chemical corrosion tests in Ringer solution and Ringer + 40 g/L H₂O₂ indicated that oxidized surfaces maintain structural stability in physiological media, whereas exposure to oxidizing environments induces partial pore closure and crack formation due to localized corrosion. The optimal anodizing condition was identified at 200 V for 1 min, yielding a uniform distribution of pores and improved morpho-functional characteristics suitable for biomedical applications. The optimal electrochemical oxidation conditions were identified at 200 V for 1 min, ensuring a uniform pore distribution. Full article

The influence of electron beam melting (EBM) scan speed on the corrosion, nano-biotribological, and cellular adhesion properties of Ti-6Al-4V-ELI (extra low interstitials) was systematically investigated. Specimens were fabricated using five different scanning speeds, and tribological performance was assessed via reciprocating dry wear tests, while corrosion behaviour was evaluated through monitoring the open circuit potential and anodic potentiodynamic polarization tests in Ringer’s solution. Human fibroblasts from the FN1 cell line were used to assess cell adhesion. Specimens produced using scanning speeds of 4530 mm·s⁻¹ and 4983 mm·s⁻¹ exhibited increased passive current densities, indicating reduced corrosion protection, although all surfaces maintained the passive film characteristic. Tribological behaviour was strongly dependent on scan speed, with wear rate and penetration depth increasing at higher speeds; notably, an intermediate scan speed produced a surface with minimal wear and penetration depth despite a wide wear track, suggesting enhanced resistance to tribological degradation. Fibroblast cultures demonstrated robust adhesion and spindle-shaped morphology across all samples, with the disk produced using a scanning speed of 4983 mm·s⁻¹ showing the highest surface coverage, highlighting the role of EBM process parameters in modulating surface properties relevant to cell–biomaterial interactions. These findings underscore the critical influence of scan speed on the multifunctional performance of Ti-6Al-4V-ELI for biomedical applications. Full article

Background: The implant–abutment interface has been thoroughly examined due to its impact on the success of implant healing and longevity. Removing the abutment is advantageous, but it changes the biomechanics of the implant fixture and restoration. This in vitro three-dimensional finite element analytical (FEA) study aims to evaluate the distribution of von Mises stress (VMS) in abutment-free and three additional implant abutment connections composed of various titanium alloys. Materials and methods: A three-dimensional implant-supported single-crown prosthesis model was digitally generated on the mandibular section using a combination of microcomputed tomography imaging (microCT), a computer-assisted designing (CAD) program (SolidWorks), Analysis of Systems (ANSYS), and a 3D digital scan (Visual Computing Lab). Four digital models [A (BioHorizons), B (Straumann AG), C abutment-free (Matrix), and D (TRI)] representing three different functional biomaterials [wrought Ti-6Al-4Va ELI, Roxolid (85% Ti, 15% Zr), and Ti-6Al-4V ELI] were subjected to simulated static/cyclic static loading in axial/oblique directions after being restored with highly translucent monolithic zirconia restoration. The stresses generated on the implant fixture, abutment, crown, screw, cortical, and cancellous bones were measured. Results: The highest VMSs were generated by the abutment-free (Model C, Matrix) implant system on the implant fixture [static (32.36 Mpa), cyclic static (83.34 Mpa)], screw [static (16.85 Mpa), cyclic static (30.33 Mpa), oblique (57.46 Mpa)], and cortical bone [static (26.55), cyclic static (108.99 Mpa), oblique (47.8 Mpa)]. The lowest VMSs in the implant fixture, abutment, screw, and crown were associated with the binary alloy Roxolid [83–87% Ti and 13–17% Zr]. Conclusions: Abutment-free implant systems generate twice the stress on cortical bone than other abutment implant systems while producing the highest stresses on the fixture and screw, therefore demanding further clinical investigations. Roxolid, a binary alloy of titanium and zirconia, showed the least overall stresses in different loadings and directions. Full article

This work presents a non-destructive methodology to estimate the residual porosity and mechanical properties of titanium foams produced via Hot Isostatic Pressing (HIP) followed by solid-state foaming (SSF). Pulsed laser-spot thermography was employed to measure thermal diffusivity in compact and foamed Ti6Al4V-ELI samples derived from powders of different granulometries. A power-law correlation between thermal diffusivity and porosity was used to estimate post-foaming porosity, which was then used to predict elastic modulus, yield strength, and ultimate tensile strength. Results highlight the potential of thermal diffusivity as a reliable indicator of structural performance, offering a rapid and fully non-destructive route for evaluating metallic foams in biomedical and aerospace applications. Full article

Background: Mandibular defects caused by trauma or tumor resection pose significant challenges in both functional and aesthetic reconstruction. Additive manufacturing (AM) technologies offer promising solutions for surgical planning and personalized treatment. Objectives: This review aims to evaluate current trends in the application of AM technologies for mandibular resection and reconstruction, with a particular focus on material selection, clinical integration, and technology-specific advantages. Methods: A structured literature review was performed using PubMed, Scopus, Web of Science, and Google Scholar. Studies published between January 2020 and May 2025 were screened using the following inclusion criteria: original peer-reviewed English-language research involving AM in mandibular surgery. The exclusion criteria included review articles, non-English sources, and non-mandibular studies. A total of 77 studies met the inclusion criteria and were analyzed in this review. Results: Based on the literature review conducted from 2020 to 2025, the most common restorative methods for the mandible using additively manufactured models include reconstruction with a titanium surgical plate bent to the curvature of the edges and angle of the mandible or a personalized titanium or PEEK surgical plate made directly based on the patient’s diagnosis. Implants made of Ti-6AL-4V ELI and bioceramic scaffolds are also used in the reconstruction process. They are developed based on patient diagnostic data and effectively replace the loss of mandibular bone structure. In addition, based on models and surgical guides created using additive manufacturing techniques, the performance of autogenous grafts from the fibula or iliac crest has improved significantly when used with a titanium implant plate. Conclusions: Additive manufacturing supports highly personalized and accurate mandibular reconstruction. The advantages of these methods include a reduced overall duration of procedures, a lower health risk for patients due to less reliance on general anesthesia, a near perfect match between the implant and the remaining hard tissues, and satisfactory aesthetic outcomes. However, success depends on the appropriate selection AM technology and material, particularly in load-bearing applications. Full article