Search Results (75)

TiAl alloy offers advantages including low density, high specific strength and stiffness, and excellent high-temperature creep resistance. It is widely used in the aerospace, automotive, and chemical sectors, as well as in other fields. However, at temperatures of 800 °C and above, it forms a porous oxide film predominantly composed of TiO₂, which fails to provide adequate protection. Applying high-temperature protective coatings is therefore essential. Oxides demonstrating protective efficacy at elevated temperatures include Al₂O₃, Cr₂O₃, and SiO₂. The Pilling–Bedworth Ratio (PBR)—defined as the ratio of the volume of the oxide formed to the volume of the metal consumed—serves as a critical criterion for assessing oxide film integrity. A PBR value greater than 1 but less than 2 indicates superior film integrity and enhanced oxidation resistance. Among common oxides, Al₂O₃ exhibits a PBR value within this optimal range (1−2), rendering aluminum-based compound coatings the most extensively utilized. Aluminum coatings can be applied via methods such as pack cementation, thermal spraying, and hot-dip aluminizing. Pack cementation, being the simplest to operate, is widely employed. In this study, a powder mixture with the composition Al:Al₂O₃:NH₄Cl:CeO₂ = 30:66:3:1 was used to aluminize γ-TiAl intermetallic compound specimens via pack cementation at 600 °C for 5 h. Subsequent isothermal oxidation at 900 °C for 20 h yielded an oxidation kinetic curve adhering to the parabolic rate law. This treatment significantly enhanced the high-temperature oxidation resistance of the γ-TiAl intermetallic compound, thereby broadening its potential application scenarios. Full article

Titanium alloys are frequently subjected to surface treatments to enhance their biocompatibility and corrosion resistance in biological environments. Plasma electrolytic oxidation (PEO) is an environmentally friendly electrochemical technique capable of forming oxide layers characterized by high corrosion resistance, biocompatibility, and strong adhesion to the substrate. In this study, the PEO process was performed using a low-melting-point ternary eutectic electrolyte composed of Ca(NO₃)₂–NaNO₃–KNO₃ (41–17–42 wt.%) with the addition of ammonium dihydrogen phosphate (ADP). The use of this electrolyte system enables a reduction in the operating temperature from 280 to 160 °C. The effects of applied voltage from 200 to 400V, current frequency from 50 to 1000 Hz, and ADP concentrations of 0.1, 0.5, 1, 2, and 5 wt.% on the growth of titanium oxide composite coatings on a Ti-6Al-4V substrate were investigated. The incorporation of Ca and P was confirmed by phase and chemical composition analysis, while scanning electron microscopy (SEM) revealed a porous surface morphology typical of PEO coatings. Corrosion resistance in Hank’s solution, evaluated via Tafel plot fitting of potentiodynamic polarization curves, demonstrated a substantial improvement in electrochemical performance of the PEO-treated samples. The corrosion current decreased from 552 to 219 nA/cm², and the corrosion potential shifted from −102 to 793 mV vs. the Reference Hydrogen Electrode (RHE) compared to the uncoated alloy. These findings indicate optimal PEO processing parameters for producing composite oxide coatings on Ti-6Al-4V alloy surfaces with enhanced corrosion resistance and potential bioactivity, which are attributed to the incorporation of Ca and P into the coating structure. Full article

A SiO₂-Al₂O₃-B₂O₃-CaO-MgO-Na₂O glass-based protective lubricant coating was developed for Ti-6Al-4V alloy forging, featuring a fully non-toxic formulation. The coating consisted of a composite glass matrix formed by blending two phases with distinct softening temperatures, extending its operational window to 700–950 °C. The composite glass showed initial softening at 700 °C and complete melting at 800 °C, with contact angle measurements confirming superior wettability (θ < 90°) across the forging range (800~950 °C). With an increase in temperature, the surface tension of the composite glass melt decreased, and subsequently, the wettability of the composite glass melt was significantly improved. XRD revealed that the uncoated Ti-6Al-4V formed a 22 μm thick rutile TiO₂ scale with a porous structure and interfacial cracks, while the coated sample retained an amorphous glass layer with no TiO₂. Cross-sectional SEM showed a crack-free, poreless interface with strong metallurgical bonding, in contrast to the uncoated sample’s spalled oxide layer. EDS showed minimal oxygen diffusion of the glass coating into the substrate. Ring upsetting tests showed that the coating reduced friction from 0.5–0.7 to 0.3 (50–57% decrease). Collectively, the glass protective lubricant coating showed good performance in terms of protection and lubrication. Full article

The aim of the study was to assess the mechanical and material properties of porous titanium capsules, produced by 3D printing via the DMLS (Direct Metal Laser Sintering) technique based on their potential application as carriers for anticancer drugs. The study used capsules made from the Ti-6Al-4V alloy, and analyzes the impact of geometric parameters, structural features, and printing angles (0°, 45°, and 90°) on their compressive strength. A total of 36 capsules were tested, 18 of type KTD and 18 of type KTM, each in two loading directions. The surface roughness and damage characteristics resulting from mechanical loading have also been evaluated. Statistical analysis of the results was performed using Student’s t-test. The results show that the capsules printed at an angle of 45° are characterized by the highest compressive strength, while their resistance significantly exceeds the values typical of human bone tissue. Additionally, the observed damage does not lead to the formation of sharp edges or loose fragments, which confirms the safety of their use in the body. The high surface roughness promotes tissue integration and limits capsule migration after implantation. The analyses confirm the potential of 3D-printed titanium capsules as effective and safe drug carriers in personalized anticancer therapy. Full article

Critical-sized bone defects or CSDs result from bone loss due to trauma, tumor removal, congenital defects, or degenerative diseases. Though autologous bone transplantation is the current gold standard in treating CSDs, its limitations include donor-site morbidity, unavailability of donor bone tissues, risk of infection, and mismatch between the bone geometry and the defect site. Customized scaffolds fabricated using 3D printing and biocompatible materials can provide mechanical integrity and facilitate osseointegration. Ti-6Al-4V (Ti64) is one of the most widely used commercial alloys in orthopedics. To avoid elastic modulus mismatch between bones and Ti64, it is imperative to use porous lattice structures. Ti64 scaffolds with diamond, cubic, and triply periodic minimal surface (TPMS) gyroid lattice architectures were fabricated using selective laser melting (SLM)with pore sizes ranging from 300 to 900 μm using selective laser melting and evaluated for mechanical and biological performance. Increasing pore size led to higher porosity (up to 90.54%) and reduced mechanical properties. Young’s modulus ranged from 13.18 GPa to 1.01 GPa, while yield stress decreased from 478.16 MPa to 14.86 MPa. Diamond and cubic scaffolds with 300–600 μm pores exhibited stiffness within the cortical bone range, while the 900 μm diamond scaffold approached trabecular stiffness. Gyroid scaffolds (600–900 μm) also showed modulus and yield strength within the cortical bone range but were not suitable for trabecular applications due to their higher stiffness. Cytocompatibility was confirmed through leachate analysis and DAPI-stained osteoblast nuclei. The biological evaluation reported maximum cell adherence in lower pore sizes, with gyroid scaffolds showing a statistically significant (p < 0.01) increase in cell proliferation. These findings suggest that 300–600 μm lattice scaffolds offer an optimal balance between mechanical integrity and biological response for load-bearing bone repair. Full article

Titanium and its alloy scaffolds are widely utilized in clinical settings; however, their biologically inert surfaces and inherent mechanical characteristics impede osteogenesis and soft tissue integration, thereby limiting their application. Selective laser melting (SLM) was employed to fabricate scaffolds with matched cortical bone mechanical properties, achieving a composite coating of hydroxyapatite complexed with trace elements of silicon, strontium, and fluoride (mHA), along with type I collagen (Col I) and fibrinogen (Fg), thus activating the scaffold surface. Initially, we utilized the excellent adhesive properties of dopamine to co-deposit mHA and polydopamine (PDA) onto porous Ti-6Al-4V scaffolds, which was followed by immobilization of type I collagen and fibrinogen onto PDA. This bioinorganic/bioprotein composite coating, formed via PDA bonding, exhibits excellent stability. Moreover, in vitro cell experiments demonstrate excellent biocompatibility of the porous Ti-6Al-4V scaffold with composite bioactive coatings on its surface. Preosteoblasts (MC3T3-E1) and human keratinocytes (HaCaT) exhibit enhanced adhesion and proliferation activity, and the osteogenic performance of the scaffold is significantly improved. The PDA-mHA-Col I-Fg composite-coated porous titanium alloy scaffold holds significant promise in enhancing the efficacy of percutaneous bone transplantation and requires further investigation. Full article

Open-cellular Ti6Al4V lattice structures have found application in porous scaffolds that can match the properties of human bone, which consists of a dense cortical shell and a less-dense cancellous core with an apparent density ranging from 1.3 to 2.1 g/cm³ and 0.1 to 1.3 g/cm³, respectively. The implantation of porous scaffolds is essential for treating large bone defects and must mimic natural bone’s geometric and mechanical behaviour. Functionally graded lattice structures offer spatial variation in mechanical properties, making them suitable for biomedical applications. While the mechanical behaviour of lattice structures is typically evaluated under compression, their flexural properties remain largely underexplored. The aim of this research is to assess the flexural rigidity of a novel lattice material, namely Triply Arranged Octagonal Rings (TAORs), with both uniform and functionally graded architectures, to reproduce the flexural properties of long bones. Titanium alloy scaffolds have been designed with a TAOR cell, whose relative densities range from 10% to 40% with full and hollow sections. Morphological considerations were carried out during the design process to obtain a scaffold geometry which complies with the optimal characteristics required to promote osteointegration. A non-linear finite element (FE) model was developed. Three- and four-point bending tests were simulated, and the results were compared with those of a bone surrogate for long bones. Scaffolds with 10% and 20% relative densities showed flexural rigidity close to that of the bone surrogate and proved to be potential candidates for application in biomedical devices for long bones. Full article

Ti6Al4V is widely utilized in orthopedic implants due to its excellent mechanical properties, corrosion resistance, and biocompatibility. However, traditional solid titanium implants exhibit an elastic modulus (90–115 GPa) significantly higher than that of human bone (10–30 GPa), leading to stress shielding and implant loosening. To address this, porous titanium alloys have been developed to better match bone elasticity. Additive manufacturing, particularly selective laser melting (SLM), enables precise control over pore size and porosity, thereby tuning mechanical properties. Nevertheless, SLM-produced porous structures often suffer from powder adhesion, which compromises bone integration and patient safety. In this study, bulk Ti6Al4V samples were fabricated via SLM with a fixed laser power of 200 W and varying scanning speeds (800–1400 mm/s). Density measurements and surface defect analysis identified 1200 mm/s as the optimal scanning speed. Cubic unit cell scaffolds with different pore diameters (400, 600, 800 μm) and porosities (60%, 80%) were subsequently designed. Compression tests revealed that scaffolds with a 400 μm pore diameter and 60% porosity exhibited the highest compressive strength (794 MPa) and fracture strain (41.35%). Chemical polishing using a diluted HF-HNO₃ solution (1:2:97) effectively removed adhered powder without significant structural degradation, with 40 min identified as the optimal polishing duration. Full article

This study investigated the effects of plasma electrolytic oxidation (PEO) treatment in a Ca- and P-rich electrolyte on the surface of the Ti-6Al-4V alloy with distinct α/β phase proportions previously induced by heat treatments. The results revealed that the α/β phase proportions were successfully altered by the heat treatment temperatures, forming α phase plates surrounded by β phase precipitates. PEO-treated samples exhibited a thick and microsized porous TiO₂ coating in the anatase and rutile crystalline forms. The oxide layer was depleted by Al and V atoms, while Ca and P were gradually enriched along the coatings. Chemical analysis also indicated the absorption of water and organic molecules into the outer layer. PEO-treated samples had microscale roughness and thickness, hydrophilic behavior, and surface energy mainly formed by the dispersive component. The bulk’s elastic modulus decreased with β phase precipitation, while the alloying elements directly influenced the Vickers microhardness. The corrosion tests indicated a stable and protective layer in the PEO-treated samples, showing better corrosion resistance than untreated ones. Overall, the findings indicated that the α and β phase proportion significantly impacts the mechanical properties, while the PEO treatment acts in the corrosion protection and surface aspects, suggesting that combining both approaches could be a powerful tool in biomedical applications. Full article

This work investigates the fabrication of Ti6Al4V composites manufactured by powder metallurgy through pressureless infiltration. Porous Ti6Al4V alloy compacts with different particle sizes were fabricated by sintering and then, liquid Ag was infiltrated to obtain composites. Computed microtomography was used to analyze the samples before and after infiltration. Numerical flow simulations and dilatometry tests evaluated the kinetics of Ag infiltration into porous Ti6Al4V compacts. Microstructure was observed by SEM and mechanical strength was evaluated by compression tests. Results showed that the pore properties play a crucial role in the infiltration timing and the distribution of the Ag’s liquid. In particular, large pores allowed the infiltration to start a few °C degrees earlier than samples with smaller pores. Three-dimensional images after infiltration showed that most of the pores were filled and the remaining ones were isolated. The resulting microstructure was composed of Ti₂Ag, α-Ti and Ag phases, indicating that the Ag diffusion occurred. Furthermore, the mechanical strength depends on the interparticle neck sizes and the Ag improves the plastic deformation reached during compression tests. The best results were obtained for the samples with larger pore sizes because the resulting mechanical properties (E = 23 GPa and σ_y = 403 MPa) are close to that of human bones, making it the best candidate as an antibacterial material for biomedical use. Full article

Plasma electrolytic oxidation (PEO) has emerged as a promising surface coating technique producing high-quality ceramic coating for light metals like Al, Mg, Ti, and their alloys. AA7075 is one of the commonly used Al alloys for aircraft structures, gears and shafts, and automotives as it provides high yield and tensile strength. However, Al and its alloys have drawbacks that limit their further application. Thus, surface treatments are proposed to improve the metal and its alloy’s properties. In this study, the PEO of AA7075 was carried out with an AC power source under a pulsed unipolar potentiostatic mode at varying voltages of 425 and 450 V in 1000 Hz and at 80% duty cycles of 30 m. The effect of varying voltages on the morphology, coating thickness, and corrosion resistance of the PEO-coated samples was investigated. Surface morphology, elemental distribution, and phase composition were characterized using SEM, EDX, and XRD. A porous structure with a pancake-like shape, a crater, and nodular structures were observed with coating thickness ranges from 12.1 to 55.3 ± 4.67 µm. Al, α-alumina, and γ-alumina were detected in all surface coatings. The PEO-coated sample at 450 V exhibited higher corrosion resistance evaluated via potentiodynamic polarization and EIS. Full article

Hard bone disease is a clinical problem affecting more than 20 million people annually worldwide, with significant health, social, and economic consequences. For successful integration of any implant, the key aspects are bone regeneration, osseointegration at the bone–implant interface, and the mitigation of inflammation. The purpose of this research work is to demonstrate an innovative material system and method of biomaterial preparation for regenerative medicine. A number of studies were carried out for both hydroxyapatite powder and composites. Wet-precipitated synthesized hydroxyapatite was compared to commercial products through accurate physicochemical studies that confirmed the high purity of the obtained calcium phosphate without any impurities. Ti/HAp composites before and after sintering were compared by XRF, XRD, SEM, EDS, PSA, and roughness measurements, and the Vickers microhardness was analyzed. The fabrication of the biomaterial was based on a bottom-up approach, which involved fabricating HAp particles with specific morphologies using powder metallurgy (PM) to sinter Ti composites. The resulting gradient structures consisting of two compositions (5%HAp%5CMC and 10%HAp10%CMC) mimic the structure of bone tissue. The created pores of 10–100 µm in size will allow bone cells to penetrate the implant and regenerate bone. In turn, the introduction of hydroxyapatite into the material reduces the microhardness of the composite and introduces properties such as bioactivity. The developed composite material contains a combination of Ti alloy and hydroxyapatite (HAp), creating an excellent biomaterial that promotes bone growth and eliminates the problem of implant loosening by integrating it into the bone. This material requires further research, especially biological research. However, it shows promising potential for further experiments. Full article

Ti and its alloys have been vastly employed in the manufacturing of biomedical implants for orthopedy and dentistry, especially the Ti-6Al-4V alloy (wt%), which is the most-used Ti alloy worldwide. However, the ion release of Al and V in the long term has been related to harmful effects on the human body. In this scenario, surface modification strategies, such as plasma electrolytic oxidation (PEO), have often been performed in Ti alloys to match the clinical needs. This study evaluated the effect of electrical AC parameters on the surface of the commercial Ti-6Al-4V alloy immersed in ZrO₂-rich electrolytic solution regarding the chemical, physical, structural, and topographical aspects. Then, the selected PEO-treated samples surpassed the electrochemical test in saline solution. The results indicated that the electrical AC parameters affect the duration and intensity of the oxidative reactions and plasma micro-discharge steps, resulting in porous and thick oxide layers. PEO treatment promoted bio-camouflage of the surface, enriching it with TiO₂, ZrO₂, and ZrTiO₄ compounds and depleting it of Al and V. After screening the PEO-treated samples and their corrosion behavior, the results indicated that the porous ZrO₂–TiO₂ ceramic coatings in the Ti-6Al-4V alloy can be a viable alternative for the manufacturing of biomedical implants. Full article

This study investigates the impact of varying powder size on porosity, pore parameters, and intermetallic phase reaction during the reactive sintering of porous TiAl alloys. Ti52Al48 alloys were prepared using coarse (200 mesh) and fine (325 mesh) Ti powders through elemental powder metallurgy and were subsequently sintered at different temperatures, 600 and 1200 °C. Our findings reveal a consistent pore morphology and intermetallic phase microstructure across both alloys. However, samples containing fine Ti powder exhibited a higher number density of small pores compared to those incorporating coarse Ti powders. Additionally, alloys prepared with fine Ti powders demonstrated a higher porosity than those prepared with coarse powders. Consequently, fine Ti powder promoted enhanced diffusion between Ti and Al during sintering, as reflected by the lower onset temperature and enthalpy of intermetallic reaction during sintering. Full article

In response to concerns of potential cytotoxicity and adverse tissue reactions caused by vanadium and aluminum in the currently used biomaterial Ti-6Al-4V, the Ti–20Zr alloy was evaluated in this study because it has been suggested as a candidate for human body implant material. The Ti-20Zr alloy was obtained by vacuum-melting, followed by heat treatment at 1000 °C for 1 h, and then air-cooled. Optical and scanning electron microscopy revealed that the sample had an α and β lamellar microstructure. Analysis showed that the mechanical properties, in terms of hardness measurements performed at low loads, were significantly different between the two phases. Thus, it was found out that the α phase is softer by about 30% compared to the β phase. The Electrochemical Impedance Spectroscopy technique (EIS) was employed to study the electrochemical behavior in simulated body fluid (SBF). The electrochemical behavior demonstrated that Ti-20Zr alloy exhibits excellent corrosion resistance due to the stable oxide layer formed on its surface. SEM and EDS investigations showed that the surface topography, after electrochemical studies, is characterized by a porous film with increased oxygen content, which might be suitable for the osteoinductive growth of bone. Full article