Technology fusion of metal injection moulding and selective laser melting for the manufacture of complex and multifunctional (hydraulic) components

Selective laser melting (SLM) and metallic injection moulding (MIM) are established processes for the production of high-performance metallic components for small and large series. In the aerospace industry, where very high demands are placed on materials and components, both processes are still considered to be relatively new. In both processes, the conventional titanium alloy Ti-6Al-4V can be used in the form of powder. Currently, both technologies are only considered separately. By fusing components of the same type, multifunctional components with a high lightweight construction potential can be produced. In order to generate direct material fusion, the MIM component must be mechanically processed accordingly. In addition, suitable SLM process parameters must be developed in order to ensure both generative construction and high joint strength. To this end, a characterisation of the joining zone and the static joint strength was carried out. Furthermore, pressure test samples were designed and examined both statically and for fatigue strength. Thus, a high static joint strength could be proven. The compression test samples also withstood a fatigue strength of over 1 million cycles.

Development of Bioactive Apatite Nuclei-Precipitated Ti-12Ta-9Nb-6Zr-3V-O Alloy

Ti-12Ta-9Nb-6Zr-3V-O alloy, one of the shape-memory alloys with lower Young’s modulus in comparison with conventional titanium alloy, was treated with sulfuric acid to form roughened surface on the substrate. In order to impart hydroxyapatite formation ability to the Ti-12Ta-9Nb-6Zr-3V-O alloy, apatite nuclei (AN) were precipitated on the roughened surface using simulated body fluid (SBF) adjusted at higher pH than physiological condition. By this treatment, AN-precipitated Ti-12Ta-9Nb-6Zr-3V-O alloy was obtained. The AN-precipitated Ti-12Ta-9Nb-6Zr-3V-O alloy showed high hydroxyapatite formation ability in physiological SBF.

Comparing Initial Wound Healing and Osteogenesis of Porous Tantalum Trabecular Metal and Titanium Alloy Materials

Porous tantalum trabecular metal (PTTM) has long been used in orthopedics to enhance neovascularization, wound healing, and osteogenesis; recently, it has been incorporated into titanium alloy dental implants. However, little is known about the biological responses to PTTM in the human oral cavity. We have hypothesized that, compared with conventional titanium alloy, PTTM has a greater expression of genes specific to neovascularization, wound healing, and osteogenesis during the initial healing period. Twelve subjects requiring at least 4 implants in the mandible were enrolled. Four 3 × 5mm devices, including 2 titanium alloy tapered screws and 2 PTTM cylinders, were placed in the edentulous mandibular areas using a split-mouth design. One device in each group was trephined for analysis at 2 and 4 weeks after placement. RNA microarray analysis and ingenuity pathway analysis were used to analyze osteogenesis gene expression and relevant signaling pathways. Compared to titanium alloy, PTTM samples exhibited significantly higher expressions of genes specific to cell neovascularization, wound healing, and osteogenesis. Several genes—including bone morphogenic proteins, collagens, and growth factors—were upregulated in the PTTM group compared to the titanium alloy control. PTTM materials may enhance the initial healing of dental implants by modifying gene expression profiles.

Biocompatibility and Osteogenic Capacity of Mg-Zn-Ca Bulk Metallic Glass for Rabbit Tendon-Bone Interference Fixation

Mg-based alloys have great potential for development into fixation implants because of their highly biocompatible and biodegradable metallic properties. In this study, we sought to determine the biocompatibility of Mg60Zn35Ca5 bulk metallic glass composite (BMGC) with fabricated implants in a rabbit tendon–bone interference fixation model. We investigated the cellular cytotoxicity of Mg60Zn35Ca5 BMGC toward rabbit osteoblasts and compared it with conventional titanium alloy (Ti6Al4V) and polylactic acid (PLA). The results show that Mg60Zn35Ca5 BMGC may be classed as slightly toxic on the basis of the standard ISO 10993-5. We further characterized the osteogenic effect of the Mg60Zn35Ca5 BMGC extraction medium on rabbit osteoblasts by quantifying extracellular calcium and mineral deposition, as well as cellular alkaline phosphatase activity. The results of these tests were found to be promising. The chemotactic effect of the Mg60Zn35Ca5 BMGC extraction medium on rabbit osteoblasts was demonstrated through a transwell migration assay. For the in vivo section of this study, a rabbit tendon–bone interference fixation model was established to determine the biocompatibility and osteogenic potential of Mg60Zn35Ca5 BMGC in a created bony tunnel for a period of up to 24 weeks. The results show that Mg60Zn35Ca5 BMGC induced considerable new bone formation at the implant site in comparison with conventional titanium alloy after 24 weeks of implantation. In conclusion, this study revealed that Mg60Zn35Ca5 BMGC demonstrated adequate biocompatibility and exhibited significant osteogenic potential both in vitro and in vivo. These advantages may be clinically beneficial to the development of Mg60Zn35Ca5 BMGC implants for future applications.

An Effective Approach for Optimization of a Composite Intramedullary Nail for Treating Femoral Shaft Fractures

The high stiffness of conventional intramedullary (IM) nails may result in stress shielding and subsequent bone loss following healing in long bone fractures. It can also delay union by reducing compressive loads at the fracture site, thereby inhibiting secondary bone healing. This paper introduces a new approach for the optimization of a fiber-reinforced composite nail made of carbon fiber (CF)/epoxy based on a combination of the classical laminate theory, beam theory, finite-element (FE) method, and bone remodeling model using irreversible thermodynamics. The optimization began by altering the composite stacking sequence and thickness to minimize axial stiffness, while maximizing torsional stiffness for a given range of bending stiffnesses. The selected candidates for the seven intervals of bending stiffness were then examined in an experimentally validated FE model to evaluate their mechanical performance in transverse and oblique femoral shaft fractures. It was found that the composite nail having an axial stiffness of 3.70 MN and bending and torsional stiffnesses of 70.3 and 70.9 N⋅m2, respectively, showed an overall superiority compared to the other configurations. It increased compression at the fracture site by 344.9 N (31%) on average, while maintaining fracture stability through an average increase of only 0.6 mm (49%) in fracture shear movement in transverse and oblique fractures when compared to a conventional titanium-alloy nail. The long-term results obtained from the bone remodeling model suggest that the proposed composite IM nail reduces bone loss in the femoral shaft from 7.9% to 3.5% when compared to a conventional titanium-alloy nail. This study proposes a number of practical guidelines for the design of composite IM nails.

Wear Properties of Ti-6Al-4V/Ti-29Nb-13Ta-4.6Zr Combination for Spinal Implants

The wear mechanisms of a conventional titanium alloy, Ti–6Al–4V extra-low interstitial (Ti64), and a new titanium alloy, Ti–29Nb–13Ta–4.6Zr alloy (TNTZ) were studied to investigate the wear properties of a Ti64/TNTZ combination for spinal fixation devices. Balls and discs made of Ti64 and TNTZ were prepared to be used as wear-test specimens. Frictional wear tests of Ti64 and TNTZ discs were carried out against Ti64 and TNTZ balls in air using a ball-on-disc frictional wear testing system. The wear mechanisms were investigated by analysis of worn surfaces and wear debris using scanning electron microscopy. Volume losses of the TNTZ discs were found to be larger than those of the Ti64 discs, regardless of mating ball. Furthermore, the morphologies of wear tracks and debris were found to be different between TNTZ and Ti64 discs. It is considered that the wear mechanism for a Ti64 disc is oxidative wear, whereas that for a TNTZ disc is delamination wear, regardless of mating ball material.

Mechanical Strength and Biocompatibility of Ultrafine-Grained Commercial Purity Titanium

The effect of grain refinement of commercial purity titanium by equal channel angular pressing (ECAP) on its mechanical performance and bone tissue regeneration is reported.In vivostudies conducted on New Zealand white rabbits did not show an enhancement of biocompatibility of ECAP-modified titanium found earlier byin vitrotesting. However, the observed combination of outstanding mechanical properties achieved by ECAP without a loss of biocompatibility suggests that this is a very promising processing route to bioimplant manufacturing. The study thus supports the expectation that commercial purity titanium modified by ECAP can be seen as an excellent candidate material for bone implants suitable for replacing conventional titanium alloy implants.

Surface Plasma Molybdenized Burn-Resistant Titanium Alloy

Conventional titanium alloy may be ignited and burnt under high temperature, high pressure and high gas flow velocity condition. In order to avoid this problem, a new kind of burn-resistant titanium alloy-double glow plasma surface alloying burn-resistant titanium alloy has been developed. Alloying element Mo is induced into the Ti-6Al-4V substrate according to double glow discharge phenomenon, Ti-Mo binary burn-resistant alloy layer is formed on the surface of Ti-6Al-4V alloy. The depth of the surface burn-resistant alloy layer can reach about 100 microns and alloying element concentration can reach 59%. High energy laser ignition experiments reveal that the ignition temperature of alloyed layer with Mo concentration about 10% is about 200°C higher than ignition temperature of Ti-6Al-4V.