Laser-deposited Ti-Nb-Zr-Ta orthopedic alloys

Additive manufacturing of Ni-free Ti-based shape memory alloys: A review

Ni-free Ti-based Shape Memory Alloys composed of non-toxic elements have been studied as promising candidates for biomedical applications. However, high tool wear makes them complex to manufacture with conventional techniques. In this way, Additive Manufacturing technologies allow to fabricate complex three-dimensional structures overcoming their poor workability. Control of composition, porosity, microstructure, texture and processing are the key challenges for developing Ni-free Ti-based Shape Memory Alloys. This article reviews various studies conducted on the Additive Manufacturing of Ni-free Ti-based shape memory alloys, including their processing, microstructures and properties.

Gallium-Containing Materials and Their Potential within New-Generation Titanium Alloys for Biomedical Applications

With the rising demand for implantable orthopaedic medical devices and the dominance of device-associated infections, extensive research into the development of novel materials has been prompted. Among these, new-generation titanium alloys with biocompatible elements and improved stiffness levels have received much attention. Furthermore, the development of titanium-based materials that can impart antibacterial function has demonstrated promising results, where gallium has exhibited superior antimicrobial action. This has been evidenced by the addition of gallium to various biomaterials including titanium alloys. Therefore, this paper aims to review the antibacterial activity of gallium when incorporated into biomedical materials, with a focus on titanium-based alloys. First, discussion into the development of new-generation Ti alloys that possess biocompatible elements and reduced Young's moduli is presented. This includes a brief review of the influence of alloying elements, processing techniques and the resulting biocompatibilities of the materials found in the literature. The antibacterial effect of gallium added to various materials, including bioglasses, liquid metals, and bioceramics, is then reviewed and discussed. Finally, a key focus is given to the incorporation of gallium into titanium systems for which the inherent mechanical, biocompatible, and antibacterial effects are reviewed and discussed in more detail, leading to suggestions and directions for further research in this area.

Laser-Deposited Beta Type Ti-42Nb Alloy with Anisotropic Mechanical Properties for Pioneering Biomedical Implants with a Very Low Elastic Modulus

Present commercial titanium alloy implants have an elastic modulus higher than 100 GPa, whereas that of the cortical bone is much smaller (17−28 GPa). This elastic modulus mismatch produces a stress shielding effect and the resorption of the bone surrounding the implant. In the present work, a <100> fiber texture is developed in β type Ti-42Nb (wt%) alloy ingots generated by laser-directed energy deposition (LDED) in order to achieve anisotropic mechanical properties. In addition, we demonstrate that laser-deposited β type Ti-42Nb alloy ingots with an intense <100> fiber texture exhibit a very low elastic modulus in the building direction (Ez < 50 GPa) and high yield (σ0.2z > 700 MPa) and tensile (UTSz > 700 MPa) strengths. Laser-deposited Ti-42Nb alloy enhances the osteoinductive effect, promoting the adhesion, proliferation, and spreading of human osteoblast-like cells. Hence, we propose that laser-deposited β type Ti-42Nb alloy is a potentially promising candidate for the manufacturing of pioneering biomedical implants with a very low elastic modulus that can suppress stress shielding.

Mechanobiologically optimized Ti-35Nb-2Ta-3Zr improves load transduction and enhances bone remodeling in tilted dental implant therapy

The tilted implant with immediate function is increasingly used in clinical dental therapy for edentulous and partially edentulous patients with excessive bone resorption and the anatomic limitations in the alveolar ridge. However, peri-implant cervical bone loss can be caused by the stress shielding effect. Herein, inspired by the concept of “materiobiology”, the mechanical characteristics of materials were considered along with bone biology for tilted implant design. In this study, a novel Ti–35Nb–2Ta–3Zr alloy (TNTZ) implant with low elastic modulus, high strength and favorable biocompatibility was developed. Then the human alveolar bone environment was mimicked in goat and finite element (FE) models to investigate the mechanical property and the related peri-implant bone remodeling of TNTZ compared to commonly used Ti–6Al–4V (TC4) in tilted implantation under loading condition. Next, a layer-by-layer quantitative correlation of the FE and X-ray Microscopy (XRM) analysis suggested that the TNTZ implant present better mechanobiological characteristics including improved load transduction and increased bone area in the tilted implantation model compared to TC4 implant, especially in the upper 1/3 region of peri-implant bone that is “lower stress”. Finally, combining the static and dynamic parameters of bone, it was further verified that TNTZ enhanced bone remodeling in “lower stress” upper 1/3 region. This study demonstrates that TNTZ is a mechanobiological optimized tilted implant material that enhances load transduction and bone remodeling.

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The mechanical properties and deformation mechanisms of Ti–35Nb–2Ta–3Zr alloys were studied.

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The cell biocompatibility, a layer-by-layer correlation of the finite element and X-ray Microscopy analysis were evaluated.

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Ti–35Nb–2Ta–3Zr implant improves load transduction and enhances bone remodeling in tilted implantation models.

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Mechanobiologically optimized Ti–35Nb–2Ta–3Zr alloy meets the clinical application requirements of tilted implant therapy.

In-Situ Laser Directed Energy Deposition of Biomedical Ti-Nb and Ti-Zr-Nb Alloys from Elemental Powders

In order to achieve the required properties of titanium implants, more resources and research are needed to turn into reality the dream of developing the perfect implant material. The objective of this study was to evaluate the viability of the Laser Directed Energy Deposition to produce biomedical Ti-Nb and Ti-Zr-Nb alloys from elemental powders (Ti, Nb and Zr). The Laser Directed Energy Deposition is an additive manufacturing process used to build a component by delivering energy and material simultaneously. The material is supplied in the form of particles or wire and a laser beam is employed to melt material that is selectively deposited on a specified surface, where it solidifies. Samples with different compositions are characterized to analyze their morphology, microstructure, constituent phases, mechanical properties, corrosion resistance and cytocompatibility. Laser-deposited Ti-Nb and Ti-Zr-Nb alloys show no relevant defects, such as pores or cracks. Titanium alloys with lower elastic modulus and a significantly higher hardness than Ti grade 2 were generated, therefore a better wear resistance could be expected from them. Moreover, their corrosion resistance is excellent due to the formation of a stable passive protective oxide film on the surface of the material; in addition, they also possess outstanding cytocompatibility.

New Ti–35Nb–7Zr–5Ta Alloy Manufacturing by Electron Beam Melting for Medical Application Followed by High Current Pulsed Electron Beam Treatment

High-current pulsed electron-beam (PEB) treatment was applied as a surface finishing procedure for Ti–35Nb–7Zr–5Ta (TNZT) alloy produced by electron beam melting (EBM). According to the XRD results the TNZT alloy samples before and after the PEB treatment have shown mainly the single body-centered cubic (bcc) β-phase microstructures. The crystallite size, dislocation density, and microstrain remain unchanged after the PEB treatment. The investigation of the texture coefficient at the different grazing angle revealed the evolution of the crystallite orientations at the re-melted zone formed at the top of the bulk samples after the PEB treatment. The top-view SEM micrographs of the TNZT samples treated by PEB exhibited the bcc β-phase grains with an average size of ~85 μm. TEM analysis of as-manufactured TNZT alloy revealed the presence of the equiaxed β-grains with the fine dispersion of nanocrystalline α and NbTi4 phases together with β-Ti twins. Meanwhile, the β phase regions free of α phase precipitation are observed in the microstructure after the PEB irradiation. Nanoindentation tests revealed that the surface mechanical properties of the melted zone were slightly improved. However, the elastic modulus and microhardness in the heat-affected zone and the deeper regions of the sample were not changed after the treatment. Moreover, the TNZT alloy in the bulk region manufactured by EBM displayed no significant change in the corrosion resistance after the PEB treatment. Hence, it can be concluded that the PEB irradiation is a viable approach to improve the surface topography of EBM-manufactured TNZT alloy, while the most important mechanical parameters remain unchanged.

Superelastic Behavior of Ti-Nb Alloys Obtained by the Laser Engineered Net Shaping (LENS) Technique

The effect of Nb content on microstructure, mechanical properties and superelasticity was investigated for a series of Ti-xNb alloys, fabricated by the laser engineered net shaping method, using elemental Ti and Nb powders. The microstructure of as-deposited materials consisted of columnar β-phase grains, elongated in the built direction. However, due to the presence of undissolved Nb particles during the deposition process, an additional heat treatment was necessary. The observed changes in mechanical properties were explained in relation to the phase constituents and deformation mechanisms. Due to the elevated oxygen content in the investigated materials (2 at.%), the specific deformation mechanisms were observed at lower Nb content in comparison to the conventionally fabricated materials. This made it possible to conclude that oxygen increases the stability of the β phase in β–Ti alloys. For the first time, superelasticity was observed in Ti–Nb-based alloys fabricated by the additive manufacturing method. The highest recoverable strain of 3% was observed in Ti–19Nb alloy as a result of high elasticity and reverse martensitic transformation stress-induced during the loading.

Direct Synthesis of Fe-Al Alloys from Elemental Powders using Laser Engineered Net Shaping

The laser engineered net shaping (LENS®) process is shown here as an alternative to melting, casting, and powder metallurgy for manufacturingiron aluminides. This technique was found to allow for the production ofFeAl and Fe₃Al phases from mixtures of elemental iron and aluminum powders. Theinsitusynthesis reduces the manufacturing cost and enhances the manufacturing efficiency due to the control of the chemical and phase composition of the deposited layers. The research was carried out on samples with different chemical compositionsthat were deposited on the intermetallic substrates that were produced by powder metallurgy. The obtained samples withthe desired phase composition illustrated that LENS® technology can be successfully applied to alloys synthesis.

Comparison of the Microstructure and Biocorrosion Properties of Additively Manufactured and Conventionally Fabricated near β Ti-25Nb-3Zr-3Mo-2Sn Alloy

The microstructure and biodegradability of a near β Ti-25Nb-3Zr-3Mo-2Sn alloy produced by laser engineered net shaping have been compared to those of alloys produced via casting and cold rolling in order to identify the key effects of processing pathways on the development of microstructure and biocorrosion properties. Results confirm the significant influence of processing technique on microstructure and concomitant biocompatibility of the alloy. Tests using mesenchymal stem cells confirm the ability of the additively manufactured alloy to support cell adhesion and spreading.

Hypersensitivity reactions to metallic implants - diagnostic algorithm and suggested patch test series for clinical use

Cutaneous and systemic hypersensitivity reactions to implanted metals are challenging to evaluate and treat. Although they are uncommon, they do exist, and require appropriate and complete evaluation. This review summarizes the evidence regarding evaluation tools, especially patch and lymphocyte transformation tests, for hypersensitivity reactions to implanted metal devices. Patch test evaluation is the gold standard for metal hypersensitivity, although the results may be subjective. Regarding pre-implant testing, those patients with a reported history of metal dermatitis should be evaluated by patch testing. Those without a history of dermatitis should not be tested unless considerable concern exists. Regarding post-implant testing, a subset of patients with metal hypersensitivity may develop cutaneous or systemic reactions to implanted metals following implant. For symptomatic patients, a diagnostic algorithm to guide the selection of screening allergen series for patch testing is provided. At a minimum, an extended baseline screening series and metal screening is necessary. Static and dynamic orthopaedic implants, intravascular stent devices, implanted defibrillators and dental and gynaecological devices are considered. Basic management suggestions are provided. Our goal is to provide a comprehensive reference for use by those evaluating suspected cutaneous and systemic metal hypersensitivity reactions.