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Mace AO, Kurtz MA, Gilbert JL. Fretting and Fretting Corrosion Behavior of Additively Manufactured Ti-6Al-4V and Ti-Nb-Zr Alloys in Air and Physiological Solutions. J Funct Biomater 2024; 15:38. [PMID: 38391891 PMCID: PMC10889821 DOI: 10.3390/jfb15020038] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/12/2023] [Revised: 01/31/2024] [Accepted: 02/02/2024] [Indexed: 02/24/2024] Open
Abstract
Additive manufacturing (AM) of orthopedic implants has increased in recent years, providing benefits to surgeons, patients, and implant companies. Both traditional and new titanium alloys are under consideration for AM-manufactured implants. However, concerns remain about their wear and corrosion (tribocorrosion) performance. In this study, the effects of fretting corrosion were investigated on AM Ti-29Nb-21Zr (pre-alloyed and admixed) and AM Ti-6Al-4V with 1% nano yttria-stabilized zirconia (nYSZ). Low cycle (100 cycles, 3 Hz, 100 mN) fretting and fretting corrosion (potentiostatic, 0 V vs. Ag/AgCl) methods were used to compare these AM alloys to traditionally manufactured AM Ti-6Al-4V. Alloy and admixture surfaces were subjected to (1) fretting in the air (i.e., small-scale reciprocal sliding) and (2) fretting corrosion in phosphate-buffered saline (PBS) using a single diamond asperity (17 µm radius). Wear track depth measurements, fretting currents and scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) analysis of oxide debris revealed that pre-alloyed AM Ti-29Nb-21Zr generally had greater wear depths after 100 cycles (4.67 +/- 0.55 µm dry and 5.78 +/- 0.83 µm in solution) and higher fretting currents (0.58 +/- 0.07 µA). A correlation (R2 = 0.67) was found between wear depth and the average fretting currents with different alloys located in different regions of the relationship. No statistically significant differences were observed in wear depth between in-air and in-PBS tests. However, significantly higher amounts of oxygen (measured by oxygen weight % by EDS analysis of the debris) were embedded within the wear track for tests performed in PBS compared to air for all samples except the ad-mixed Ti-29Nb-21Zr (p = 0.21). For traditional and AM Ti-6Al-4V, the wear track depths (dry fretting: 2.90 +/- 0.32 µm vs. 2.51 +/- 0.51 μm, respectively; fretting corrosion: 2.09 +/- 0.59 μm vs. 1.16 +/- 0.79 μm, respectively) and fretting current measurements (0.37 +/- 0.05 μA vs. 0.34 +/- 0.05 μA, respectively) showed no significant differences. The dominant wear deformation process was plastic deformation followed by cyclic extrusion of plate-like wear debris at the end of the stroke, resulting in ribbon-like extruded material for all alloys. While previous work documented improved corrosion resistance of Ti-29Nb-21Zr in simulated inflammatory solutions over Ti-6Al-4V, this work does not show similar improvements in the relative fretting corrosion resistance of these alloys compared to Ti-6Al-4V.
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Affiliation(s)
- Annsley O Mace
- Clemson-Medical University of South Carolina Bioengineering Program, Department of Bioengineering, Clemson University, Charleston, SC 29464, USA
| | - Michael A Kurtz
- Clemson-Medical University of South Carolina Bioengineering Program, Department of Bioengineering, Clemson University, Charleston, SC 29464, USA
| | - Jeremy L Gilbert
- Clemson-Medical University of South Carolina Bioengineering Program, Department of Bioengineering, Clemson University, Charleston, SC 29464, USA
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Czapczyk K, Zawadzki P, Wierzbicka N. Influence of Dispersed Phase Content on the Mechanical Properties of Electroless Nanocomposite Ni-P/Si 3N 4 and Hybrid Ni-P/Si 3N 4/Graphite Layers Deposited on the AW-7075 Alloy. MATERIALS (BASEL, SWITZERLAND) 2023; 16:6100. [PMID: 37763378 PMCID: PMC10532759 DOI: 10.3390/ma16186100] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/26/2023] [Revised: 08/24/2023] [Accepted: 08/28/2023] [Indexed: 09/29/2023]
Abstract
The article presents the results of mechanical testing of Ni-P/Si3N4 nanocomposite and hybrid Ni-P/Si3N4/graphite coatings deposited on AW-7075 aluminum alloy using the chemical reduction method. In terms of mechanical testing, microhardness was measured, and surface roughness and adhesion of the coatings to the aluminum substrate were determined using the "scratch test" method. The surface morphology of the deposited layers was also analyzed using light microscopy and scanning electron microscopy. Samples made of AW-7075 aluminum alloy with electroless deposited Ni-P/Si3N4 nanocomposite, Ni-P/graphite composite and hybrid Ni-P/Si3N4/graphite coatings with different content of dispersed phases were tested, and also, for comparison purposes, the Ni-P layer that constituted the matrix of the tested materials. Reinforcing phases in the form of silicon nitride nanoparticles and graphite particles were used in the layers. The purpose of the research was a thorough characterization of the coating materials used on aluminum alloys in terms of mechanical properties. Graphite is considered in this paper as it enables the reduction of the coefficient of friction through its lubricating properties. Unfortunately, graphite is difficult to use in selected layers as the only dispersion phase, because it has much lower hardness than the Ni-P coating. For this reason, a layer with a single dispersion phase in the form of graphite will be characterized by worse mechanical properties. It is necessary to add particles or nanoparticles with hardness higher than the base Ni-P coating, e.g., Si3N4, which improve the mechanical properties of the coating. The presented analyses of the results of the conducted research complement the previous studies on selected properties of nanocomposite layers with an amorphous structure and supplement the knowledge regarding their suitability for application to aluminum machine parts.
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Affiliation(s)
- Kazimierz Czapczyk
- Faculty of Mechanical Engineering and Ship Technology, Gdansk University of Technology, G. Narutowicza 11/12, 80-233 Gdansk, Poland
| | - Paweł Zawadzki
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (P.Z.); (N.W.)
| | - Natalia Wierzbicka
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (P.Z.); (N.W.)
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Pu J, Zhang Y, Zhang X, Yuan X, Yang S, Zhang G, Cui W, Tan Q, Jin Z. Fretting corrosion behavior of Ti6Al4V alloy against zirconia-toughened alumina ceramic in simulated body fluid. J Mech Behav Biomed Mater 2023; 142:105860. [PMID: 37127011 DOI: 10.1016/j.jmbbm.2023.105860] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/19/2023] [Revised: 04/13/2023] [Accepted: 04/16/2023] [Indexed: 05/03/2023]
Abstract
The fretting corrosion at the head-neck interface of artificial hip joints is an important reason for the failure of prostheses. The Ti6Al4V alloy-zirconia-toughened alumina (ZTA) ceramic combination has been widely used to make the head and neck of artificial hip joints. In this study, its fretting corrosion behavior in simulated body fluid was studied by electrochemical monitoring, surface morphology characterization, and chemical composition analysis. A running condition fretting map (RCFM) of load and displacement was established, including three regimes, namely partial slip regime (PSR), mixed fretting regime (MFR), and gross slip regime (GSR). The friction dissipation energy increased gradually from the PSR to MFR and GSR. In the PSR, the damage mechanisms were slight abrasive wear and tribocorrosion at the edge of contact area, as well as extremely slight adhesive wear at the center. In the MFR, the damage mechanisms were mainly adhesive wear, abrasive wear, and corrosive wear. In the GSR, the damage mechanism was serious abrasive wear, fatigue wear, and corrosive wear combined with slight adhesive wear. Finally, an ion-concentration map was created, displaying the material-loss transition of different displacements and loads. The material loss increased with the increased displacement, and increased first and then decreased with the increased load.
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Affiliation(s)
- Jian Pu
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China
| | - Yali Zhang
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China.
| | - Xiaogang Zhang
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China
| | - Xinlu Yuan
- School of Mechanical Engineering, Chengdu University, Sichuan, Chengdu, 610106, China
| | - Shu Yang
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China
| | - Guoxian Zhang
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China
| | - Wen Cui
- Beijing AKEC Medical Co., Ltd., Beijing, 102200, China; School of Materials Science and Engineering, Peking University, Beijing, 100871, China
| | - Qin Tan
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China
| | - Zhongmin Jin
- School of Mechanical Engineering, Southwest Jiaotong University, Sichuan, Chengdu, 610031, China; School of Mechanical Engineering, University of Leeds, Leeds, LS2 9JT, UK
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Long-term fretting corrosion performance of modular head-neck junctions with self-reinforced composite gaskets from PEEK and UHMWPE. J Mech Behav Biomed Mater 2022; 129:105149. [DOI: 10.1016/j.jmbbm.2022.105149] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/06/2021] [Revised: 11/12/2021] [Accepted: 02/27/2022] [Indexed: 01/11/2023]
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Czapczyk K, Zawadzki P, Wierzbicka N, Talar R. Microstructure and Properties of Electroless Ni-P/Si 3N 4 Nanocomposite Coatings Deposited on the AW-7075 Aluminum Alloy. MATERIALS 2021; 14:ma14164487. [PMID: 34443010 PMCID: PMC8398758 DOI: 10.3390/ma14164487] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/16/2021] [Revised: 08/06/2021] [Accepted: 08/08/2021] [Indexed: 10/25/2022]
Abstract
The article presents the results of mechanical and tribological tests of Ni-P/Si3N4 nanocomposite coatings deposited on the AW-7075 aluminum alloy using the chemical reduction method. The influence of the chemical composition on the Vickers microhardness determined by the DSI method was examined. The nanocomposite layers were made of Si3N4 silicon nitride in a polydisperse powder with a particle size ranging from 20 to 25 nm. The influence of the content of the dispersion layer material on the adhesion to the substrate was analyzed. The abrasive wear was tested and determined in the reciprocating motion using the "ball-on-flat" method. The surface topography was examined by the contact method with the use of a profilometer. Based on the obtained test results, it was found that the Ni-P/Si3N4 layers produced in the bath with the Si3N4 nanoparticle content in the amount of 2 g/dm3 are more resistant to wear and show greater adhesion than the Ni-P/Si3N4 layers deposited in the bath with 5 g/dm3 of the dispersion phase. NiP/Si3N4 layers provide protection against abrasive wear under various loads and environmental conditions.
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Affiliation(s)
- Kazimierz Czapczyk
- Faculty of Ocean Engineering and Ship Technology, Gdańsk University of Technology, G. Narutowicza 11/12, 80-233 Gdansk, Poland;
| | - Paweł Zawadzki
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (N.W.); (R.T.)
- Correspondence:
| | - Natalia Wierzbicka
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (N.W.); (R.T.)
| | - Rafał Talar
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (N.W.); (R.T.)
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Tribological Properties of Ni-P/Si 3N 4 Nanocomposite Layers Deposited by Chemical Reduction Method on Aluminum Alloy AW-7075. MATERIALS 2020; 13:ma13245797. [PMID: 33353149 PMCID: PMC7766131 DOI: 10.3390/ma13245797] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/04/2020] [Revised: 12/04/2020] [Accepted: 12/14/2020] [Indexed: 12/31/2022]
Abstract
The article presents the results of tribological tests of Ni-P/Si3N4 nanocomposite and Ni-P nickel layers deposited on the AW-7075 aluminum alloy by chemical reduction method, and the AW-7075 alloy without coating. Nanocomposite layers were produced using Si3N4 siliconnitride in the form of a polydisperse powder whose particle sizes ranged from 20 to 25 nm. The influence of the content of the dispersion phase layer material on the abrasive wear, which was determined as the "ball on disc" method, was analyzed. Surface topography was examined by the contact method using a profilometer. The purpose of introducing Si3N4 particles into the Ni-P layer was to increase the wear resistance of AW-7075 aluminum alloy parts with an embedded nanocomposite coating. Based on the obtained test results, it was found that the Ni-P/Si3N4 layers are more resistant to wear than the Ni-P layers and the AW-7075 alloy layers, and are a good barrier against abrasive wear at various loads and environmental conditions.
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Zhu D, Liu Y, Gilbert JL. In vitro fretting crevice corrosion damage of CoCrMo alloys in phosphate buffered saline: Debris generation, chemistry and distribution. Acta Biomater 2020; 114:449-459. [PMID: 32771589 DOI: 10.1016/j.actbio.2020.07.052] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/02/2020] [Revised: 07/21/2020] [Accepted: 07/30/2020] [Indexed: 12/17/2022]
Abstract
Fretting crevice corrosion in modular tapers of total hip replacements has become a major concern in orthopedic medical devices. Solid and ionic debris arising from fretting crevice corrosion have been implicated in device failure and revision surgery. This study aims to use a 2D pin-on-disk fretting corrosion test system to visualize damage progression and debris generation during fretting corrosion of CoCrMo alloys in phosphate buffered saline (PBS). The results provide direct evidence of rapid debris generation during fretting corrosion (after only 12 min of testing). Debris was generated and either extruded from the contact region or impacted into adjacent crevice sites as long as fretting continued. After testing, the fretting region consisted of a damaged and plastically deformed contact region surrounded by a halo of fretting debris consisting entirely of oxides and phosphates within the crevice region. Evidence of pitting corrosion and grain boundary corrosion was observed. Solid debris consisted of chromium (Cr), phosphate (P) and oxygen (O). X-ray photoelectron spectroscopy analysis of the near-fretted metal surface area showed a thicker oxygen (O1s) containing film with the depth profile of O1s above 10% penetrating up to 5.75 nm while the O1s concentration on the unfretted area fell to below 10% after 1 nm depth. Ion concentration in the PBS, measured using inductively coupled mass spectrometry, showed cobalt (Co) ions were most prevalent (1.46 ppm) compared to chromium (Cr) (0.07 ppm) and molybdenum (Mo) (0.05 ppm) (p <0.05). All of these results are consistent with the analysis of in vivo modular taper corrosion processes. STATEMENT OF SIGNIFICANCE: CoCrMo alloys has been widely used as a metallic biomaterial for implant devices and can lose their durability and reliability due to wear, corrosion and tribocorrosion. Debris, as one of the major products of these reactions, is associated with implant device failure. In the first time, we developed a fretting corrosion testing system to visualize the debris generation process in real-time between CoCrMo alloy pin and disk samples. Debris was generated rapidly during fretting corrosion and some of the debris egressed from the crevice site while also accumulating within the crevice area as fretting continued. Our study opens a new method for future studies to advance understanding of debris generation processes during wear and tribocorrosion phenomenon.
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Affiliation(s)
- Dongkai Zhu
- Syracuse Biomaterials Institute, Department of Biomedical and Chemical Engineering, Syracuse University, Syracuse, NY 13244, United States; Clemson - MUSC Bioengineering Program, Department of Bioengineering, Clemson University and the Medical University of South Carolina, 68 Presidents Street, Charleston, SC 20425, United States
| | - Yangping Liu
- Syracuse Biomaterials Institute, Department of Biomedical and Chemical Engineering, Syracuse University, Syracuse, NY 13244, United States; Clemson - MUSC Bioengineering Program, Department of Bioengineering, Clemson University and the Medical University of South Carolina, 68 Presidents Street, Charleston, SC 20425, United States
| | - Jeremy L Gilbert
- Syracuse Biomaterials Institute, Department of Biomedical and Chemical Engineering, Syracuse University, Syracuse, NY 13244, United States; Clemson - MUSC Bioengineering Program, Department of Bioengineering, Clemson University and the Medical University of South Carolina, 68 Presidents Street, Charleston, SC 20425, United States.
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