Studies on laser- and plasma-welded titanium

Microscopic and Mechanical Characterization of Co-Cr Dental Alloys Joined by the TIG Welding Process

Due to their good mechanical and other properties, cobalt-chromium alloys (Co-Cr) are often used in prosthetic therapy. The metal structures of prosthetic works can be damaged and break, and depending on the extent of the damage, they can be re-joined. Tungsten inert gas welding (TIG) produces a high-quality weld with a composition very close to that of the base material. Therefore, in this work, six commercially available Co-Cr dental alloys were joined by TIG welding, and their mechanical properties were evaluated to determine the quality of the TIG process as a technology for joining metallic dental materials and the suitability of the Co-Cr alloys used for TIG welding. Microscopic observations were made for this purpose. Microhardness was measured using the Vickers method. The flexural strength was determined on a mechanical testing machine. The dynamic tests were carried out on a universal testing machine. The mechanical properties were determined for welded and non-welded specimens, and the results were statistically evaluated. The results show the correlation between the investigated mechanical properties and the process TIG. Indeed, characteristics of the welds have an effect on the measured properties. Considering all the results obtained, the TIG-welded I-BOND NF and Wisil M alloys showed the cleanest and most uniform weld and, accordingly, satisfactory mechanical properties, highlighting that they withstood the maximum number of cycles under dynamic load.

Comparative analysis of titanium coating on cobalt-chrome alloy in vitro and in vivo direct metal fabrication vs. plasma spraying

Background

Titanium surface coating on cobalt-chromium (CoCr) alloy has characteristics desirable for an orthopedic implant as follows: strength, osteointegrative capability, and biocompatibility. Creating such a coated surface takes a challenging process and two dissimilar metals are not easily welded. In our study, we utilized additive manufacturing with a 3D printing called direct metal fabrication (DMF) and compared it to the plasma spraying method (TPS), to coat titanium onto CoCr alloy. We hypothesized that this would yield a coated surface quality as acceptable or better than the already established method of plasma spraying. For this, we compared characteristics of titanium-coated surfaces created by direct metal fabrication method (DMF) and titanium plasma spraying (TPS), both in vitro and in vivo, for (1) cell morphology, (2) confocal microscopy images of immunofluorescent assay of RUNX2 and fibronectin, (3) quantification of cell proliferation rate, (4) push-out biomechanical test, and (5) bone histomorphometry.

Method

For in vitro study, human osteoblast cells were seeded onto the coated surfaces. Cellular morphology was observed with a scanning electron microscope. Cellular proliferation was validated with ELISA, immunofluorescent assay. For in vivo study, coated rods were inserted into the distal femur of the rabbit and then harvested. The rods were biomechanically tested with a push-out test and observed for histomorphometry to evaluate the microscopic bone to implant ratio.

Result

For cell morphology observation, lamellipodia and filopodia, a cytoplasmic projection extending into porous structure, formed on both surfaces created by DMF and TPS. The proliferation of the osteoblasts, the DMF group showed a better result at different optic density levels (p = 0.035, 0.005, 0.001). Expression and distribution of fibronectin and Runx-2 genes showed similar degrees of expressions. The biomechanical push-out test yielded a similar result (p = 0.714). Histomorphometry analysis also showed a similar result (p = 0.657).

Conclusion

In conclusion, DMF is a method which can reliably create a proper titanium surface on CoCr alloy. The resulting product of the surface shows a similar quality to that of the plasma spraying method, both in vivo and in vitro, in terms of biological and mechanical property.

Corrosion behaviours of the dental magnetic keeper complexes made by different alloys and methods

The keeper and cast dowel–coping, as a primary component for a magnetic attachment, is easily subjected to corrosion in a wet environment, such as the oral cavity, which contains electrolyte-rich saliva, complex microflora and chewing behaviour and so on. The objective of this in vitro study was to examine the corrosion resistance of a dowel and coping-keeper complex fabricated by finish keeper and three alloys (cobalt–chromium, CoCr; silver–palladium–gold, PdAu; gold–platinum, AuPt) using a laser-welding process and a casting technique. The surface morphology characteristics and microstructures of the samples were examined by means of metallographic microscope and scanning electron microscope (SEM). Energy-dispersive spectroscopy (EDS) with SEM provided elements analysis information for the test samples after 10% oxalic acid solution etching test. Tafel polarization curve recordings demonstrated parameter values indicating corrosion of the samples when subjected to electrochemical testing. This study has suggested that massive oxides are attached to the surface of the CoCr–keeper complex but not to the AuPt–keeper complex. Only the keeper area of cast CoCr–keeper complex displayed obvious intergranular corrosion and changes in the Fe and Co elements. Both cast and laser-welded AuPt–keeper complexes had the highest free corrosion potential, followed by the PdAu–keeper complex. We concluded that although the corrosion resistance of the CoCr–keeper complex was worst, the keeper surface passive film was actually preserved to its maximum extent. The laser-welded CoCr– and PdAu–keeper complexes possessed superior corrosion resistance as compared with their cast specimens, but no significant difference was found between the cast and laser-welded AuPt–keeper complexes. The Fe-poor and Cr-rich band, appearing on the edge of the keeper when casting, has been proven to be a corrosion-prone area.

Effects of soldering methods on tensile strength of a gold-palladium metal ceramic alloy

STATEMENT OF PROBLEM

The tensile strength obtained by conventional postceramic application soldering and laser postceramic welding may require more energy than microwave postceramic soldering, which could provide similar tensile strength values.

PURPOSE

The purpose of the study was to compare the tensile strength obtained by microwave postceramic soldering, conventional postceramic soldering, and laser postceramic welding.

MATERIAL AND METHODS

A gold-palladium metal ceramic alloy and gold-based solder were used in this study. Twenty-seven wax specimens were cast in gold-palladium noble metal and divided into 4 groups: laser welding with a specific postfiller noble metal, microwave soldering with a postceramic solder, conventional soldering with the same postceramic solder used in the microwave soldering group, and a nonsectioned control group. All the specimens were heat treated to simulate a normal porcelain sintering sequence. An Instron Universal Testing Machine was used to measure the tensile strength for the 4 groups. The means were analyzed statistically with 1-way ANOVA. The surface and fracture sites of the specimens were subjectively evaluated for fracture type and porosities by using a scanning electron microscope.

RESULTS

The mean (standard deviation) ultimate tensile strength values were as follows: nonsectioned control 818 ±30 MPa, microwave 516 ±34 MPa, conventional 454 ±37 MPa, and laser weld 191 ±39 MPa. A 1-way ANOVA showed a significant difference in ultimate tensile strength among the groups (F3,23=334.5; P<.001). Follow-up multiple comparisons showed a significant difference among all the groups. Microwave soldering resulted in a higher tensile strength for gold and palladium noble metals than either conventional soldering or laser welding.

CONCLUSION

Conventional soldering resulted in a higher tensile strength than laser welding. Under the experimental conditions described, either microwave or conventional postceramic soldering would appear to satisfy clinical requirements related to tensile strength.

Effect of Nd:YAG laser parameters on the penetration depth of a representative Ni-Cr dental casting alloy

The effects of voltage and laser beam (spot) diameter on the penetration depth during laser beam welding in a representative nickel-chromium (Ni-Cr) dental alloy were the subject of this study. The cast alloy specimens were butted against each other and laser welded at their interface using various voltages (160-390 V) and spot diameters (0.2-1.8 mm) and a constant pulse duration of 10 ms. After welding, the laser beam penetration depths in the alloy were measured. The results were plotted and were statistically analyzed with a two-way ANOVA, employing voltage and spot diameter as the discriminating variables and using Holm-Sidak post hoc method (a = 0.05). The maximum penetration depth was 4.7 mm. The penetration depth increased as the spot diameter decreased at a fixed voltage and increased as the voltage increased at a fixed spot diameter. Varying the parameters of voltage and laser spot diameter significantly affected the depth of penetration of the dental cast Ni-Cr alloy. The penetration depth of laser-welded Ni-Cr dental alloys can be accurately adjusted based on the aforementioned results, leading to successfully joined/repaired dental restorations, saving manufacturing time, reducing final cost, and enhancing the longevity of dental prostheses.

Tensile and Flexural Strength of Commercially Pure Titanium Submitted to Laser and Tungsten Inert Gas Welds

This study evaluated the tensile and flexural strength of tungsten inert gas (TIG) welds in specimens made of commercially pure titanium (CP Ti) compared with laser welds. Sixty cylindrical specimens (2 mm diameter x 55 mm thick) were randomly assigned to 3 groups for each test (n=10): no welding (control), TIG welding (10 V, 36 A, 8 s) and Nd:YAG laser welding (380 V, 8 ms). The specimens were radiographed and subjected to tensile and flexural strength tests at a crosshead speed of 1.0 mm/min using a load cell of 500 kgf applied on the welded interface or at the middle point of the non-welded specimens. Tensile strength data were analyzed by ANOVA and Tukey's test, and flexural strength data by the Kruskal-Wallis test (α=0.05). Non-welded specimens presented significantly higher tensile strength (control=605.84±19.83) (p=0.015) and flexural strength (control=1908.75) (p=0.000) than TIG- and laser-welded ones. There were no significant differences (p>0.05) between the welding types for neither the tensile strength test (TIG=514.90±37.76; laser=515.85±62.07) nor the flexural strength test (TIG=1559.66; laser=1621.64). As far as tensile and flexural strengths are concerned, TIG was similar to laser and could be suitable to replace laser welding in implant-supported rehabilitations.

Effect of plasma welding parameters on the flexural strength of Ti-6Al-4V alloy

The aim of this study was to assess the effect of different plasma arc welding parameters on the flexural strength of titanium alloy beams (Ti-6Al-4V). Forty Ti-6Al-4V and 10 NiCr alloy beam specimens (40 mm long and 3.18 mm diameter) were prepared and divided into 5 groups (n=10). The titanium alloy beams for the control group were not sectioned or subjected to welding. Groups PL10, PL12, and PL14 contained titanium beams sectioned and welded at current 3 A for 10, 12 or 14 ms, respectively. Group NCB consisted of NiCr alloy beams welded using conventional torch brazing. After, the beams were subjected to a three-point bending test and the values obtained were analyzed to assess the flexural strength (MPa). Statistical analysis was carried out by one-way ANOVA and Tukey's HSD test at 0.05 confidence level. Significant difference was verified among the evaluated groups (p<0.001), with higher flexural strength for the control group (p<0.05). No significant differences was observed among the plasma welded groups (p>0.05). The NCB group showed the lowest flexural strength, although it was statistically similar to the PL 14 group (p>0.05). The weld depth penetration was not significantly different among the plasma welded groups (p=0.05). Three representative specimens were randomly selected to be evaluated under scanning electron microcopy. The composition of the welded regions was analyzed by energy dispersive X-ray spectroscopy. This study provides an initial set of parameters supporting the use of plasma welding during fabrication of titanium alloy dental frameworks.

Fatigue performance of joints executed in pure titanium structures with several diameters

This study evaluated fatigue strength of CP-Ti laser-welded joints. Sixty (20/diameter) CP-Ti casted dumbbell rods with diameters of 1.5, 2.0, and 3.5 mm were sectioned and welded using two joint openings (0.0 (00) and 0.6 mm (06)). Six groups were formed, amounting to a total of 9 (n=10) with inclusion of intact groups. Welding was executed using 360 V/8 ms (1.5 and 2.0 mm) and 380 V/9 ms (3.5 mm). Joints were finished, polished, and submitted to radiographic examination to visually analyze presence of porosity (PP). Specimens were submitted to cyclic tests, and the number of cycles until failure (NC) was recorded. Fractured surfaces were examined by SEM. Kruskal-Wallis and Dunn (α=0.05) tests demonstrated that NC was lower for all diameters with 06, and for 3.5 mm/00. NC and PP were found to have a negative correlation (Spearman Coefficient). For CP-Ti frameworks with thin diameters, laser welding is better when structures are juxtaposed.

Comparison of joint designs for laser welding of cast metal plates and wrought wires

The purpose of the present study was to compare joint designs for the laser welding of cast metal plates and wrought wire, and to evaluate the welded area internally using X-ray micro-focus computerized tomography (micro-CT). Cast metal plates (Ti, Co-Cr) and wrought wires (Ti, Co-Cr) were welded using similar metals. The specimens were welded using four joint designs in which the wrought wires and the parent metals were welded directly (two designs) or the wrought wires were welded to the groove of the parent metal from one or both sides (n = 5). The porosity and gap in the welded area were evaluated by micro-CT, and the maximum tensile load of the welded specimens was measured with a universal testing machine. An element analysis was conducted using an electron probe X-ray microanalyzer. The statistical analysis of the results was performed using Bonferroni's multiple comparisons (α = 0.05). The results included that all the specimens fractured at the wrought wire when subjected to tensile testing, although there were specimens that exhibited gaps due to the joint design. The wrought wires were affected by laser irradiation and observed to melt together and onto the filler metal. Both Mo and Sn elements found in the wrought wire were detected in the filler metal of the Ti specimens, and Ni was detected in the filler metal of the Co-Cr specimens. The four joint designs simulating the designs used clinically were confirmed to have adequate joint strength provided by laser welding.

Effect of laser irradiation conditions on the laser welding strength of cobalt-chromium and gold alloys

Using tensile tests, this study investigated differences in the welding strength of casts of cobalt-chromium and gold alloys resulting from changes in the voltage and pulse duration in order to clarify the optimum conditions of laser irradiation for achieving favorable welding strength. Laser irradiation was performed at voltages of 150 V and 170 V with pulse durations of 4, 8, and 12 ms. For cobalt-chromium and gold alloys, it was found that a good welding strength could be achieved using a voltage of 170 V, a pulse duration of 8 ms, and a spot diameter of 0.5 mm. However, when the power density was set higher than this, defects tended to occur, suggesting the need for care when establishing welding conditions.

Non-destructive three-dimensional evaluation of pores at different welded joints and their effects on joints strength

OBJECTIVES

The purpose of this study was to measure the porosity in different laser welded cast alloys non-destructively using X-ray micro-focus computerized tomography (micro-CT) and to evaluate the effect of porosity on the tensile strength of the welded joints.

MATERIALS AND METHODS

The welding procedure was conducted in rectangular cast metals, CoCr, Ti and platinum added gold alloy (AuPt). The metal plates were butted CoCr to CoCr (CoCr/CoCr) or Ti to Ti (Ti/Ti) for welding of similar metals and Ti to AuPt (Ti/AuPt) for welding of dissimilar metals. Specimens were welded under several laser-welding conditions; with groove (normal), without groove (no groove), spatter, crack, or no overlapped welding (no overlap) (n=5). Porosity in the welded area was evaluated using a micro-CT. Tensile strength of the welded specimens was measured at a crosshead speed of 1mm/min. Multiple comparisons of the group means were performed using ANOVA and Fisher's multiple comparisons test (α=.05). The relationship between the porosity and the tensile strength was investigated with a regression analysis.

RESULTS

Three-dimensional images of Ti/AuPt could not be obtained due to metal artifacts and the tensile specimens of Ti/AuPt were debonded prior to the tensile test. All other welded specimens had porosity in the welded area and the porosities ranged from 0.01% to 0.17%. The fractures of most of the CoCr/CoCr and Ti/Ti specimens occurred in the parent metals. Joint strength had no relationship with the porosity in the welded area (R(2)=0.148 for CoCr/CoCr, R(2)=0.088 for Ti/Ti, respectively).

SIGNIFICANCE

The small amount of porosity caused by the laser-welding procedures did not affect the joint strength. The joint strength of Ti/AuPt was too weak to be used clinically.

An alternative section method for casting and posterior laser welding of metallic frameworks for an implant-supported prosthesis

PURPOSE

The aim of this study was to compare the accuracy of fit of three types of implant-supported frameworks cast in Ni-Cr alloy: specifically, a framework cast as one piece compared to frameworks cast separately in sections to the transverse or the diagonal axis, and later laser welded.

MATERIALS AND METHODS

Three sets of similar implant-supported frameworks were constructed. The first group of six 3-unit implant-supported frameworks were cast as one piece, the second group of six were sectioned in the transverse axis of the pontic region prior to casting, and the last group of six were sectioned in the diagonal axis of the pontic region prior to casting. The sectioned frameworks were positioned in the matrix (10 N.cm torque) and laser welded. To evaluate passive fit, readings were made with an optical microscope with both screws tightened and with only one-screw tightened. Data were submitted to ANOVA and Tukey-Kramer's test (p < 0.05).

RESULTS

When both screws were tightened, no differences were found between the three groups (p > 0.05). In the single-screw-tightened test, with readings made opposite to the tightened side, the group cast as one piece (57.02 +/- 33.48 mum) was significantly different (p < 0.05) from the group sectioned diagonally (18.92 +/- 4.75 microm) but no different (p > 0.05) from the group transversally sectioned (31.42 +/- 20.68 microm). On the tightened side, no significant differences were found between the groups (p > 0.05).

CONCLUSIONS

Results of this study showed that casting diagonally sectioned frameworks lowers misfit levels of prosthetic implant-supported frameworks and also improves the levels of passivity to the same frameworks when compared to structures cast as one piece.

Micro-XRD study of beta–titanium wires and infrared soldered joints

OBJECTIVE

The purpose of this study was to investigate the metallurgical phases in beta-titanium soldered joints prepared by infrared soldering, using the Micro X-ray diffraction technique (Micro-XRD), and to characterize the Vickers hardness in the soldered beta-titanium wires.

METHODS

Beta-titanium wires with cross-section dimensions of 0.032in.x0.032in. (TMA, Ormco), and both titanium-based solder (Ti-30Ni-20Cu, Selec) and silver-based solder (Ag-22Cu-17Zn-5Sn, Tomy) were selected. Soldering was performed using infrared radiation (RS-1, Morita) under argon atmosphere. Micro-XRD analyses were performed at room temperature. Micro-XRD spectra were obtained for the boundary region of the soldered beta-titanium wires using 50microm and 10microm diameter analysis regions. Hardness was measured at 30microm intervals from boundary of the diffusion layer and beta-titanium wire. The Kruskal-Wallis test with the Bonferroni and Wilcoxson Mann-Whitney tests for nonparametric means were employed as statistical methods (P<0.05).

RESULTS

For both types of soldered beta-titanium samples, the Micro-XRD spectra contained four major peaks for body-centered cubic (bcc) beta-titanium. Additional peaks at about 41 and 45 degrees are attributed to Cu-Ti intermetallic phase(s), which may be metastable under soldering conditions. The diffusion layer had greater hardness than bulk beta-titanium for both types of soldered specimens (P<0.05).

SIGNIFICANCE

Soldering of beta-titanium orthodontic wire by infrared radiation may be acceptable for clinical use, since Micro-XRD spectra revealed that both types of soldered specimens largely retained the bcc beta-titanium structure. Further research is needed to investigate the mechanical properties and corrosion behavior of infrared-soldered beta-titanium wire.

Nd:YAG laser penetration into cast titanium and gold alloy with different surface preparations

This study investigated the effect of surface preparation on the Nd:YAG laser penetration into cast titanium and gold alloy. Cast blocks of each metal were given four different surface preparations: (i) coloured with black marker; (ii) air-abraded with 50 microm Al2O3; (iii) ground with SiC points and (iv) polished with 1 microm Al2O3 (mirror-polished). Two blocks with each of the surface preparations were abutted and laser-welded at their interface using the voltages of 210-260 V in increments of 10 V. After the welded blocks were mechanically separated, the laser penetration was measured using computer graphics. Regardless of the surface preparation, an increase in voltage increased the laser penetration for both metals. The laser penetration into titanium prepared with black marker and air-abrasion was significantly deeper than into the titanium ground with SiC points and mirror-polished. Although there were no statistical differences in penetration among the surface preparations for the gold alloy, the penetration in the mirror-polished specimens was shallower than any of the other preparation methods at higher voltages of 240-260 V. The results obtained in this study suggested that broken metal frameworks with finished surfaces should be painted with black marker or air-abraded before laser welding.

Joining characteristics of orthodontic wires with laser welding

Laser welding 0.016 x 0.022 in. beta-Ti, Ni-Ti, and Co-Cr-Ni orthodontic wires was investigated by measuring joint tensile strength, measuring laser penetration depth, determining metallurgical phases using micro X-ray diffraction (micro-XRD), and examining microstructures with an scanning electron microscope (SEM). Welding was performed from 150 to 230 V. Mean tensile strength for Ni-Ti groups was significantly lower (p < 0.05) than for most other groups of laser-welded specimens. Although mean tensile strength for beta-Ti and Co-Cr-Ni was significantly lower than for control specimens joined by silver soldering, it was sufficient for clinical use. The beta-Ti orthodontic wire showed deeper penetration depth from laser welding than the Ni-Ti and Co-Cr-Ni orthodontic wires. Micro-XRD patterns of laser-welded beta-Ti and Ni-Ti obtained 2 mm from the boundary were similar to as-received specimens, indicating that original microstructures were maintained. When output voltages of 190 V and higher were used, most peaks from joint areas disappeared or were much weaker, perhaps because of a directional solidification effect, evidenced by SEM observation of fine striations in welded beta-Ti. Laser welding beta-Ti and Co-Cr-Ni wires may be acceptable clinically, since joints had sufficient strength and metallurgical phases in the original wires were not greatly altered.

Microstructures of beta-titanium orthodontic wires joined by infrared brazing

The microstructures and interdiffusion in brazed beta-titanium orthodontic wires were investigated by scanning electron microscopy and electron probe microanalysis, respectively. Beta-titanium wire (Ti-11Mo-6Zr-4Sn) with cross-section dimensions of 0.032 in. x 0.032 in., titanium-based braze alloy (Ti-30Ni-20Cu), and silver-based braze alloy (Ag-22Cu-17Zn-5Sn) were selected for the study. Brazing was performed using infrared radiation (RS-1) under an argon atmosphere. Specimens were etched with two solutions (2.5% HF + 2.5% HNO(3) + 95% H(2)O; 25% HN(4)OH + 30% H(2)O(2) + 45%H(2)O). It was found that the silver-based braze alloy has a eutectic structure. In the diffusion layer between the beta-titanium wire and this silver-based braze alloy, Cu and Ti were enriched on the wire side, and Sn and Ti were enriched on the braze alloy side. The titanium-based braze alloy has a dendritic structure. Beta-titanium wire specimens brazed with the titanium-based braze alloy had a thicker intermediate area compared to the silver alloy; Ti in the diffusion layer had an irregular concentration gradient, and the braze alloy side had higher Ti concentration. The original microstructure of the beta-titanium wire was not altered with the use of either braze alloy. Infrared brazing of beta-titanium orthodontic wire is acceptable for clinical use, since the wire microstructure did not deteriorate with either the titanium-based or silver-based braze alloy. The differing microstructures of the joint regions for the two braze alloys suggest that the joint strengths may also differ.

Evaluation of welded titanium joints used with cantilevered implant-supported prostheses

STATEMENT OF PROBLEM

Early failure of laser-welded titanium implant frameworks in clinical practice has prompted an investigation of the strength and durability of welded cantilevered titanium sections.

PURPOSE

The purpose of this study was to determine the effect that the use of filler wire in laser welding of titanium cantilever frameworks had on the flexural strength and fatigue resistance of the welded joints.

MATERIAL AND METHODS

Sixty titanium implant-supported frameworks with 12-mm cantilevers were fabricated in 4 groups (n=15), using 3 different laser welding protocols with 0, 1, and 2 weld passes with filler wire, and 1 conventional tungsten inert gas welding method. The volume of filler wire used (mean volumes 0, 1.7, 3.4, and 8.3 mm(3)) was determined by measurement of the length of wire before and after welding each joint. Ten frameworks from each group were tested for ultimate flexural strength by loading the cantilevers 10 mm from the abutment. The remaining 5 frameworks from each group were similarly tested under a simulated masticatory load of 200 N until failure, or to 1 million cycles. A 2-way analysis of variance was used to examine the flexural strengths, and log-rank statistics were applied to cyclic test data (alpha=.05).

RESULTS

There were significant differences between the 4 groups for ultimate flexural strength (P<.001) and resistance to cyclic loading (P=.002). The volume of filler wire added was a significant predictor of ultimate flexural strength (P=.03), and was a borderline determinant of the number of cycles to failure at 200 N (P=.05). Each laser weld pass with filler wire roughly doubled the ultimate flexural strength and fatigue resistance of the joint relative to the previous weld. Tungsten inert gas welding with efficient argon shielding deposited the most filler wire and produced the strongest and most fatigue-resistant joints.

CONCLUSION

The ultimate flexural strength and fatigue resistance of cantilevered joints in laser-welded titanium prostheses are improved by the use of filler wire. Tungsten inert gas welding with efficient argon shielding can be used in situations when a high-strength joint is required.

Laser welding of cast titanium and dental alloys using argon shielding

PURPOSE

This study investigated the effect of argon gas shielding on the strengths of laser-welded cast Ti and Ti-6Al-7Nb and compared the results to those of two dental casting alloys.

MATERIALS AND METHODS

Cast plates of Ti, Ti-6Al-7Nb, gold, and Co-Cr alloy were prepared. After polishing the surfaces to be welded, two plates were abutted and welded using Nd:YAG laser at a pulse duration of 10 ms, spot diameter of 1 mm, and voltage of 200 V. Five specimens were prepared for each metal by bilaterally welding them with three or five spots either with or without argon shielding. The failure load and percent elongation were measured at a crosshead speed of 1.0 mm/min.

RESULTS

The factor of argon shielding significantly affected the failure load and elongation of the laser-welded specimens. The failure loads of argon-shielded laser-welded CP Ti and Ti-6Al-7Nb were greater compared with the failure loads of specimens welded without argon shielding for both three- and five-spot welding. Regardless of argon shielding, the failure loads of the laser-welded gold alloy were approximately half that of the control specimens. In contrast, the failure loads of the nonshielded laser-welded Co-Cr alloy were greater. The percent elongations positively correlated with the failure loads.

CONCLUSIONS

The use of argon shielding is necessary for effective laser-welding of CP Ti and Ti-6Al-7Nb but not for gold and Co-Cr alloy.

Effect of Heat Treatment on Joint Properties of Laser-Welded Ag-Au-Cu-Pd and Co-Cr Alloys

PURPOSE

This study investigated the effect of heat treatment on the strengths of laser-welded cast Ag-Au-Cu-Pd and Co-Cr alloys.

MATERIALS AND METHODS

Cast plates of Ag-Au-Cu-Pd (Ag) and Co-Cr (Co) alloys were prepared. After polishing the surfaces to be welded, the plates were matched and butted Ag to Ag (Ag/Ag), Co to Co (Co/Co), and Ag to Co (Ag/Co) and welded using Nd:YAG laser at a pulse duration of 10 ms, spot diameter of 1 mm, and voltage of 200 V. Five specimens were prepared for each experimental condition by bilaterally welding them with five spots. The Ag/Ag, Ag/Co, and control Ag underwent two heat treatments-softening (ST) and hardening (AH). A group of as-cast specimens serving as controls was not given either heat treatment. The failure load and percent elongation were measured at a crosshead speed of 1.0 mm/min.

RESULTS

The fracture resistance of Co/Co was similar to that of the control Co, while the fracture resistance of Co/Ag was significantly lower than that of both like alloy pairings for all heat-treating conditions. The control Ag had greater fracture resistance after AH and lower fracture resistance after ST. The AH treatment increased the fracture resistance, and the ST treatment decreased the fracture resistance of both Ag/Ag and Co/Ag, although not significantly. The percentage of elongation appeared to positively correlate with the fracture resistance results.

CONCLUSIONS

The results obtained in this study indicated that the age-hardening heat treatment increased the weld strength between the paired Au-Ag-Cu-Pd alloys and between the Au-Ag-Cu-Pd and Co-Cr alloys.

Mechanical strength of laser-welded cobalt-chromium alloy

The purpose of this study was to investigate the effect of the output energy of laser welding and welding methods on the joint strength of cobalt-chromium (Co-Cr) alloy. Two types of cast Co-Cr plates were prepared, and transverse sections were made at the center of the plate. The cut surfaces were butted against one another, and the joints welded with a laser-welding machine at several levels of output energy with the use of two methods. The fracture force required to break specimens was determined by means of tensile testing. For the 0.5-mm-thick specimens, the force required to break the 0.5-mm laser-welded specimens at currents of 270 and 300 A was not statistically different (p > 0.05) from the results for the nonwelded control specimens. The force required to break the 1.0-mm specimens double-welded at a current of 270 A was the highest value among the 1.0-mm laser-welded specimens. The results suggested that laser welding under the appropriate conditions improved the joint strength of cobalt- chromium alloy.

Optimization of operator and physical parameters for laser welding of dental materials

OBJECTIVE

Interactions between lasers and materials are very complex phenomena. The success of laser welding procedures in dental metals depends on the operator's control of many parameters. The aims of this study were to evaluate factors relating to the operator's dexterity and the choice of the welding parameters (power, pulse duration and therefore energy), which are recognized determinants of weld quality.

DESIGN

In vitro laboratory study.

MATERIALS AND METHODS

FeNiCr dental drawn wires were chosen for these experiments because their properties are well known. Different diameters of wires were laser welded, then tested in tension and compared to the control material as extruded, in order to evaluate the quality of the welding. Scanning electron microscopy of the fractured zone and micrograph observations perpendicular and parallel to the wire axis were also conducted in order to analyse the depth penetration and the quality of the microstructure. Additionally, the micro-hardness (Vickers type) was measured both in the welded and the heat-affected zones and then compared to the non-welded alloy.

RESULTS

Adequate combination of energy and pulse duration with the power set in the range between 0.8 to 1 kW appears to improve penetration depth of the laser beam and success of the welding procedure. Operator skill is also an important variable.

CONCLUSION

The variation in laser weld quality in dental FeNiCr wires attributable to operator skill can be minimized by optimization of the physical welding parameters.

Application of cast magnetic attachments to sectional complete dentures for a patient with microstomia: a clinical report

Patients with microstomia who must wear removable dental prostheses often state that they are unable to insert or remove the prosthesis because of the constricted opening of the oral cavity. This article presents a cast iron-platinum magnetic attachment system applied to sectional collapsed complete dentures for an edentulous patient with microstomia. With the use of lingual and palatal midline hinges and a cast iron-platinum magnetic attachment, the sectional prosthesis was successfully and easily inserted and provided adequate function in the patient's mouth.

Joint strength of laser-welded titanium

OBJECTIVE

The objective of this study was to examine the joint strength of titanium laser-welding using several levels of laser output energy [current (A)].

METHODS

Cast titanium plates (0.5 x 3.0 x 40 and 1.0 x 3.0 x 40 mm(3)) were prepared and perpendicularly cut at the center of the plate. After the cut halves were fixed in a jig, they were laser-welded using a Nd: YAG laser at several levels of output energy in increments of 30A from 180 to 300A. The penetration depths of laser to titanium were measured under various conditions for output energy, pulse duration, and spot diameter to determine the appropriate conditions for these parameters. Based on the correlation between the results obtained for penetration depth and the size of the specimens (thickness: 0.5 and 1.0 mm, width: 3.0 mm), the pulse duration and spot diameter employed in this study were 10 ms and 1.0 mm, respectively. Three laser pulses (spot diameter: 1.0 mm) were applied from one side to weld the entire joint width (3.0 mm) of the specimens. Uncut specimens served as the non-welded control specimens. Tensile testing was conducted at a crosshead speed of 2 mm/min and a gage length of 10 mm. The breaking force (N) was recorded, and the data (n=5) were statistically analyzed.

RESULTS

For the 0.5 mm thick specimens, the breaking force of the specimens laser-welded at currents of 240, 270, and 300A were not statistically (P>0.05) different from the non-welded control specimens. There were no significant differences in breaking force among the 1.0mm thick specimens laser-welded at currents of 270 and 300A, and the non-welded control specimens.

SIGNIFICANCE

Under appropriate conditions, joint strengths similar to the strength of the non-welded parent metal were achieved.

Effects of heat treatments on mechanical strength of laser-welded equi-atomic AuCu-6at%Ga alloy

There is little information available on the mechanical strengthening of laser-welded gold alloys to achieve reliable dental prostheses. This study examined the hypothesis that heat treatments increase the mechanical strength of a laser-welded equi-atomic AuCu-6at%Ga alloy with age "hardenability" at intra-oral temperature. Cut cast gold alloy plates were laser-welded. The specimens were given one of three heat treatments: (1) solution treatment, (2) high-temperature aging after solution treatment, and (3) simulated intra-oral aging after solution treatment. As-cast and uncut specimens were also prepared. Tensile testing was conducted, and the breaking stress and yield strength were recorded. The yield strength values of all the heat-treated specimens nearly reached the values of the corresponding heat-treated control specimens. The results of this study indicated that, for high mechanical strength to be achieved, the laser-welded alloy tested should be aged at a high temperature or be intraorally aged after being laser-welded.

The laser welding technique applied to the non precious dental alloys procedure and results

AIM

The laser welding technique was chosen for its versatility in the repair of dental metal prosthesis. The aim of this research is to assess the accuracy, quality and reproducibility of this technique as applied to Ni-Cr-Mo and Cr-Co-Mo alloys often used to make prosthesis

METHOD

The alloy's ability to weld was evaluated with a pulsed Nd-Yag Laser equipment. In order to evaluate the joining, various cast wires with different diameters were used. The efficiency of the joining was measured with tensile tests. In order to understand this difference, metallographic examinations and X-Ray microprobe analysis were performed through the welded area and compared with the cast part.

RESULTS

It was found that a very slight change in the chemistry of the Ni-Cr alloys had a strong influence on the quality of the joining. The Co-Cr alloy presented an excellent weldability. A very important change in the microstructure due to the effect of the laser was pointed out in the welding zone, increasing its micro-hardness.

CONCLUSION

The higher level of carbon and boron in one of the two Ni-Cr was found to be responsible for its poor welding ability. However for the others, the maximum depth of welding was found to be around 2mm which is one of the usual thicknesses of the components which have to be repaired.

The CrescoTi Precision method: description of a simplified method to fabricate titanium superstructures with passive fit to osseointegrated implants

Casting distortion and inadequate handling in the dental laboratory are 2 factors that can cause misfit between a cast framework and the implant analogs in the master cast. This article describes the CrescoTi Precision procedure, which has been developed for correction of misfit between cast titanium frameworks and supporting dental implants. The simplicity and accuracy of the procedure appear to demonstrate technical progress toward obtaining optimal precision of fit of the superstructure components, thereby eliminating stress forces that may be transformed to the peri-implant bone.

Silicon nitride coating on titanium to enable titanium-ceramic bonding

Failures that occur in titanium-ceramic restorations are of concern to clinicians. The formation of poorly adhering oxide on titanium at dental porcelain sintering temperatures causes adherence problems between titanium and porcelain, which is the main limiting factor in the fabrication of titanium-ceramic restorations. To overcome this problem a 1-microm thick Si3N4 coating was applied to a titanium surface using a plasma-immersion implantation and deposition method. Such a coating serves as an oxygen diffusion barrier on titanium during the porcelain firings. The protective coating was characterized in the as-deposited condition and after thermal cycling. Cross sections of Ti/Si3N4-porcelain interface regions were examined by various electron microscopy methods and by energy dispersive analysis of X-rays to study the Si3N4 film's effectiveness in preventing titanium oxidation and in forming a bond with porcelain. The experiments have shown that this Si3N4 coating enables significant improvement in Ti-ceramic bonding.

Comparison of the bond compatibility of titanium and an NiCr alloy to dental porcelain

OBJECTIVES

The aim of this study was to investigate the bond compatibility between porcelain and titanium, by using three-point bending, oxide adherence and thermal expansion tests, and to compare the results with those of a conventional NiCr alloy-porcelain system.

METHODS

The three-point bending test was used and the results were evaluated according to DIN draft 13927. Fractured surfaces of the metal and porcelain were examined macroscopically. The oxide adherence test was applied to titanium and NiCr alloy with appropriate oxidation degrees. After an oxide film was formed on the specimens, tensile strength test was applied. Oxide adherence strength values were set and fractured surfaces were examined macroscopically. In the thermal expansion test, thermal expansion curves and thermal expansion coefficients of titanium, NiCr alloy and tested porcelains were determined. Differences in thermal expansion values (delta alpha) in all metal-porcelain pairs were calculated to allow inferences to be made about residual stress levels.

RESULTS

The bending strengths of all groups were found to be within the acceptable standard levels. At the end of the oxide adherence test, the results indicated that the adherence of the formed oxides to the metals were at a desired level. As a result of the thermal expansion test, the titanium-porcelain and NiCr-porcelain systems showed compressive thermal stress. However, the titanium-porcelain pair exhibited large positive delta alpha values. This results is found to be above the proposed thermal compatibility.

CONCLUSIONS

It was concluded that the bond compatibility between titanium and porcelain was comparable with the NiCr-porcelain system.

Mechanical properties of laser-welded cast titanium joints under different conditions

STATEMENT OF THE PROBLEM

Data on optimal conditions for laser welding commercial pure cast titanium used in dental restorations are sparse and not well established.

PURPOSE

The mechanical properties of laser-welded cast commercially pure titanium under different laser welding conditions were evaluated to find the optimal parameters in terms of duration and voltage (energy level).

MATERIAL AND METHODS

Fifty-seven cast pure titanium specimens according to ISO specification 6871 were divided into nine experimental groups and one control group. The sectioned titanium bars were laser-welded under different duration (8, 10, and 12 ms) and energy (290, 300, and 310 V) levels and evaluated for ranges of ultimate tensile strength (374 to 562 MPa), 0.2% yield strength (206 to 338 MPa), and percentage elongation (2.49% to 10.58%).

RESULTS

Under a suitable laser-welding setting parameter the ultimate tensile strength and 0.2% yield strength of experimental groups were weaker than the unsectioned control specimens (control group ultimate tensile strength 540 +/- 11 MPa, 0.2% yield strength 258 +/- 49 MPa) or too brittle (control group percentage elongation 12.41% +/- 1.83%). Two-way ANOVA, nonparametric tests showed that voltage was the only significant factor for all parameters studied (p < 0.01). Optimal conditions were determined with three-dimensional response curves (305 V, 12 ms ultimate tensile strength; 310 V, 10 ms 0.2% yield strength; 300 V, 12 ms percentage elongation).

CONCLUSION

Optimal duration and voltage (energy level) used in laser welding for cast CP grade I titanium bar was superior to or comparable with and produced properties that were superior to or comparable with the unsectioned control specimens.

Laser welding of a cobalt-chromium removable partial denture alloy

STATEMENT OF PROBLEM

The electric alloy brazed joints of removable partial denture alloys have failed frequently after routine usage.

PURPOSE

A technique providing higher joint strengths was investigated. This investigation compared the tensile strengths of electric-brazed and laser-welded joints for a cobalt-chromium removable partial denture alloy.

MATERIAL AND METHODS

Twenty-four cobalt-chromium standard tensile testing rods were prepared and divided into three groups of eight. All specimens in the control group (group 1) were left in the as-cast condition. Groups 2 and 3 were the test specimens, which were sectioned at the center of the rod. Eight specimens were joined by using electric brazing, and the remaining specimens were joined by using laser welding. After joining, each joint was ground to a uniform diameter, then tested to tensile failure on an Instron universal testing machine. Failure loads were recorded and fracture stress calculated. Statistical analysis was applied.

RESULTS

The student-Newman-Keuls test showed a highly significant difference between the joint strengths of the as-cast control specimens, the electric-brazed and laser-welded joints.

CONCLUSIONS

The tensile strengths of the as-cast joints were higher than those for the laser-welded joints, and both were higher than the electric-brazed joint strengths.

Effects of joint configuration for the arc welding of cast Ti-6Al-4V alloy rods in argon

STATEMENT OF PROBLEM

Titanium and its alloys are more commonly used in prosthodontics and welding has become the most common modality for their joining. Studies on the welding of titanium and its alloys have not quantified this value, though its importance has been suggested.

PURPOSE

This study compared the strength and properties of the joint achieved at various butt joint gaps by the arc-welding of cast Ti-6Al-4V alloy tensile bars in an argon atmosphere.

MATERIAL AND METHODS

Forty of 50 specimens were sectioned and welded at four gaps. All specimens underwent tensile testing to determine ultimate tensile strength and percentage elongation, then oxygen analysis and scanning electron microscopy.

RESULTS

As no more than 3 samples in any group of 10 actually fractured in the weld itself, a secondary analysis that involved fracture location was initiated. There were no differences in ultimate tensile strength or percentage elongation between specimens with weld gaps of 0.25, 0.50, 0.75, and 1.00 mm and the as-cast specimens. There were no differences in ultimate tensile strength between specimens fracturing in the weld and those fracturing in the gauge in welded specimens; however, as-cast specimens demonstrated a higher ultimate tensile strength than welded specimens that fractured in the weld. Specimens that fractured in the weld site demonstrated less ductility than those that fractured in the gauge in both welded and as-cast specimens, as confirmed by scanning electron microscopy examination. The weld wire showed an oxygen scavenging effect from the as-cast parent alloy.

CONCLUSIONS

The effects of the joint gap were not significant, whereas the characteristics of the joint itself were, which displayed slightly lower strength and significantly lower ductility (and thus decreased toughness). The arc-welding of cast titanium alloy in argon atmosphere appears to be a reliable and efficient prosthodontic laboratory modality producing predictable results, although titanium casting and joining procedures must be closely controlled to minimize heat effects and oxygen contamination.

Thermal modeling of laser welding for titanium dental restorations

STATEMENT OF PROBLEM

Concerns of laser welding for titanium dental prostheses are the limited depth of laser beam penetration and extensive surface damage.

PURPOSE

This study used numerical heat transfer simulation to explain this behavior and offers an alternate multiple-pulsed method.

MATERIAL AND METHODS

A one-dimensional finite difference analysis was used to simulate heat transfer in pure titanium and gold during laser welding with a custom-constructed software program.

RESULTS

The thermal gradient profiles revealed the problem to be inherent in titanium's low thermal conductivity; gold did not have this problem. Time-elapsed multiple pulses on titanium relieved this problem by giving the energy time to diffuse into the depth of the material.

CONCLUSIONS

With single-pulse laser irradiation on titanium, an increase in power could not greatly increase melting depth. The excess energy only vaporized the material surface.

Joining titanium materials with tungsten inert gas welding, laser welding, and infrared brazing

Titanium has a number of desirable properties for dental applications that include low density, excellent biocompatibility, and corrosion resistance. However, joining titanium is one of the practical problems with the use of titanium prostheses. Dissolved oxygen and hydrogen may cause severe embrittlement in titanium materials. Therefore the conventional dental soldering methods that use oxygen flame or air torch are not indicated for joining titanium materials. This study compared laser, tungsten inert gas, and infrared radiation heating methods for joining both pure titanium and Ti-6Al-4V alloy. Original rods that were not subjected to joining procedures were used as a control method. Mechanical tests and microstructure analysis were used to evaluate joined samples. Mechanical tests included Vickers microhardness and uniaxial tensile testing of the strength of the joints and percentage elongation. Two-way analysis of variance and Duncan's multiple range test were used to compare mean values of tensile strength and elongation for significant differences (p < or = 0.05). Tensile rupture occurred in the joint region of all specimens by cohesive failure. Ti-6Al-4V samples exhibited significantly greater tensile strength than pure titanium samples. Samples prepared by the three joining methods had markedly lower tensile elongation than the control titanium and Ti-6Al-4V rods. The changes in microstructure and microhardness were studied in the heat-affected and unaffected zones. Microhardness values increased in the heat-affected zone for all the specimens tested.

Porcelain bond to laser-welded titanium surfaces

OBJECTIVES

The purpose of this investigation was to determine if laser-welding titanium had an effect on the bond strength of porcelain to metal. This is an important consideration since the metal copings for many multi-unit porcelain restorations are fabricated as single units and then either soldered or welded.

METHODS

The bond strength of porcelain to laser-welded titanium was measured with a four-point bending test and the interface was examined using SEM/EDX analysis.

RESULTS

The result showed no statistically significant differences (p<0.05) in bond strengths between laser-welded surfaces and mechanically machined surfaces and neither were there any alterations in composition identified after the welding. The use of a special bonding agent did not improve the bond strength significantly.

SIGNIFICANCE

Fusing porcelain to laser-welded areas in titanium fixed restorations implies no deterioration of bond strength.