Biodegradation-affected fatigue behavior of extrusion-based additively manufactured porous iron-manganese scaffolds

Additively manufactured (AM) biodegradable porous iron-manganese (FeMn) alloys have recently been developed as promising bone-substituting biomaterials. However, their corrosion fatigue behavior has not yet been studied. Here, we present the first study on the corrosion fatigue behavior of an extrusion-based AM porous Fe35Mn alloy under cyclic loading in air and in the revised simulated body fluid (r-SBF), including the fatigue crack morphology and distribution in the porous structure. We hypothesized that the fatigue behavior of the architected AM Fe35Mn alloy would be strongly affected by the simultaneous biodegradation process. We defined the endurance limit as the maximum stress at which the scaffolds could undergo 3 million loading cycles without failure. The endurance limit of the scaffolds was determined to be 90 % of their yield strength in air, but only 60 % in r-SBF. No notable crack formation in the specimens tested in air was observed even after loading up to 90 % of their yield strength. As for the specimens tested in r-SBF, however, cracks formed in the specimens subjected to loads exceeding 60 % of their yield strength appeared to initiate on the periphery and propagate toward the internal struts. Altogether, the results show that the extrusion-based AM porous Fe35Mn alloy is capable of tolerating up to 60 % of its yield strength for up to 3 million cycles, which corresponds to 1.5 years of use of load-bearing implants subjected to repetitive gait cycles. The fatigue performance of the alloy thus further enhances its potential for trabecular bone substitution subjected to cyclic compressive loading. STATEMENT OF SIGNIFICANCE: Fatigue behavior of extrusion-based AM porous Fe35Mn alloy scaffolds in air and revised simulated body fluid was studied. The Fe35Mn alloy scaffolds endured 90 % of their yield strength for up to 3 × 106 loading cycles in air. Moreover, the scaffolds tolerated 3 × 106 loading cycles at 60 % of their yield strength in revised simulated body fluid. The Fe35Mn alloy scaffolds exhibited a capacity of withstanding 1.5-year physiological loading when used as bone implants.

Fatigue behavior of biodegradable Zn-Li binary alloys in air and simulated body fluid with pure Zn as control

Zn-Li-based alloys have drawn great attention as promising candidates for load-bearing sites, such as intramedullary nails and bone plates. They possess high monotonic strength (over 500MPa) and better pitting resistance with lithium-rich layers acting as barriers for corrosion attack under (quasi-)static conditions. However, their response to dynamic loadings such as fatigue is still unknown. Herein, the corrosion fatigue behavior of a series of Zn-Li binary alloys with different lithium addition amounts was tested in simulated body fluid. Tensile and fatigue strength of the materials were proportional to lithium content while corrosion fatigue strength was not. Extremely long cracks that extended parallel to the loading direction were found in Zn-1.0wt.%Li alloys. These cracks propagated by selective dissolution of the lithium-rich phase in the eutectoid regions and drastically reduced the corrosion fatigue strength of Zn-1.0wt.%Li alloy owing to exacerbated crack propagation. To sum up, Zn-Li binary alloys showed fatigue strength comparable to pure iron and pure titanium, which confirmed their loading capacity under dynamic conditions. STATEMENT OF SIGNIFICANCE: Zn-Li-based alloys are qualified as biodegradable metals and are dedicated to load-bearing applications. Current research has shown that lithium can suppress pitting corrosion by the formation of lithium-rich layers on the alloy surface during (quasi-)static conditions. However, how these materials respond to dynamic loading is still unknown. The present study investigated the influence of lithium amount (0.1∼1.0wt.%) on the corrosion fatigue behavior of binary Zn-Li alloys. The results showed that lithium effectively improved the mechanical strength but can harm corrosion fatigue strength at high content due to selective dissolution of lithium-rich phase. This demonstrated that the amount of lithium should be controlled for optimal properties. Zn-0.8wt.%Li alloy demonstrated a good combination of tensile and corrosion fatigue strength, which can be further improved by proper alloying and thermomechanical treatment.

Corrosion fatigue behavior and anti-fatigue mechanisms of an additively manufactured biodegradable zinc-magnesium gyroid scaffold

Additively manufactured biodegradable zinc (Zn) alloy scaffolds constitute an important branch in orthopedic implants because of their moderate degradation behavior and bone-mimicking mechanical properties. This work investigated the corrosion fatigue response of a zinc-magnesium (Zn-Mg) alloy gyroid scaffold fabricated via laser-powder-bed-fusion additive manufacturing at the first time. The high-cycle compression-compression fatigue testing of the printed Zn-Mg scaffold was conducted in simulated body fluid, showing its favorable fatigue strength, structural reliability, and anti-fatigue capability. The printed Zn-Mg scaffold obtained a 227% higher fatigue strength than that of the printed Zn scaffold but 17% lower strain accumulation at 10⁶ cycles. The accumulative strain of the Zn-Mg scaffold at its fatigue strength was dominant by fatigue ratcheting, since the fatigue damage strain of the scaffold was approximately zero. The corrosion products (ZnO and Zn(OH)₂) were conducive to the inhibition of fatigue ratcheting and fatigue damage. Dislocation pile-up and solid solution phases at the grain boundaries of the Zn-Mg scaffold could retard the spreading of the crack tip and impede excessive grain coarsening, improving its fatigue endurance limit. Notably, the printed Zn-Mg scaffold could dissipate the fatigue energy through moderate grain boundary migration, thus reducing its plastic deformation. These findings illuminated the anti-fatigue mechanisms related to microstructural features and corrosive environments and highlighted the promising prospects of additively manufactured Zn-Mg scaffolds in orthopedic applications. STATEMENT OF SIGNIFICANCE: : Additive manufacturing (AM) of biodegradable metals shows unprecedented prospects for bone tissue regeneration medicine. The corrosion fatigue property is one of the key determinants in the performance of AM biodegradable scaffolds. In this study, a Zn-Mg gyroid scaffold was additively manufactured with admirable fatigue endurance limit and anti-fatigue capability. We reported that the corrosion fatigue performance was highly relevant to the microstructural features, validating that the grain boundary engineering strategy improved fatigue strength and inhibited crack penetration. Notably, moderate grain boundary migration could dissipate fatigue energy and reduce plastic deformation. Furthermore, corrosion products were conducive to impeding fatigue ratcheting and fatigue damage, indicating the promising potential of AM Zn-Mg scaffolds in treating load-bearing bone defects.

A review of crack growth models for near-neutral pH stress corrosion cracking on oil and gas pipelines

This paper presents a review of four existing growth models for near-neutral pH stress corrosion cracking (NNpHSCC) defects on buried oil and gas pipelines: Chen et al.'s model, two models developed at the Southwest Research Institute (SwRI) and Xing et al.'s model. All four models consider corrosion fatigue enhanced by hydrogen embrittlement as the main growth mechanism for NNpHSCC. The predictive accuracy of these growth models is investigated based on 39 crack growth rates obtained from full-scale tests conducted at the CanmetMATERIALS of Natural Resources Canada of pipe specimens that are in contact with NNpH soils and subjected to cyclic internal pressures. The comparison of the observed and predicted crack growth rates indicates that the hydrogen-enhanced decohesion (HEDE) component of Xing et al.'s model leads to on average reasonably accurate predictions with the corresponding mean and coefficient of variation (COV) of the observed-to-predicted ratios being 1.06 and 61.2%, respectively. The predictive accuracy of the other three models are markedly poorer. The analysis results suggest that further research is needed to improve existing growth models or develop new growth models to facilitate the pipeline integrity management practice with respect to NNpHSCC.

Hydrothermally grown TiO2-nanorods on surface mechanical attrition treated Ti: Improved corrosion fatigue and osteogenesis

Current bioactive modifications of Ti-based materials for promoting osteogenesis often decrease corrosion fatigue strength (σ_cf) of the resultant implants, thereby shortening their service lifespan. To solve this issue and accelerate the osteogenesis process, in the present study, a TiO₂ nanorods (TNR)-arrayed coating was hydrothermally grown on optimal surface mechanical attrition treated (SMATed) titanium (S-Ti). The microstructure, bond integrity, residual stress distribution, and corrosion fatigue of TNR-coated S-Ti (TNR/S-Ti) and the response of macrophages and bone marrow-derived mesenchymal stem cells (BMSCs) to TNR/S-Ti were investigated and compared with those of mechanically polished Ti (P-Ti), S-Ti, and TNR-coated P-Ti (TNR/P-Ti). S-Ti showed a nanograined layer and an underlying grain-deformed region with residual compressive stress, which was sustained even when it was hydrothermally coated with TNR. TNR on S-Ti showed nanotopography, composition, and bond strength almost identical to those of P-Ti. While TNR/P-Ti showed a considerable decrease in σ_cf compared to P-Ti, TNR/S-Ti exhibited an improved σ_cf which was even higher than that of P-Ti. Biologically, TNR/S-Ti enhanced adhesion, differentiation, and mineralization of BMSCs, and it also promoted adhesion and M1-to-M2 transition of macrophages as compared to S-Ti and P-Ti. With rapid phenotype switch of macrophages, the level of proinflammatory cytokines decreased, while anti-inflammatory cytokines were upregulated. In co-culture conditions, the migration, differentiation, and mineralization of BMSCs were enhanced by increased level of secretion factors of macrophages on TNR/S-Ti. The modified structure accelerated bone apposition in rabbit femur and is expected to induce a favorable immune microenvironment to facilitate osseointegration earlier; it can also simultaneously improve corrosion fatigue resistance of Ti-based implants and thereby enhance their service life.

Corrosion fatigue behavior of additively manufactured biodegradable porous zinc

Additively manufactured (AM) biodegradable porous zinc exhibits great potential as a promising bone-substituting biomaterial. However, there is no information whatsoever available regarding its corrosion fatigue behavior. In this study, we used direct metal printing to fabricate topologically ordered biodegradable porous zinc based on a diamond unit cell. We compared the compression-compression fatigue behavior of AM porous zinc in air and in revised simulated body fluid (r-SBF). The fatigue strength of AM porous zinc was high in air (i.e., 70% of its yield strength) and even higher in r-SBF (i.e., 80% of its yield strength). The high value of the relative fatigue strength in air could be attributed to the good ductility of pure zinc itself. The formation of corrosion products around the strut junctions might explain the higher fatigue strength of AM zinc in r-SBF. Furthermore, we compared the fatigue behavior of a uniform design of the AM porous zinc with a functionally graded design. The functionally graded structure exhibited higher relative fatigue strengths than the uniform structure. The inspection of the fatigue crack distribution revealed that the functionally graded design controlled the sequence of crack initiation, which occurred early in the thicker struts and moved towards the thinner struts over time. The theoretical fatigue life models suggest that optimizing the functionally graded structure could be used as an effective means to improve the fatigue life of AM porous zinc. In conclusion, the favorable fatigue behavior of AM porous zinc further highlights its potential as a promising bone-substituting biomaterial. STATEMENT OF SIGNIFICANCE: Additively manufactured (AM) biodegradable porous zinc exhibits great potential for the treatment of large bony defects. However, there is no information available regarding its corrosion fatigue behavior. Here, we compared the fatigue behavior of AM porous zinc in air and in revised simulated body fluid (r-SBF). The fatigue strength of AM porous Zn was even higher in r-SBF than in air, which were attributed to the formation of corrosion products. Furthermore, we found that the functionally graded structure controlled the sequence of crack initiation in differently sized struts and exhibited higher relative fatigue strengths than the uniform structure, suggesting that optimizing the functionally graded structure could be an effective means to improve the fatigue life of AM porous Zn.

A numerical corrosion-fatigue model for biodegradable Mg alloy stents

Biodegradable magnesium alloys have attracted research interest as matrix materials for next-generation absorbable metallic coronary stents. Subject to cyclic stresses, magnesium alloy stents (MAS) are prone to premature failures caused by corrosion fatigue damage. This work aimed to develop a numerical continuum damage mechanics model, implemented with the finite element method, which can account for the corrosion fatigue of Mg alloys and the applications in coronary stents. The parameters in the resulting phenomenological model were calibrated using our previous experimental data of HP-Mg and WE43 alloy and then applied in assessing the performance of the MAS. The results indicated that it was valid to predict the degradation rate, the damage-induced reduction of the radial stiffness, and the critical location of the MAS. Furthermore, this model and the numerical procedure can be easily adapted for other biodegradable alloy systems, for instance, Fe and Zn, and used to achieve the optimal degradation rate while improving fatigue endurance. STATEMENT OF SIGNIFICANCE: Subject to cyclic stresses, magnesium alloy stents are prone to premature failures caused by corrosion fatigue damage. This work aimed to develop a numerical continuum damage mechanics model, implemented with the finite element method, which can account for the corrosion fatigue of Mg alloys and the applications in coronary stents. The results indicated that it was valid to predict the degradation rate, damage-induced reduction of the radial stiffness, and the critical location of the Mg alloy stent; therefore, these stents can be easily adapted to other biodegradable alloy systems such as Fe and Zn.

In-vitro biodegradation and corrosion-assisted cracking of a coated magnesium alloy in modified-simulated body fluid

A calcium phosphate coating was directly synthesized on AZ91D magnesium (Mg) alloy. Resistance of this coating to corrosion in a modified-simulated body fluid (m-SBF) was investigated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). Mechanical properties of the bare and coated alloy were investigated using slow strain rate tensile (SSRT) and fatigue testing in air and m-SBF. Very little is reported in the literature on human-body-fluid-assisted cracking of Mg alloys, viz., resistance to corrosion fatigue (CF) and stress corrosion cracking (SCC). This study has a particular emphasis on the effect of bio-compatible coatings on mechanical and electrochemical degradations of Mg alloys for their applications as implants. The results suggest the coating to improve the general as well as pitting corrosion resistance of the alloy. The coating also provides visible improvement in resistance to SCC, but little improvement in CF resistance. This is explained on the basis of pitting behaviour in the presence and absence of the coating.

Fatigue behaviors of HP-Mg, Mg-Ca and Mg-Zn-Ca biodegradable metals in air and simulated body fluid

The dynamic loading in human body, along with the corrosive body fluid, presents a great challenge for the practical use of biodegradable magnesium implants. In this study, a high purity magnesium (99.99wt.%) and two typical promising biodegradable magnesium alloys (binary Mg-1Ca and ternary Mg-2Zn-0.2Ca) were chosen as the experimental materials. Their dynamic mechanical performances were comparatively evaluated by carrying out fatigue tests in air and in simulated body fluid (SBF). The fatigue strengths of HP-Mg, Mg-1Ca and Mg-2Zn-0.2Ca were all around 90MPa in air, however, they decreased to 52MPa, 70MPa and 68MPa in SBF at 4×10(6)cycles, respectively. The fatigue cracks initiated from the microstructural defects when tested in air, but nucleated from surface corrosion pits when tested in SBF. Cyclic loading significantly increased the corrosion rates of all the experimental materials compared to that in static SBF. Moreover, based on our findings, the fatigue failure processes and interactions between material, corrosion and cyclic loading were systematically discussed.

STATEMENT OF SIGNIFICANCE

Fatigue strength and life are vital parameters to the design of metallic implant devices. For the corrosion fatigue of biomedical magnesium alloys, we reported the corrosion fatigue behavior of AZ91D and WE43 in SBF (Acta Biomaterialia, 6 (2010) 4605-4613), and till now there is no other reports to our knowledge. We spent 3years to finish the fatigue testing and get S-N curves for three more magnesium biomaterials, and our significant finding is that the fatigue strengths of HP-Mg, Mg-1Ca and Mg-2Zn-0.2Ca are all around 90MPa in air but 52MPa, 70MPa and 68MPa in SBF at 4×10(6)cycles, which will provide the first-hand data for the future magnesium implants design.

Degradation of Ti-6Al-4V alloy under cyclic loading in a simulated body environment with cell culturing

The present study reports the corrosion fatigue of the Ti-6Al-4V alloy using cyclic deformation test in a simulated body fluid under cell culturing for the first time. Cyclic deformation tests were carried out using three types of specimens to reveal the effects of proteins and cells on the corrosion fatigue of the alloy. For the 1-day-immersed and 1-week-immersed specimens, tensile specimens were soaked in a simulated body fluid for 1 day and 1 week, respectively, before cyclic deformation test, whereas for the cell-cultured specimen, MC3T3-E1 osteoblast-like cells were seeded and then cultured on tensile specimens for 1 week. The incubation period for crack initiation was longer for the cell-cultured and 1-week-immersed specimens compared to that for the 1-day-immersed specimen. On the other hand, crack propagation period for the cell-cultured and 1-week-immersed specimens was shorter than that for the 1-day-immersed specimen. These results indicate that proteins and cells adhered on the alloy surface inhibit metal dissolution at newly created surface emerged by cyclic deformation to suppress crack initiation, whereas they accelerate crack propagation because dissolution at crack tip is accelerated in the occluded space formed under proteins and cells.

Influence of environment on the fatigue crack growth behaviour of 12% Cr steel

In the present work, the influence of different environments on the fatigue crack growth behaviour of 12% Cr steam turbine blade steel is investigated. Fatigue crack growth rates (FCGRs) in the near threshold regime are measured with ultrasonic fatigue testing technique. Fatigue tests are performed in vacuum, air and different aqueous environments with defined chloride and oxygen content. Furthermore, the influence of different stress ratios is investigated. It is found that crack propagation is not necessarily enhanced with increasing corrosiveness. In the aqueous environments, the FCGRs below 10⁻⁸ m/cycle are lower than in air. The threshold stress intensity factor ranges are higher or equal. Observation of the fracture surfaces shows oxide formation and partly intergranular fracture for specimens tested in aqueous environments. Crack closure effects seem to be responsible for this unexpected behaviour.