Orthopedic Implants Research Articles

Soft Tissue Reconstruction and Integration to Implant After Bone-Tumor Resection: A Current Concept Review

Introduction: With the advancements in chemotherapy for malignant bone tumors, the number of patients eligible for limb salvage surgery has increased. Surgeons face a subsequent challenge in limb-sparing resection due to the need for reconstructing soft tissue coverage. The aim of this review is to focus on the present state of the field in these areas, highlighting recent advancements. Methods: A literature research was conducted using keywords such as “soft tissue”, “integration”, “reconstruction”, “megaprosthesis”, and “soft tissue coverage”, on different databases, and following the Preferred Reporting Items for Systematic Reviews and Meta-analyses (PRISMA) criteria, a total of 35 studies were selected. Results: In recent times, there has been a growing emphasis on different techniques such mesh application, allograft-prosthesis composites, allograft reconstruction, a polyethylene terephthalate (PET) tube, prosthesis itself and certain metals utilized for implant coatings are used in soft tissue reconstruction. Conclusion: While tissue-engineered constructs and advancements in biological and cellular approaches have shown potential for enhancing osseointegration and interactions with soft tissues and implants, the actual clinical outcomes have frequently fallen short of expectations. The success of soft tissue integration is crucial for achieving functional outcomes, minimizing complications, and ensuring the long-term stability of orthopedic implants.

Nanotechnology-Enhanced Orthopaedic Surgery

Nanomaterials hold significant promise for the future of orthopaedic implants due to their ability to mimic the nanoscale components of the bone, such as collagen fibrils and hydroxyapatite. Nanomaterials can regulate cell behaviour while offering mechanical strength and biocompatibility, making them ideal for bone repair and tissue regeneration. This comprehensive review explores the key existing and potential applications of nanotechnology in orthopaedics, including bone tissue engineering, drug delivery systems, systems combatting implant-related infections, and the surface preparation of implants to enhance osseointegration. These innovations are poised to revolutionise orthopaedic care by improving implant durability, reducing infection risks, and promoting bone regeneration to deliver personalised treatment and create better patient outcomes.

Synthesis methods of Mg-based scaffolds and their applications in tissue engineering: A review.

Repair and regeneration of damaged tissues due to disease and accidents have become a severe challenge to tissue engineers and researchers. In recent years, biocompatible metal materials such as stainless steels, cobalt alloys, titanium alloys, tantalum alloys, nitinol, and Mg alloys have been studied for tissue engineering applications; as suitable candidates in orthopedic and dentistry implants. These materials and their alloys are used for load-bearing and physiological roles in biological applications. Due to the suitable conditions provided by a porous material, many studies have been performed on the porous implants, including Mg-based scaffolds. Mg alloy scaffolds are attractive due to some outstanding features and susceptibilities, such as providing a cell matrix for cell proliferation, migration, and regeneration, providing metabolic substances for bone tissue growth, biocompatibility, good biodegradability, elastic modulus comparable to the natural bone, etc. Accordingly, in the present study, a general classification of all the production methods of Mg-based scaffolds is provided. Strengths and weaknesses, the effect of the production approach on the final properties of scaffolds, including mechanical and biological capabilities, and the impact of alloying elements and process parameters have been reviewed, and discussed. Finally, the manufacturing methods have been compared and the upcoming challenges have been stated.

Corrosion Behavior of SLMed Ti6Al4V-Equine Bone Nanocomposites

Ti6Al4V is one of the most widely used Ti alloys in biomedical applications, such as orthopedic and dental implants, due to its excellent mechanical properties, biocompatibility, and high corrosion resistance. Metal implants require high bonding strength between the implant and bone for long-term use in the human body; Hydroxyapatite (HAp) has generally been used as it can be expected to provide high osseointegration. However, in this study, Equine Bone (EB), which is a biowaste with a similar chemical composition to HAp and is environmentally friendly, was used instead. Ti6Al4V and EB were mixed through ball milling and then fabricated into Ti6Al4V-0.05EB composites using Selective Laser Melting (SLM). During the SLM process, localized high thermal gradients and rapid cooling rates leads to high strength and low ductility, making it challenging to use as a biomaterial. To overcome these issues, heat treatment was performed at temperatures corresponding to the <i>β</i> phase transformation. Subsequently, to evaluate the corrosion behavior after implantation in the body, the corrosion resistance of the Ti6Al4V-0.05EB nanocomposites was assessed through potentiodynamic polarization tests in a 0.9% NaCl solution, which simulates the physiological environment of the human body. Additionally, the effects of EB addition and heat treatment temperature on the corrosion behavior were also observed.

Integrating machine learning for predicting biomechanical properties of layered manufactured bone implants

AbstractThe layered manufacturing (LM) based locking bone plates (LBPs) are highly favored for biomedical applications due to its implant customization flexibility, control over porosity, and functional parameters. Design of experiments mainly relies on predefined experimental run orders; however, machine learning (ML) can handle complex and nonlinear relationships for predicting output responses. This research investigates the application of various ML models for predicting the impact strength, torque values, and punch shear strength of poly lactic acid (PLA) based LBPs. A dataset of 100 data points for each response variable was developed, analyzing the influence of printing parameters, like infill density (ID), layer height (LH), wall thickness (WT), and print speed (PS). The ID, LH, WT, and PS were varied within the ranges of 20%–100%, 0.1–0.5 mm, 0.4–1.2 mm, and 20–100 mm/s, respectively. Among the ML models evaluated, XGBoost and Adaboost exhibited strong alignment of the predicted values with actual values. The decision tree regression, showed the lowest predictive accuracy due to its tendency to overfit and lack of iterative refinement. The findings suggest that ML models can effectively predict the mechanical properties of PLA‐based LBPs, offering valuable insights for optimizing printing parameters to enhance the performance of orthopedic implants. The findings can guide biomedical engineers in making data‐driven decisions to enhance the strength of LBPs, thereby improving patient outcomes in orthopedic treatments.Highlights Predicted impact strength, torque, and shear strength of biomedical specimens. Evaluated 100 data points per variable to assess printing parameters' influence. XGBoost and Adaboost showed superior accuracy, with R2 consistently above 0.9. Decision Tree regression exhibited the lowest accuracy due to overfitting issues. Aims to guide biomedical engineers in data‐driven decisions for better patient outcomes.

Incorporation of Cerium Oxide Nanoparticles into the Micro-arc Oxidation Layer Promotes Bone Formation and Achieves Structural Integrity in Magnesium Orthopedic Implants

Biodegradable metals offer significant advantages by reducing the need for additional surgeries following bone fixation. These materials, with their optimal mechanical and degradable properties, also mitigate stress-shielding effects while promoting biological processes essential for healing. This study investigated the in vitro and in vivo biocompatibility of ZK60 magnesium alloy coated with a micro-arc oxidative layer incorporated with cerium oxide nanoparticles in orthopedic implants. The results demonstrated that the magnesium substrate undergoes gradual degradation, effectively eliminating long-term inflammation during bone formation. The micro-arc oxidative coating forms a dense ceramic layer, acting as a protective barrier that reduces corrosion rates and enhances the biocompatibility of the magnesium substrate. The incorporation of cerium oxide nanoparticles improves the tribological properties of the coating, refining degradation patterns and improving osteogenic characteristics. Furthermore, cerium oxide nanoparticles enhance bone reconstruction by facilitating appropriate interconnections between newly formed bone and native bone tissue. Consequently, cerium oxide nanoparticles contribute to favorable biosafety outcomes and exceptional bone remodeling capabilities by supporting bone healing and sustaining a prolonged degradation process, ultimately achieving dynamic equilibrium in bone tissue formation. Statement of SignificanceThis study comprehensively examined the incorporation of ceria nanoparticles into biodegradable magnesium through a micro-arc oxidative process for use in orthopedic implants. This study conducted a comprehensive analysis involving material characterization, biodegradability testing, in vitro osteogenesis assays, and in vivo implantation, highlighting the potential benefits of the distinctive properties of ceria nanoparticles. This research emphasizes the ability of ceria nanoparticles to enhance the biodegradability of magnesium and facilitate remarkable bone regeneration, suggesting promising advantages for additive materials in orthopedic implants.

3D printed TC4 titanium alloy bone scaffolds with TNTs-VA-PLGA composite coating on the surface:improved infection resistance and biocompatibility

Titanium-based bone scaffolds are prone to aseptic infection and loosening after implantation,which seriously limits their clinical applications. Preparation of titanium dioxide nanotubes (TNTs) on the surface of the scaffolds and loading of anti-infective drugs is an effective method to solve this problem, but the current TNTs prepared on the surface of titanium-based scaffolds have a high internal and external variability in morphology and low drug loading capacity. In this study, we prepared TNTs on the surface of three kinds of TC4 titanium alloy scaffolds with TPMS structure with controllable morphology, tube diameter of 90-125 nm and tube length of 14-35 μm,and the difference between inner and outer diameters of the tubes was less than 2 μm,and the drug released from the composite scaffolds was maintained at a concentration of more than 1.5 μg/ml within 11 days after loading anti-infective drug Vancomycin-polylactic acid-hydroxyacetic acid copolymer(VA-PLGA) on the surface of the TNTs. Based on the simulation of drug release, the TNTs-VA-PLGA drug delivery system conforms to the Korsmeyer-Peppas model. Cell experiments confirmed that the composite scaffolds significantly increased cell proliferation by 65.33% compared with the unmodified scaffolds. The results indicated that the TNTs coating containing vancomycin and polylactic acid-hydroxyacetic acid copolymer had a promising application in orthopedic implants.

A biodegradable, osteo-regenerative and biomechanically robust polylactide bone screw for clinical orthopedic surgery

Poly (L-lactic acid) (PLLA) has emerged as a promising orthopedic implant material due to its favorable strength and biodegradability. However, challenges such as low toughness and limited osteoinductivity hinder its widespread use in bone fixation. This study focuses on enhancing the toughness and osteogenic activity of PLLA-based orthopedic implants. Inspired by reinforcement techniques in the construction industry, we designed a structure comprising flexible fibers enveloped by PLLA/hydroxyapatite (HA) crystalline phases. Initially, PLLA/poly (butylene succinate-co-adipate) (PBSA)/HA composites with “sea-island” morphology were prepared through melt-compounding. Subsequently, the highly oriented PBSA fibers were in situ formed during microinjection molding for bone screw fabrication. Comprehensive investigation into the structural-mechanical property relationship revealed a significant increase in elongation at break (from 5.4 % to 59.4 % with an optimal PBSA/HA ratio), while maintaining a high stiffness and a slight decrease in tensile strength (from 62 MPa to 56 MPa). The flexural tests of the resulting composite bone screws demonstrated a significant increase in toughness. Additionally, the in vivo studies corroborated the osteogenic potential of the microinjection molded bone screws by using hematoxylin and eosin (HE) and Masson staining. The methodology presented in this study offers a promising approach for advancing PLLA-based fixation devices in bone repair applications.

Bioresorbable composites based on magnesium and hydroxyapatite for use in bone tissue engineering: focus on controlling and minimizing corrosion activity

A biodegradable matrix with a significant content of bioactive components can be applied for bone tissue replacement, including load-bearing applications in orthopedic surgery. The study outlines the optimized procedure for the production of bioresorbable magnesium-hydroxyapatite (Mg-HA) composites and their corrosion resistance properties. Composites were meticulously crafted by combining pure magnesium with microwave-synthesized hydroxyapatite nanopowder. Sintering occurred via spark plasma sintering technology (SPS). To align the degradation time of the resulting composites with bone remodeling, the corrosion resistance of SPS materials was enhanced through the application of plasma electrolytic oxidation (PEO) and polycaprolactone (PCL) spin-coating methods. The protective properties, morphology dynamics, and composition due to surface treatment and corrosion propagation were investigated using Electrochemical Impedance Spectroscopy (EIS), Potentiodynamic Polarization (PDP), hydrogen evolution tests, Scanning Electron Microscopy (SEM), Energy-dispersive X-ray (EDX) as well as X-ray diffraction (XRD) analysis. Analytics of the physicochemical properties data of the formed coatings indicate a significant improvement in protective characteristics and deceleration of the corrosive degradation of the samples. The application of polycaprolactone to the PEO coating leads to a decrease in the corrosion current compared to uncoated magnesium composites by more than three orders of magnitude: from 1 10-5 to 2 10-9 A cm-2. During long-term exposure of samples to 0.9 % NaCl solution, it was found that coating reduced the rate of corrosion degradation of samples from 1.5 to 80 times compared to an unprotected Mg-HA composite and sintered magnesium. Mg-HA composites treated with PEO exhibit potential application as bioactive and biodegradable materials for orthopedic implants and fixation devices.

Processing of Reduced Graphene Oxide Reinforced Ultra High Molecular Weight Polyethylene for Orthopedic Implants

Ultra-high molecular weight polyethylene (UHMWPE) has been used as a bearing material in total joint replacements due to its excellent mechanical properties and biocompatibility. The acetabular cup in total hip replacement and the tibial component in total knee replacement is widely fabricated from UHMWPE. The use of UHMWPE in total joint replacements is well established, and the goal is to improve its mechanical properties, wear resistance, and oxidation resistance. The quality and life span of the artificial joints can be further increased by enhancing the relevant mechanical properties of UHMWPE. The addition of filler material to UHMWPE is an effective way to enhance its relevant properties. In this study, relevant properties of UHMWPE were enhanced by incorporating an appropriate filler. Reduced Graphene Oxide (rGO) was selected as a filler material as it improves mechanical properties, wear resistance, toughness, and thermal stability. Graphene oxide (GO) was synthesized by Modified Hummer’s Method (MHM), and it was thermally reduced to obtain rGO. The synthesized GO was characterized by Fourier Transform Infrared spectroscopy (FTIR) and X-Ray Diffraction (XRD) which confirmed the accurate synthesis. The reduction of GO was validated by the disappearance of (OH) broad peak in the FTIR analysis. The rGO/UHMWPE nanocomposite was prepared by adding 0.7 wt.% of rGO employing the solvent mixing method. The morphology of the composite was validated by Scanning Electron Microscopy (SEM). Tensile and Izod Impact tests were performed on the samples which showed an increase in tensile strength of 33.2% and the impact strength increased by 140.5%. The rGO/UHMWPE nanocomposite with greater tensile and impact strength is an excellent candidate to produce orthopedic implants with superior properties.

New low elastic modulus equimassic βeta Ti-Nb-Zr-(Ta-Mo) multiprincipal alloys

The increasing life expectancy, evolving patient demographics, and advancements in implant technologies underscore the need for better biomaterials, particularly alloys with superior mechanical and chemical biocompatibility for biomedical applications like orthopedic implants. β-Ti alloys are promising due to their mechanical properties, including an elasticity modulus (E) of 44–80 GPa, and chemical/biological attributes such as corrosion resistance and osseointegration. This work developed equimassic multicomponent high (HEA) and medium entropy (MEA) β-Ti alloys within the ternary Ti-33Nb-33Zr, quaternary Ti-25Nb-25Zr-25Ta, and quinary Ti-20Nb-20Zr-20Ta-20Mo weight percent systems to achieve an optimized elastic modulus. The study analyzed β-Ti alloys with different β-stabilizing elements, leading to varying entropy levels, and established a relationship between microstructure and properties for enhanced implant efficacy. For the high entropy quinary alloy, increasing the number of alloying elements decreases lattice parameters, increasing the elastic modulus and Vickers microhardness (HV), from 247 HV for the ternary alloy to 453 HV for the quinary alloy. This corresponds to an increase in the entropy degree from 1.041 R to 1.523 R. While a higher entropy degree hinders a low elastic modulus, medium entropy β-Ti alloys such as the quaternary β-Ti-25Nb-25Zr-25Ta alloy achieve an elastic modulus as low as 73 GPa.

The Deposition of Hydroxyapatite Particles Within an Organic Matrix on the Surface of Poly(lactic acid).

Hydroxyapatite (HAP) is a well-established material in biomedical applications, especially for bone tissue regeneration, dental implants, and drug delivery systems. Recent research emphasizes enhancing the biocompatibility and osteoconductivity of orthopedic implants using HAP. This study explores the potential of combining HAP with a lipid matrix to improve the surface properties and biocompatibility of poly(lactic acid) (PLA)-based, 3D-printed, resorbable bone implants. We utilized the Langmuir-Blodgett method to deposit HAP within a dihexadecyl phosphate (DHP) matrix onto PLA substrates. This study demonstrates that DHP and HAP form stable monolayers at the air/water interface with HAP particles distributed within a homogeneous lipid matrix. The presence of HAP and the resulting changes in surface free energy (SFE) are hypothesized to enhance the biocompatibility of PLA implants. Our findings indicate that films composed of DHP + HAP 5:1 are particularly effective in altering PLA surface characteristics, potentially improving osteointegration, and reducing microbial adherence. Overall, this work highlights that surface modification of PLA with HAP and lipid matrices is the first step towards new, promising, and cost-effective strategies for developing advanced biomaterials for bone regeneration.

Recent Advances in Antibacterial Strategies Based on TiO2 Biomimetic Micro/Nano-Structured Surfaces Fabricated Using the Hydrothermal Method

Ti and its alloys, widely utilized in orthopedic and dental implants, inherently lack antibacterial properties, posing significant infection risks, especially in the context of growing antibiotic resistance. This review critically evaluates non-antibiotic antibacterial strategies, with a particular focus on surface modifications and micro/nano-structured surfaces. Micro/nano-structured surfaces, inspired by natural topographies, utilize physical mechanisms to eradicate bacteria. Despite their potential, the antibacterial efficacy of these surfaces remains insufficient for clinical application. Titanium dioxide (TiO2), known for its excellent photocatalytic antibacterial activity and biocompatibility, is emerging as an ideal candidate for enhancing micro/nano-structured surfaces. By combining the photocatalytic antibacterial effects of TiO2 with the mechanical bactericidal properties of micro/nano-structured surfaces, superior antibacterial performance can be achieved. The hydrothermal method is frequently employed to fabricate TiO2 micro/nano-structured surfaces, and this area of research continues to thrive, particularly in the development of antibacterial strategies. With demonstrated efficacy, combined antibacterial strategies based on TiO2 micro/nano-structured surfaces have become a prominent focus in current research. Consequently, the integration of physical stimulation and chemical release mechanisms may represent the future direction for TiO2 micro/nano-structured surfaces. This review aims to advance the study of TiO2 micro/nano-structured surfaces in antibacterial applications and to inspire more effective non-antibiotic antibacterial solutions.

Risk of orthopaedic implant infection during bacteraemia.

Orthopaedic implant material can get infected via haematogenous spread from a distant source at any point after implantation. The sources of haematogenous orthopaedic implant infections have been studied only for prosthetic joints. The most common source of infection has varied, but it can be, for example from the skin and soft tissues, cardiovascular system and dental infections. The risk for developing a periprosthetic joint infection (PJI) during bacteraemia is dependent on the pathogen: it is highest for Staphylococcus aureus and beta-haemolytic streptococci, but low for gram-negative bacteria. The risk for developing a (PJI) during Staphylococcus aureus bacteraemia (SAB) has varied between 12 and 41%; the risk for developing an infection in any orthopaedic implant in the extremities during SAB is probably almost the same as for prosthetic joints, but data are very limited. The risk of developing an infection in spinal implants during bacteraemia is not known, as it has not been studied. Especially in the case of SAB, infected orthopaedic implants are usually symptomatic, so asymptomatic implants do not routinely require further diagnostic work-up, such as synovial fluid aspiration.

A review on the mechanical and biocorrosion behaviour of iron and zinc-based biodegradable materials fabricated using powder metallurgy routes

Abstract Over the past two decades, research on alloys and composites based on Mg, Fe, and Zn has focused on biodegradable orthopaedic implants. Mg-based materials face issues like excessive corrosion rates and hydrogen gas evolution, while Fe and Zn-based materials show lower corrosion rates. However, these rates are slower than the optimal rate, which can be modified using powder metallurgy (PM) manufacturing. The PM process offers precise control over porosity distribution which in turn affects the mechanical and corrosion properties of the fabricated specimen. The highest rate of corrosion i.e. 0.944 mmpy was observed with the alloying of 2 wt% Pd in Fe and by using conventional sintering technique. Similarly, Zn-based samples fabricated by conventional sintering was found to exhibit higher corrosion rate as compared to microwave and spark plasma sintered specimen. PM-fabricated Fe and Zn-based bone scaffolds have been investigated for in-vitro corrosion and osseointegration. A higher porosity in the Fe and Zn scaffolds (>60 %) resulted in high corrosion rate which adversely impacted the cell proliferation. This timely review critically assessed PM-fabricated Fe and Zn-based materials that have the potential to transform regenerative medicine and patient care by redefining the field of biodegradable implants.

Ti6Al4V Implants with Dense-Trabecular Bilayer Morphology for Bone Ingrowth: Synergy of Green Net Shaping and Sacrificial Templating.

Stress shielding in dental and orthopedic implants is a long-standing hurdle, and trabecular porous architecture to improve bone ingrowth is deemed to be a potential solution. Fabricating Ti6Al4V components with dense-porous bilayer structures is complicated with limited lab-scale and commercial success. Here, a green dough-forming technique with metal powders is successfully explored to develop heterogeneous structures with a monolith-like dense-porous interface. The porous region achieved 70% porosity with a 25 MPa compressive strength comparable to human cancellous bone. Due to its simplicity and versatility, this process is a promising solution for developing and mass-manufacturing customized designs for bone-related implants with improved bone ingrowth and osseointegration.

Progress in Designing Therapeutic Antimicrobial Hydrogels Targeting Implant-associated Infections: Paving the Way for a Sustainable Platform Applied to Biomedical Devices.

Implantable biomedical devices have found widespread use in restoring lost functions or structures within the human body, but they face a significant challenge from microbial-related infections, which often lead to implant failure. In this context, antimicrobial hydrogels emerge as a promising strategy for treating implant-associated infections owing to their tunable physicochemical properties. However, the literature lacks a comprehensive analysis of antimicrobial hydrogels, encompassing their development, mechanisms, and effect on implant-associated infections, mainly in light of existing in vitro, in vivo, and clinical evidence. Thus, this review addresses the strategies employed by existing studies to tailor hydrogel properties to meet the specific needs of each application. Furthermore, this comprehensive review critically appraises the development of antimicrobial hydrogels, with a particular focus on solving infections related to metallic orthopedic or dental implants. Then, preclinical and clinical studies centering on providing quantitative microbiological results associated with the application of antimicrobial hydrogels are systematically summarized. Overall, antimicrobial hydrogels benefit from the tunable properties of polymers and hold promise as an effective strategy for the local treatment of implant-associated infections. However, future clinical investigations, grounded on robust evidence from in vitro and preclinical studies, are required to explore and validate new antimicrobial hydrogels for clinical use.

Magnesium-Titanium Alloys: A Promising Solution for Biodegradable Biomedical Implants.

Magnesium (Mg) has attracted considerable attention as a biodegradable material for medical implants owing to its excellent biocompatibility, mitigating long-term toxicity and stress shielding. Nevertheless, challenges arise from its rapid degradation and low corrosion resistance under physiological conditions. To overcome these challenges, titanium (biocompatibility and corrosion resistance) has been integrated into Mg. The incorporation of titanium significantly improves mechanical and corrosion resistance properties, thereby enhancing performance in biological settings. Mg-Ti alloys are produced through mechanical alloying and spark plasma sintering (SPS). The SPS technique transforms powder mixtures into bulk materials while preserving structural integrity, resulting in enhanced corrosion resistance, particularly Mg80-Ti20 alloy in simulated body fluids. Moreover, Mg-Ti alloy revealed no more toxicity when assessed on pre-osteoblastic cells. Furthermore, the ability of Mg-Ti-based alloy to create composites with polymers such as PLGA (polylactic-co-glycolic acid) widen their biomedical applications by regulating degradation and ensuring pH stability. These alloys promote temporary orthopaedic implants, offering initial load-bearing capacity during the healing process of fractures without requiring a second surgery for removal. To address scalability constraints, further research is necessary to investigate additional consolidation methods beyond SPS. It is essential to evaluate the relationship between corrosion and mechanical loading to confirm their adequacy in physiological environments. This review article highlights the importance of mechanical characterization and corrosion evaluation of Mg-Ti alloys, reinforcing their applicability in fracture fixation and various biomedical implants.

Stacking fault energy during DRV-DRX competition in high-nitrogen austenitic stainless steel used in orthopedic implants

High-nitrogen (high-N) austenitic stainless steels (ASS) are used in orthopedic implants due to their mechanical properties, human biocompatibility, and affordable cost. However, the high content of (Ni–Nb–N)-rich precipitates can cause allergic reactions and significant challenges in the manufacturing of prostheses. This study investigates the competition between work hardening (WH), dynamic recovery (DRV), and dynamic recrystallization (DRX) during the physical simulation of an ASTM F-1586 steel by thermomechanical processing, using the Kocks-Mecking and Avrami constitutive models. The parameters were obtained through continuous isothermal torsion tests at the temperature range of 900–1200 °C, strain rates between 0.01 and 10 s−1 and a total deformation of 4.0. Determined by compositional-analytical methods, the stacking fault energy (γsfe) was correlated with the stress level (σi) according to the Uesugi and Dai models. Results indicated a high activation energy for hot deformation (Qdef = 587 kJ/mol), affecting the shape of the curves. The γsfe value varied along the curves, delaying the onset of the DRX (σc = 0.928σp). Scanning electron microscopy (SEM) and transmission electron microscopy (TEM) analyses revealed a direct competition between work-hardened and recrystallized grains in the early part of the curves, due to WH-DRV synergy. After the peak stress (σp), the progress of DRX was slow, with the Avrami exponent (n) between 1.1 and 1.9, completing only after large deformations (σss = 0.714σp). The moderate γsfe value (69 mJ/m2) and fine precipitates of the Z-phase (CrNbN) (<20 nm) influence the grain boundary mobility during the DRV-DRX competition, delineating the stress-strain curve shape.

In-vitro study of Ti6Al4V alloy fabricated by laser-based additive manufacturing for orthopedic implant applications

The Ti6Al4V alloy is widely used in orthopedic implants due to its excellent mechanical properties and biocompatibility. However, traditional manufacturing techniques are unable to fabricate complex geometrical shapes with tailored properties. This leads to premature failure due to wear, corrosion, and poor osseointegration. Recent advancements in laser-based additive manufacturing, particularly in direct metal laser sintering (DMLS), offer new opportunities to produce Ti6Al4V implants with tailored microstructures, mechanical properties, and biocompatibility. However, wear, corrosion, and cell viability behavior, required for evaluating the biomedical applicability of Ti6Al4V alloy produced through the DMLS route have not been reported. The present study fulfills this gap in the literature. Micro structural study revealed that DMLS-produced Ti6Al4V has a porous and fine grain structure (with mostly α′ phase) without any crack formation due to the controlled parameters during DMLS. Corrosion tests were conducted in simulated body fluid as an electrolytic media, while fibroblast cell lines were used to evaluate the cell viability. Compared to the conventional cast product, DMLS-produced Ti6Al4V alloy exhibited significantly higher porosity (4.8 times), scratch resistance (23.25%), wear resistance (11.53%), corrosion resistance (16.56%), and cell growth. (4.37%), thus making it a more suitable alloy for implants.