Multi-functional Ti6Al4V-CoCrMo implants fabricated by multi-material laser powder bed fusion technology: A disruptive material's design and manufacturing philosophy.

A home-made 3D Multi-Material Laser Powder Bed Fusion (3DMMLPBF) technology was exploited to manufacture novel multi-material Ti6Al4V-CoCrMo parts. This multi-material concept aims to bring to life a new and disruptive material's design concept for the acetabular cup. Only using a layer-by-layer approach it is possible to manufacture an acetabular cup capable to combine CoCrMo alloy wear resistance and Ti6Al4V alloy bone-friendly nature, in a single component, fabricated at once. This system works with multiple powder deposition functions and vacuum cleaning procedures allowing to use two different powders (Ti6Al4V and CoCrMo) in each layer and thus, allowing to construct 3D Multi-Material transition between distinct materials, point-by-point and layer-by-layer. In this sense, the manufacturing strategies and the functional transition between Ti6Al4V and CoCrMo with a mechanical interlocking were analyzed and discussed both from mechanical and metallurgical point of view. A small diffusion area and no evidence of defects or cracks can be found in the transition's regions between the distinct materials which are strong evidences of a solid metallurgical bonding at the interfacial regions of Ti6Al4V and CoCrMo materials. A functional transition is also obtained through a design capable to provide a 3D mechanical interlocking with potential of assuring, simultaneously, tensile and compressive strength. This proof of concept might be a step-ahead in Laser Powder Bed Fusion in which the most desired intrinsic of individual materials can be combined in a single component targeting biomedical disruptive solutions.

Multi-material cellular structured orthopedic implants design: In vitro and bio-tribological performance.

In this study, Selective Laser Melting (SLM) was used to produce mono-material Ti64Al4V- and NiTi-cubic cellular structures with an open-cell size and wall thickness of 500 µm and 100 µm, respectively. Bioactive beta-tricalcium phosphate (ßTCP) and polymer poly-ether-ether ketone (PEEK) were used to fill the produced structures open-cells, thus creating multi-material components. These structures were characterized in vitro in terms of cell viability, adhesion, differentiation and mineralization. Also, bio-tribological experiments were performed against bovine plate to mimic the moment of implant insertion. Results revealed that metabolic activity and mineralization were improved on SLM mono-material groups, when compared to the control group. All cell metrics were improved with the addition of PEEK, conversely to ßTCP where no significant differences were found. These results suggest that the proposed solutions can be used to improve implants performance.

Predicting the output dimensions, porosity and elastic modulus of additive manufactured biomaterial structures targeting orthopedic implants.

SLM accuracy for fabricating porous materials is a noteworthy hindrance when aiming to obtain biomaterial cellular structures owing precise geometry, porosity, open-cells dimension and mechanical properties as outcomes. This study provides a comprehensive characterization of seventeen biomaterial Ti6Al4V-based structures in which experimental and numerical investigations (compression stress-strain tests) were carried out. Mono-material Ti6Al4V cellular structures and multi-material Ti6Al4V-PEEK cellular structures were designed, produced by SLM and characterized targeting orthopedic implants. In this work, the differences between the CAD design and the as-produced Ti6Al4V-based structures were obtained from image analysis and were used to develop predictive models. The results showed that dimensional deviations inherent to SLM fabrication are systematically found for different dimensional ranges. The present study proposes several mathematical models, having high coefficients of determination, that estimate the real dimensions, porosity and elastic modulus of Ti6Al4V-based cellular structures as function of the CAD model. Moreover, numerical analysis was performed to estimate the octahedral shear strain for correlating with bone mechanostat theory limits. The developed models can help engineers to design and obtain near-net shape SLM biomaterials matching the desired geometry, open-cells dimensions, porosity and elastic modulus. The obtained results show that by using these AM structures design it is possible to fabricate components exhibiting a strain and elastic modulus that complies with that of bone, thus being suitable for orthopedic implants.

Development of ß-TCP-Ti6Al4V structures: Driving cellular response by modulating physical and chemical properties.

Load-bearing implants success is strongly dependent on several physical and chemical properties that are known to drive cellular response. In this work, multi-material ß-TCP-Ti6Al4V cellular structures were designed to combine Ti6Al4V mechanical properties and ß-Tricalcium Phosphate bioactivity, in order to promote bone ingrowth as the bioactive material is being absorbed and replaced by newly formed bone. In this sense, the produced structures were characterized regarding roughness, wettability, ß-TCP quantity and quality inside the structures after fabrication and the pH measured during cell culture (as consequence of ß-TCP dissolution) and those aspects were correlated with cellular viability, distribution, morphology and proliferation. These structures displayed a hydrophilic behavior and results showed that the addition of ß-TCP to these cellular structures led to an alkalization of the medium, aspect that significantly influences the cellular response. Higher impregnation ratios were found more adequate for lowering the media pH and toxicity, and thus enhance cell adhesion and proliferation.

Multi-material Ti6Al4V & PEEK cellular structures produced by Selective Laser Melting and Hot Pressing: A tribocorrosion study targeting orthopedic applications.

Ti6Al4V-alloy is commonly used in dental and orthopedic applications where tribochemical reactions occur at material/bone interface. These reactions are one of the main concerns regarding Ti6Al4V implants due to the generation of wear particles, linked to the release of metallic ions in toxic concentration which occurs when TiO2 passive film is destroyed by means of wear and corrosion simultaneously. In the present study, a multi-material Ti6Al4V-PEEK cellular structure is proposed. Selective Laser Melting technique was used to produce Ti6Al4V dense and cellular structured specimens, whilst Hot-Pressing technique was employed to obtain multi-material Ti6Al4V-PEEK structures. This study investigates the tribocorrosion behavior of these materials under reciprocating sliding, comparing them with commercial forged Ti6Al4V. Open-circuit-potential was measured before, during and after sliding while dynamic coefficient of friction was assessed during sliding. The results showed an improved wear resistance and a lower tendency to corrosion for the multi-material Ti6Al4V-PEEK specimens when compared to dense and cellular structures mono-material specimens. This multi-material solution gathering Ti6Al4V and PEEK, besides being able to withstand the loads occurring after implantation on dental and orthopedic applications, is a promising alternative to fully dense metals once it enhances the tribocorrosion performance.

Damping and mechanical behavior of metal-ceramic composites applied to novel dental restorative systems.

Conversely to natural teeth, where periodontal ligament (PDL) and pulp works as a damper reducing the effect of the stress on surrounding structures, when natural teeth is lost and replaced or restored the biting forces are directly transmitted to the bone or affect the integrity of the adjacent bottom layers. In this study, damping capacity and dynamic Young's modulus of CoCrMo-porcelain composites for dental restorations were evaluated. Dynamic Young's modulus and damping capacity of materials were assessed by dynamic mechanical analyzes (DMA) at 1 and 10 Hz frequencies, over a temperature ranging (18-60 °C). Results show that by reinforcing dental porcelain with metallic particles, producing ceramic matrix composites (CMCs) with 20 vol% and 40 vol% of metallic particles, the damping capacity and dynamic Young's modulus are improved. A decrease on both properties of the metal matrix composites (MMCs) with increasing ceramic particles content (from 20 vol% to 40 vol% of ceramic phase) was observed for all the studied frequencies and temperatures. While damping capacity is strongly dependent on frequency, no significant difference in dynamic Young's modulus was found. Results show that besides the yet reported advantages of the bio-inspired functionally graded restorations over traditional bilaminate ones, traduced by improved veneer to substrate adhesion and by the enhanced thermal and mechanical stress distribution, these restorations can also display improved behavior as regard to a damping capacity, which may have a positive impact in the long-term performance of implant - supported prosthesis.

Finite element analysis of the residual thermal stresses on functionally gradated dental restorations.

The aim of this work was to study, using the finite element method (FEM), the distribution of thermal residual stresses arising in metal-ceramic dental restorations after cooling from the processing temperature. Three different interface configurations were studied: with conventional sharp transition; one with a 50% metal-50% ceramic interlayer; and one with a compositionally functionally gradated material (FGM) interlayer. The FE analysis was performed based on experimental data obtained from Dynamic Mechanical Analysis (DMA) and Dilatometry (DIL) studies of the monolithic materials and metal/ceramic composites. Results have shown significant benefits of using the 50% metal-50% ceramic interlayer and the FGM interlayer over the conventional sharp transition interface configuration in reduction of the thermal residual stress and improvement of stress profiles. Maximum stresses magnitudes were reduced by 10% for the crowns with 50% metal-50% ceramic interlayer and by 20% with FGM interlayer. The reduction in stress magnitude and smoothness of the stress distribution profile due to the gradated architectures might explain the improved behavior of these novel dental restorative systems relative to the conventional one, demonstrated by in-vitro studies already reported in literature.

Mechanical and thermal properties of hot pressed CoCrMo-porcelain composites developed for prosthetic dentistry.

In this study, mechanical and thermal properties of CoCrMo-porcelain composites for dental restorations have been evaluated. These metal-ceramic composites were produced by powder metallurgy and hot pressing techniques from the mixtures of metal and ceramic powders with different volume fractions. Young's moduli and the coefficient of thermal expansion of materials were evaluated by dynamic mechanical analysis (DMA) and dilatometry (DIL) tests, respectively. The strength in flexion and shear was measured with a universal test machine and hardness with a respective tester. The microstructures and fracture surfaces were inspected by the means of optical microscopy and Scanning Electron Microscopy/Energy Dispersive Spectroscopy (SEM/EDS). Shear strength, Flexural strength and Young' moduli of ceramic and metal-matrix composites were found to increase with higher metal particles content. The DMA tests performed at different frequencies showed no frequency-dependent features of the materials studied, indicating no viscoelastic behavior. The fracture surfaces analysis suggests the load-transfer mechanism be possibly responsible for this behavior, as the differences in CTE are low enough to cause significant thermal stresses in these materials. The results might be included in a materials properties database for further use for design and optimization of dental restorations.

Experimental evaluation of the bond strength between a CoCrMo dental alloy and porcelain through a composite metal-ceramic graded transition interlayer.

OBJECTIVES: The purpose of this study was to evaluate the shear bond strength between CoCrMo dental alloy and porcelain restorations by application of different metal-ceramic transitional interfaces aiming at improvement of the bond strength and fracture tolerances. METHODS: Several metal-ceramic specimens with different composite interlayers were produced. The interlayers consisted of metal/ceramic composites with different metal volume fractions (20 M; 40 M; 60 M; 80 M). The metal-ceramic bond strength as well as the fracture strength of the composites and monolithic base materials were assessed by the means of a shear test performed in a universal test machine. The interfaces of fractured and untested specimens were examined by the means of optical microscopy. The microstructures of monolithic base materials were analyzed using SEM/EDS. The elastic and inelastic properties of the homogeneous compositions were additionally evaluated using dynamic mechanical analysis. RESULTS: The bond strength results obtained for metal-ceramic gradated specimens were the highest (261±38 MPa) for 40 vol% metal in the interlayer [40 M] vs. 109±27 MPa for a direct metal-ceramic joint. The Young's moduli and the fracture resistance of the composites revealed an increasing trend for increasing metal contents. SIGNIFICANCE: This study shows that a graded transition between metal and ceramic, provided by a metal/ceramic composite interlayer, is regarded for an increase by 2.5 times in the bond strength between the two materials relative to conventional sharp transitions. The elastic modulus of the composites used as interlayers might be very reasonably approximated by a micromechanical model.