Investigating mechanical deformation's role in cochlear implant durability.

Platinum and platinum-based alloys are used as the electrode material in cochlear implants because of the biocompatibility and the favorable electrochemical properties. Still, these implants can fail over time. The present study was conducted to shed light on the effects of microstructure on the electrochemical degradation of platinum. After three days of stimulation with a square wave signal, corrosive attack appeared on the platinum surface. The influence of mechanical deformation, in particular rolling, on the corrosion resistance of platinum was also prominent. The cyclic voltammetry showed a clear dependence on the electrolyte used, which was interpreted as an influence of the buffer in the artificial perilymph used. In addition, the polarization curves showed a shift with grain size that was not expected. This could be attributed to the defects present on the surface. These findings are crucial for the manufacture of cochlear implants to ensure their long-term functionality.

Fracture Resistance of Repaired 5Y-PSZ Zirconia Crowns after Endodontic Access.

This study analyzed the fracture load before and after a chewing simulation of zirconia crowns that were trepanned and repaired using composite resin. Overall, 3 groups with 15 5Y-PSZ crowns in each group were tested. For group A, the fracture load of the unmodified crowns was evaluated. For group B, the crowns were trepanned and repaired using composite resin, also followed by a fracture test. For group C, crowns were prepared like in group B but received thermomechanical cycling before the final fracture tests. Furthermore, scanning electron microscopy (SEM) and X-ray microscopy (XRM) analysis were performed for group C. The mean fracture loads and standard deviation were 2260 N ± 410 N (group A), 1720 N ± 380 N (group B), and 1540 N ± 280 N (group C). Tukey-Kramer multiple comparisons showed a significant difference between groups A and B (p < 0.01) and groups A and C (p < 0.01). After ageing, surface fissures were detected via SEM, but no cracks that reached from the occlusal to the inner side of the crown were detected via XRM. Within the limitations of this study, it can be stated that trepanned and composite-repaired 5Y-PSZ crowns show lower fracture loads than 5Y-PSZ crowns without trepanation.

Investigations into Flux-Free Plasma Brazing of Aluminum in a Local XHV-Atmosphere.

As a lightweight construction material, aluminum plays a key role in weight reduction and, thus, sustainability in the transport industry. The brazing of aluminum and its alloys is impeded by the natural passivating oxide layer, which interferes with the brazing process. The presented study investigates the possibility of using a thermal silane-doped argon plasma to reduce this oxide layer in situ and thus eliminating the need to use hazardous chemical fluxes to enable high-quality brazing. Using plasma spectroscopy and an oxygen partial pressure probe, it was shown that a silane-doped argon plasma could significantly reduce the oxygen concentration around the plasma in a thermal plasma brazing process. Oxygen concentrations below 10-16 vol.-% were achieved. Additionally, metallographic analyses showed that the thickness of an artificially produced Al2O3-Layer on top of AlMg1 samples could be substantially reduced by more than 50%. With the oxide layer removed and inhibition of re-oxidation, silane-doped plasma brazing has the potential to become an economically efficient new joining method.

In vivo investigation of open-pored magnesium scaffolds LAE442 with different coatings in an open wedge defect.

The magnesium alloy LAE442 showed promising results as a bone substitute in numerous studies in non-weight bearing bone defects. This study aimed to investigate the in vivo behavior of wedge-shaped open-pored LAE442 scaffolds modified with two different coatings (magnesium fluoride (MgF2, group 1)) or magnesium fluoride/calcium phosphate (MgF2/CaP, group 2)) in a partial weight-bearing rabbit tibia defect model. The implantation of the scaffolds was performed as an open wedge corrective osteotomy in the tibia of 40 rabbits and followed for observation periods of 6, 12, 24, and 36 weeks. Radiological and microcomputed tomographic examinations were performed in vivo. X-ray microscopic, histological, histomorphometric, and SEM/EDS analyses were performed at the end of each time period. µCT measurements and X-ray microscopy showed a slight decrease in volume and density of the scaffolds of both coatings. Histologically, endosteal and periosteal callus formation with good bridging and stabilization of the osteotomy gap and ingrowth of bone into the scaffold was seen. The MgF2 coating favored better bridging of the osteotomy gap and more bone-scaffold contacts, especially at later examination time points. Overall, the scaffolds of both coatings met the requirement to withstand the loads after an open wedge corrective osteotomy of the proximal rabbit tibia. However, in addition to the inhomogeneous degradation behavior of individual scaffolds, an accumulation of gas appeared, so the scaffold material should be revised again regarding size dimension and composition.

Characterization of the Interface between Aluminum and Iron in Co-Extruded Semi-Finished Products.

Within the framework of the Collaborative Research Center 1153, we investigated novel process chains for the production of bulk components with different metals as joining partners. In the present study, the co-extrusion of coaxially reinforced hollow profiles was employed to manufacture semi-finished products for a subsequent die-forging process, which was then used for the manufacture of hybrid bearing bushings. The hybrid hollow profiles, made of the aluminum alloy EN AW-6082 paired with either the case-hardening steel 20MnCr5, the stainless steel X5CrNi18-10, or the rolling bearing steel 100Cr6, were produced by Lateral Angular Co-Extrusion. Push-out tests on hybrid hollow sections over the entire sample cross-section showed shear strengths of 44 MPa ± 8 MPa (100Cr6) up to 63 MPa ± 5 MPa (X5CrNi18-10). In particular, the influence of force and form closure on the joint zone could be determined using specimen segments tested in shear compression. Locally, shear strengths of up to 131 MPa (X5CrNi18-10) were demonstrated in the shear compression test. From these samples, lamellae for microstructural analysis were prepared with a Focused Ion Beam. Detailed analyses showed that for all material combinations, a material bond in the form of an ultra-thin intermetallic phase seam with a thickness of up to 50 nm could be established.

Induction Heating in Underwater Wet Welding-Thermal Input, Microstructure and Diffusible Hydrogen Content.

Hydrogen-assisted cracking is a major challenge in underwater wet welding of high-strength steels with a carbon equivalent larger than 0.4 wt%. In dry welding processes, post-weld heat treatment can reduce the hardness in the heat-affected zone while simultaneously lowering the diffusible hydrogen concentration in the weldment. However, common heat treatments known from atmospheric welding under dry conditions are non-applicable in the wet environment. Induction heating could make a difference since the heat is generated directly in the workpiece. In the present study, the thermal input by using a commercial induction heating system under water was characterized first. Then, the effect of an additional induction heating was examined with respect to the resulting microstructure of weldments on structural steels with different strength and composition. Moreover, the diffusible hydrogen content in weld metal was analyzed by the carrier gas hot extraction method. Post-weld induction heating could reduce the diffusible hydrogen content by -34% in 30 m simulated water depth.

Effect of pore size on tissue ingrowth and osteoconductivity in biodegradable Mg alloy scaffolds.

Magnesium has mechanical properties similar to those of bone and is being considered as a potential bone substitute. In the present study, two different pore sized scaffolds of the Mg alloy LAE442, coated with magnesium fluoride, were compared. The scaffolds had interconnecting pores of either 400 (p400) or 500 µm (p500). ß-TCP served as control. Ten scaffolds per time group (6, 12, 24, 36 weeks) were implanted in the trochanter major of rabbits. Histological analyses, µCT scans, and SEM/EDX were performed. The scaffolds showed slow volume decreases (week 36 p400: 9.9%; p500: 7.5%), which were accompanied by uncritical gas releases. In contrast, ß-TCP showed accelerated resorption (78.5%) and significantly more new bone inside (18.19 ± 1.47 mm3). Bone fragments grew into p400 (0.17 ± 0.19 mm3) and p500 (0.36 ± 0.26 mm3), reaching the centrally located pores within p500 more frequently. In particular, p400 displayed a more uneven and progressively larger surface area (week 36 p400: 253.22 ± 19.44; p500: 219.19 ± 4.76 mm2). A better osseointegration of p500 was indicated by significantly more trabecular contacts and a 200 µm wide bone matrix being in the process of mineralization and in permanent contact with the scaffold. The number of macrophages and foreign body giant cells were at an acceptable level concerning resorbable biomaterials. In terms of ingrown bone and integrative properties, LAE442 scaffolds could not achieve the results of ß-TCP. In this long-term study, p500 appears to be a biocompatible and more osteoconductive pore size for the Mg alloy LAE442.

Development of a Laser Powder Bed Fusion Process Tailored for the Additive Manufacturing of High-Quality Components Made of the Commercial Magnesium Alloy WE43.

Additive manufacturing (AM) has become increasingly important over the last decade and the quality of the products generated with AM technology has strongly improved. The most common metals that are processed by AM techniques are steel, titanium (Ti) or aluminum (Al) alloys. However, the proportion of magnesium (Mg) in AM is still negligible, possibly due to the poor processability of Mg in comparison to other metals. Mg parts are usually produced by various casting processes and the experiences in additive manufacturing of Mg are still limited. To address this issue, a parameter screening was conducted in the present study with experiments designed to find the most influential process parameters. In a second step, these parameters were optimized in order to fabricate parts with the highest relative density. This experiment led to processing parameters with which specimens with relative densities above 99.9% could be created. These high-density specimens were then utilized in the fabrication of test pieces with several different geometries, in order to compare the material properties resulting from both the casting process and the powder bed fusion (PBF-LB) process. In this comparison, the compositions of the occurring phases and the alloys' microstructures as well as the mechanical properties were investigated. Typically, the microstructure of metal parts, produced by PBF-LB, consisted of much finer grains compared to as-cast parts. Consequently, the strength of Mg parts generated by PBF-LB could be further increased.

The Applicability of the Standard DIN EN ISO 3690 for the Analysis of Diffusible Hydrogen Content in Underwater Wet Welding.

The European standard ISO 3690 regulates the measurement of diffusible hydrogen in arc-welded metal. It was designed for different welding methods performed in dry atmosphere (20% humidity). Some details of the standard are not applicable for wet underwater welding. The objective of this study was to extend the applicability of DIN EN ISO 3690:2018-12 to underwater wet-shielded metal arc welding (SMAW). Four different aspects regulated within the standard were accounted for: (1) sample dimensions and number of samples taken simultaneously; (2) time limitations defined by the standard regarding the welding and the cleaning process; (3) time, temperature, and method defined for analysis of the diffusible hydrogen content; (4) normalization of the hydrogen concentration measured. Underwater wet welding was performed using an automated, arc voltage-controlled welding machine. The results are discussed in light of standard DIN EN ISO 3690, and recommendations are provided for the analysis of diffusible hydrogen content upon underwater wet welding.

Investigation of degraded bone substitutes made of magnesium alloy using scanning electron microscope and nanoindentation.

Degradable bone substitutes made of magnesium alloys are an alternative to biological bone grafts. The main advantage is that they can be manufactured location- and patient-specific. To develop and scale appropriate implants using computational models, knowledge about the mechanical properties and especially the change in the properties during the degradation process is essential. Therefore, degraded open-pored implants were investigated using scanning electron microscope and nanoindentation to find their material composition and mechanical properties. Using both techniques the correlation of the material composition and the average modulus was determined. It could be shown that the average modulus of the degradation layer is distinctly lower than that of the base material. The local average modulus of degrading implant highly depends on the magnesium concentration and the accumulation of elements from the environment. A decrease in magnesium concentration leads to a decrease in the average modulus. Thus, the degrading implant had a lower stiffness than the initial structure.

Comparison of two pore sizes of LAE442 scaffolds and their effect on degradation and osseointegration behavior in the rabbit model.

The magnesium alloy LAE442 emerged as a possible bioresorbable bone substitute over a decade ago. In the present study, using the investment casting process, scaffolds of the Magnesium (Mg) alloy LAE442 with two different and defined pore sizes, which had on average a diameter of 400 µm (p400) and 500 µm (p500), were investigated to evaluate degradation and osseointegration in comparison to a ß-TCP control group. Open-pored scaffolds were implanted in both greater trochanter of rabbits. Ten scaffolds per time group (6, 12, 24, and 36 weeks) and type were analyzed by clinical, radiographic and µ-CT examinations (2D and 3D). None of the scaffolds caused adverse reactions. LAE442 p400 and p500 developed moderate gas accumulation due to the Mg associated in vivo corrosion, which decreased from week 20 for both pore sizes. After 36 weeks, p400 and p500 showed volume decreases of 15.9 and 11.1%, respectively, with homogeneous degradation, whereas ß-TCP lost 74.6% of its initial volume. Compared to p400, osseointegration for p500 was significantly better at week 2 postsurgery due to more frequent bone-scaffold contacts, higher number of trabeculae and higher bone volume in the surrounding area. No further significant differences between the two pore sizes became apparent. However, p500 was close to the values of ß-TCP in terms of bone volume and trabecular number in the scaffold environment, suggesting better osseointegration for the larger pore size.

A simulation model for the degradation of magnesium-based bone implants.

The development of degradable bone implants, in particular made of metal materials, is an emerging field. The advantage of degradable implants is that they do not have to be removed later. In order to be able to develop and scale appropriate implants for different applications, it is necessary to know the change in mechanical properties of the implant during the degradation process in general and at different locations. One area of bone implants are bone substitute materials. They are deployed when there is a defect in the bone which cannot be filled autonomously by the body. In this study, a numerical degradation model of magnesium-based bone substitute materials is developed using the finite element method. Computational models are being developed to reduce experimental animal research in future. Magnesium is a naturally occurring material which is needed to build enzymes in the body. Additionally, magnesium has a Young's modulus close to native bone, wherefore it is attractive for medical applications with bone contact. The simulation model is based on the assumption that the degradation is a diffusion-controlled process driven by the dissolution of magnesium. The model is adapted to a 3D open-pored structure made of the magnesium alloy LAE442. Previous studies showed that implants made of LAE442 lose stiffness without a volume reduction. To simulate the change in mechanical properties, a concentration-dependent Young's modulus is assumed. With this model the formation of the degradation layer is computable as well as the change in mechanical properties, as measured by the effective Young's modulus of the structure. The movement of the interface between the not-degraded and degraded material is modelled using the level set method.

Processing and coating of open-pored absorbable magnesium-based bone implants.

Large bone defects or fractures must be treated with an implant or transplant. Resorbable implants are attractive as these require only one surgery, whereas bone autografts, which can be cut off from the same person's hip, require more than one procedure. Moreover, porous structures promote the ingrowth of the patient's bone. Thus, the objective of the present study was to develop open-pored biodegradable implant structures with different pore sizes that provide for both adequate degradation behaviour and mechanical properties that match with those of bone. The magnesium alloys LAE442 and La2 were employed in this study, as these materials are known to feature good biocompatibility and mechanical properties close to bone. It was possible to cast magnesium sponges with different pore sizes using the alloy LAE442. However, with the MgLa2 alloy, only sponges with a minimum pore size of 0.5 mm could be produced. Overall, the sponges cast with the LAE442 alloy showed higher strength, even though the strengths of the dense parts were similar in both alloys tested. In terms of castability and mechanical behaviour, the LAE442 alloy turned out to be more favourable. In order to adapt the implant degradation behaviour to the bone ingrowth behaviour, coating of the magnesium sponges with calcium phosphate and polylactic acid was also investigated. Additionally, the different coatings were tested on their adhesive forces and influences to the in-vitro degradation behaviour.

Microstructure Formation in Cast TiZrHfCoNiCu and CoNiCuAlGaIn High Entropy Shape Memory Alloys: A Comparison.

The present study is dedicated to the microstructure characterization of the as-cast high entropy intermetallics that undergo a martensitic transformation, which is associated with the shape memory effect. It is shown that the TiZrHfCoNiCu system exhibits strong dendritic liquation, which leads to the formation of martensite crystals inside the dendrites. In contrast, in the CoNiCuAlGaIn system the dendritic liquation allows the martensite crystals to form only in interdendritic regions. This phenomenon together with the peculiarities of chemical inhomogeneities formed upon crystallization of this novel multicomponent shape memory alloys systems will be analyzed and discussed.

Crystallographic Structure Analysis of a Ti-Ta Thin Film Materials Library Fabricated by Combinatorial Magnetron Sputtering.

Ti-Ta thin films exhibit properties that are of interest for applications as microactuators and as biomedical implants. A Ti-Ta thin film materials library was deposited at T = 25 °C by magnetron sputtering employing the combinatorial approach, which led to a compositional range of Ti87Ta13 to Ti14Ta86. Subsequent high-throughput characterization methods permitted a quick and comprehensive study of the crystallographic, microstructural, and morphological properties, which strongly depend on the chemical composition. SEM investigation revealed a columnar morphology having pyramidal, sharp tips with coarser columns in the Ti-rich and finer columns in the Ta-rich region. By grazing incidence X-ray diffraction four phases were identified, from Ta-lean to Ta-rich: ω phase, α″ martensite, ß phase, and a tetragonal Ta-rich phase (Ta(tetr)). The crystal structure and microstructure were analyzed by Rietveld refinement and clear trends could be determined as a function of Ta-content. The lattice correspondences between ß as the parent phase and α″ and ω as derivative phases were expressed in matrix form. The ß â‡Œ α″ phase transition shows a discontinuity at the composition where the martensitic transformation temperatures fall below room temperature (between 34 and 38 at. % Ta) rendering it first order and confirming its martensitic nature. A short study of the α″ martensite employing the Landau theory is included for a mathematical quantification of the spontaneous lattice strain at room temperature (ϵ̂max = 22.4(6) % for pure Ti). Martensitic properties of Ti-Ta are beneficial for the development of high-temperature actuators with actuation response at transformation temperatures higher than 100 °C.

Specimen preparation by ion beam slope cutting for characterization of ductile damage by scanning electron microscopy.

To investigate ductile damage in parts made by cold sheet-bulk metal forming a suited specimen preparation is required to observe the microstructure and defects such as voids by electron microscopy. By means of ion beam slope cutting both a targeted material removal can be applied and mechanical or thermal influences during preparation avoided. In combination with scanning electron microscopy this method allows to examine voids in the submicron range and thus to analyze early stages of ductile damage. In addition, a relief structure is formed by the selectivity of the ion bombardment, which depends on grain orientation and microstructural defects. The formation of these relief structures is studied using scanning electron microscopy and electron backscatter diffraction and the use of this side effect to interpret the microstructural mechanisms of voids formation by plastic deformation is discussed. A comprehensive investigation of the suitability of ion beam milling to analyze ductile damage is given at the examples of a ferritic deep drawing steel and a dual phase steel.

Influence of cobalt on the properties of load-sensitive magnesium alloys.

In this study, magnesium is alloyed with varying amounts of the ferromagnetic alloying element cobalt in order to obtain lightweight load-sensitive materials with sensory properties which allow an online-monitoring of mechanical forces applied to components made from Mg-Co alloys. An optimized casting process with the use of extruded Mg-Co powder rods is utilized which enables the production of magnetic magnesium alloys with a reproducible Co concentration. The efficiency of the casting process is confirmed by SEM analyses. Microstructures and Co-rich precipitations of various Mg-Co alloys are investigated by means of EDS and XRD analyses. The Mg-Co alloys' mechanical strengths are determined by tensile tests. Magnetic properties of the Mg-Co sensor alloys depending on the cobalt content and the acting mechanical load are measured utilizing the harmonic analysis of eddy-current signals. Within the scope of this work, the influence of the element cobalt on magnesium is investigated in detail and an optimal cobalt concentration is defined based on the performed examinations.