Additively Manufactured Commercial Co-Cr Dental Alloys: Comparison of Microstructure and Mechanical Properties.

Laser-powder bed fusion (LPBF) is one of the preferred techniques for producing Co-Cr metal structures for dental prosthodontic appliances. However, there is generally insufficient information about material properties related to the production process and parameters. This study was conducted on samples produced from three different commercially available Co-Cr dental alloys produced on three different LPBF machines. Identically prepared samples were used for tensile, three-point bending, and toughness tests. Light microscopy (LM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) analyses of microstructure were performed after testing. Differences were observed in microstructures, which reflected statistically significant differences in mechanical properties (one-way analysis of variance (ANOVA) and Scheffé post hoc test (α = 0.05)). The material produced on the 3D Systems DMP Dental 100 had 24 times greater elongation ε than the material produced on the Sysma MySint 100 device and the EOS M100 machine. On the other hand, the material produced on the EOS M100 had significantly higher hardness (HV0.2) than the other two produced materials. However, the microstructure of the Sysma specimens with its morphology deviates considerably from the studied group. LPBF-prepared Co-Cr dental alloys demonstrated significant differences in their microstructures and, consequently, mechanical properties.

Femoral head wear and metallosis caused by damaged titanium porous coating after primary metal-on-polyethylene total hip arthroplasty: a case report.

Excessive metal femoral head wear has been described only as revision surgery complication after primary ceramic-on-ceramic total hip arthroplasty (THA). Here, we present the first case of metal femoral head wear after primary metal-on-polyethylene THA. A 56-year-old woman was referred to our outpatient clinic 17 years after primary right-sided THA, experiencing pain and decreased right hip range of motion. Radiographic examination revealed acetabular cup dislocation, eccentric femoral head wear, damaged titanium porous coating of femoral stem, metallosis, and pseudotumor formation. Endoprosthetic components were extracted, but further reconstruction was impossible due to presence of large acetabular bone defect. Macro- and micro-structure of extracted components were analyzed. Acetabular liner surface was damaged, with scratches, indentations, and embedded metal debris particles present on the entire inner surface. Analysis of metal debris by energy-dispersive spectroscopy showed that it consisted of titanium and stainless-steel particles. Femoral head was gravely worn and elliptically shaped, with abrasive wear visible under scanning electron microscope. No signs of trunnionosis at head/neck junction were observed. Microstructure of femoral head material was homogeneous austenitic, with microhardness of 145 HV 0.2, which is lower than previously described titanium hardness. In conclusion, detached titanium porous coating of femoral stem can cause stainless-steel femoral head wear in primary metal-on-polyethylene THA. As soon as such detachment becomes evident, revision surgery should be considered to prevent devastating complications.