Microstructural Origins of the Corrosion Resistance of a Mg-Y-Nd-Zr Alloy Processed by Powder Bed Fusion - Laser Beam.

Magnesium alloys are biocompatible, biodegradable and have the ability to promote bone ingrowth, making them ideal candidate materials for replacing auto- and allografts in future treatments of large bone defects. Powder bed fusion-laser beam (PBF-LB) additive manufacturing of these alloys would further allow for the production of complex structures, optimized for bone grafting. However, the corrosion rates of structures processed by PBF-LB remain too high. An improved understanding of the influence of the microstructure generated during PBF-LB on the corrosion properties is considered key to their future implementation in implants. In this study, the effect of PBF-LB processing and subsequent hot isostatic pressing (HIP) on the microstructure and texture in different sample directions was studied and related to the corrosion behavior of a Mg-Y-Nd-Zr alloy. The results were compared with an extruded Mg-Y-Nd-Zr alloy. A higher amount of secondary phases resulted in a higher rate of localized corrosion for the PBF-LB processed material compared to that for the extruded one. Due to growth of the secondary phases, the corrosion rate was further increased after HIP. Moreover, a strong texture was observed in the PBF-LB material, and it was also enhanced in the HIP material. While this affected the electrochemical activity as measured by potentiodynamic polarization tests, any texture effect appeared to be masked by the contribution of the secondary phases in the longer-term mass change and hydrogen evolution tests. Future work should look further into the influence of individual process parameters on the microstructure and the resulting corrosion behavior of the material, to further clarify its interdependence.

An Enhanced Understanding of the Powder Bed Fusion-Laser Beam Processing of Mg-Y3.9wt%-Nd3wt%-Zr0.5wt% (WE43) Alloy through Thermodynamic Modeling and Experimental Characterization.

Powder Bed Fusion-Laser Beam (PBF-LB) processing of magnesium (Mg) alloys is gaining increasing attention due to the possibility of producing complex biodegradable implants for improved healing of large bone defects. However, the understanding of the correlation between the PBF-LB process parameters and the microstructure formed in Mg alloys remains limited. Thus, the purpose of this study was to enhance the understanding of the effect of the PBF-LB process parameters on the microstructure of Mg alloys by investigating the applicability of computational thermodynamic modelling and verifying the results experimentally. Thus, PBF-LB process parameters were optimized for a Mg WE43 alloy (Mg-Y3.9wt%-Nd3wt%-Zr0.5wt%) on a commercially available machine. Two sets of process parameters successfully produced sample densities >99.4%. Thermodynamic computations based on the Calphad method were employed to predict the phases present in the processed material. Phases experimentally established for both processing parameters included α-Mg, Y2O3, Mg3Nd, Mg24Y5 and hcp-Zr. Phases α-Mg, Mg24Y5 and hcp-Zr were also predicted by the calculations. In conclusion, the extent of the applicability of thermodynamic modeling was shown, and the understanding of the correlation between the PBF-LB process parameters and the formed microstructure was enhanced, thus increasing the viability of the PBF-LB process for Mg alloys.

Release of Side-Chain Fluorinated Polymer-Containing Microplastic Fibers from Functional Textiles During Washing and First Estimates of Perfluoroalkyl Acid Emissions.

The quantity and composition of fibers released from functional textiles during accelerated washing were investigated using the GyroWash method. Two fabrics [polyamide (PA) and polyester/cotton (PES/CO)] were selected and coated with perfluorohexane-based side-chain fluorinated polymers. Fibers released during washing ranged from ∼10 to 500 µ with a similar distribution for the two textile types. The PA-based fabric released considerably more fibers >20 µm in length compared to the PES/CO-based fabric (>1000/GyroWash for PA vs ∼200/GyroWash fibers for PES/CO). After one GyroWash (2-15 domestic washes), fibers that contained approximately 240 and 1300 µg total fluorine per square meter (µg F/m2) were released from the PA and PES/CO fabrics, respectively. Current understanding of the fate of microplastic fibers suggests that a large fraction of these fibers reach the environment either in effluent wastewater or sewage sludge applied to land. In the environment, the fluorinated side chains will be slowly cleaved from the backbone of the side-chain fluorinated polymers coated on the fibers and then transformed into short-chain perfluoroalkyl acids. On the European scale, emissions of up to ∼0.7 t of fluorotelomer alcohol (6:2 FTOH) per year were estimated for outdoor rain jackets treated with fluorotelomer-based side-chain fluorinated polymers.