Effects of bio-functionalizing surface treatments on the mechanical behavior of open porous titanium biomaterials.

Bio-functionalizing surface treatments are often applied for improving the bioactivity of biomaterials that are based on otherwise bioinert titanium alloys. When applied on highly porous titanium alloy structures intended for orthopedic bone regeneration purposes, such surface treatments could significantly change the static and fatigue properties of these structures and, thus, affect the application of the biomaterial as bone substitute. Therefore, the interplay between biofunctionalizing surface treatments and mechanical behavior needs to be controlled. In this paper, we studied the effects of two bio-functionalizing surface treatments, namely alkali-acid heat treatment (AlAcH) and acid-alkali (AcAl), on the static and fatigue properties of three different highly porous titanium alloy implants manufactured using selective laser melting. It was found that AlAcH treatment results in minimal mass loss. The static and fatigue properties of AlAcH specimens were therefore not much different from as-manufactured (AsM) specimens. In contrast, AcAl resulted in substantial mass loss and also in significantly less static and fatigue properties particularly for porous structures with the highest porosity. The ratio of the static mechanical properties of AcAl specimens to that of AsM specimen was in the range of 1.5-6. The fatigue lives of AcAl specimens were much more severely affected by the applied surface treatments with fatigue lives up to 23 times smaller than that of AsM specimens particularly for the porous structures with the highest porosity. In conclusion, the fatigue properties of surface treated porous titanium are dependent not only on the type of applied surface treatment but also on the porosity of the biomaterial.

Fatigue behavior of porous biomaterials manufactured using selective laser melting.

Porous titanium alloys are considered promising bone-mimicking biomaterials. Additive manufacturing techniques such as selective laser melting allow for manufacturing of porous titanium structures with a precise design of micro-architecture. The mechanical properties of selective laser melted porous titanium alloys with different designs of micro-architecture have been already studied and are shown to be in the range of mechanical properties of bone. However, the fatigue behavior of this biomaterial is not yet well understood. We studied the fatigue behavior of porous structures made of Ti6Al4V ELI powder using selective laser melting. Four different porous structures were manufactured with porosities between 68 and 84% and the fatigue S-N curves of these four porous structures were determined. The three-stage mechanism of fatigue failure of these porous structures is described and studied in detail. It was found that the absolute S-N curves of these four porous structures are very different. In general, given the same absolute stress level, the fatigue life is much shorter for more porous structures. However, the normalized fatigue S-N curves of these four structures were found to be very similar. A power law was fitted to all data points of the normalized S-N curves. It is shown that the measured data points conform to the fitted power law very well, R(2)=0.94. This power law may therefore help in estimating the fatigue life of porous structures for which no fatigue test data is available. It is also observed that the normalized endurance limit of all tested porous structures (<0.2) is lower than that of corresponding solid material (c.a. 0.4).