In vitro and in vivo assessment of squeeze-cast Mg-Zn-Ca-Mn alloys for biomedical applications.

Squeeze casting of biodegradable Mg-4Zn-0.5Ca-xMn (x = 0, 0.4 or 0.8 all in weight %) alloys is a process intended to improve mechanical properties (i.e., strength and ductility), corrosion performance (i.e., resistance), and biocompatibility (i.e., little to no cytotoxicity). In this study, we found that an increased Mn content causes the dendritic microstructure of squeeze-cast Mg-4Zn-0.5Ca-xMn to become more refined and uniform, while the volume fraction of the Ca2Mg6Zn3 phase simultaneously increases. Squeeze-cast Mg-4Zn-0.5Ca-0.8Mn presents the best yield strength, ultimate tensile strength, and elongation of the alloys tested. An electrochemical corrosion test in Hanks' solution at 36.5°C demonstrates that the corrosion resistance of squeeze-cast Mg-4Zn-0.5Ca-xMn alloys show improvement at higher Mn levels. Additionally, squeeze-cast Mg-4Zn-0.5Ca alloys containing Mn exhibit favorable biocompatibility, as evidenced by cell viability studies with MC3T3-E1 cells and a local lymph node assay test. Squeeze-cast alloy specimens implanted into the skull and spine of Sprague-Dawley rats for four weeks showed no serious cytotoxicity or foreign body response; however, swelling was observed in the implantation areas of Mn-free squeeze-cast Mg-4Zn-0.5Ca alloy, while no swelling was observed in rats implanted with Mn-containing Mg-4Zn-0.5Ca alloy. These findings indicate potential applications of biodegradable, Mn-containing, squeeze-cast Mg-4Zn-0.5Ca specimens in bone-reconstruction devices given their biocompatibility, mechanical properties, and degradation profiles. STATEMENT OF SIGNIFICANCE: Bioresorbable magnesium alloys have recently gained attention as viable biomaterials for skeletal reconstruction implants. Extensive research on biodegradable Mg alloy design, synthesis, and as-cast versus post-processed material properties useful for medical applications have been reported. The squeeze-casting technique used in this study can improve the mechanical properties (i.e., strengthening) and corrosive performance (reduced rate) of bioresorbable Mg-Zn-Ca-Mn alloys. Squeeze-casting of these alloys is also expected to improve specimen microstructure, near-net-shape manufacturing, and cost (i.e., reduced). This study provides an in vitro and in vivo assessment of squeeze-cast Mg-Zn-Ca-Mn alloys for biomedical applications.

A new magnesium sheet alloy with high tensile properties and room-temperature formability.

Lightweight sheet alloys with superior mechanical performance such as high strength, ductility and formability at room temperature (RT) are desirable for high volume automotive applications. However, ductility or formability of metallic alloys at RT are generally inversely related to strength, thereby making it difficult to optimize all three simultaneously. Here we design a new magnesium sheet alloy-ZAXME11100 (Mg-1.0Zn-1.0Al-0.5Ca-0.4Mn-0.2Ce, wt. pct.) via CALPHAD (CALculation of PHAse Diagram) modeling and experimental validation. This new sheet alloy offers an excellent RT formability with a high Index Erichsen (I.E.) value of 7.8 mm in a solution-treated condition (T4), due to its weak and split basal texture and fine grain structure. The new ZAXME 11100 alloy also shows a rapid age-hardening response during post-forming artificial aging treatment at 210 °C for 1 hour (T6), resulting in a significant increase of yield strength from 159 MPa (T4) to 270 MPa (T6). The excellent combination of T4 ductility (31%), T4 formability (7.8 mm) and T6 yield strength (270 MPa) in this new magnesium alloy is comparable to that of common 6xxx series aluminum sheet alloys. Thus, this new magnesium sheet alloy is highly attractive for sheet applications in automotive and other industries.

Three-dimensional cellular automaton simulation of coupled hydrogen porosity and microstructure during solidification of ternary aluminum alloys.

Hydrogen-induced porosity formed during solidification of aluminum-based alloys has been a major issue adversely affecting the performance of solidification products such as castings, welds or additively manufactured components. A three-dimensional cellular automaton model was developed, for the first time, to predict the formation and evolution of hydrogen porosity coupled with grain growth during solidification of a ternary Al-7wt.%Si-0.3wt.%Mg alloy. The simulation results fully describe the concurrent nucleation and evolution of both alloy grains and hydrogen porosity, yielding the morphology of multiple grains as well as the porosity size and distribution. This model, successfully validated by X-ray micro-tomographic measurements and optical microscopy of a wedge die casting, provides a critical tool for minimizing/controlling porosity formation in solidification products.

Microstructural, mechanical and corrosion characteristics of heat-treated Mg-1.2Zn-0.5Ca (wt%) alloy for use as resorbable bone fixation material.

Mg-Zn-Ca alloys have grabbed most of the recent attention in research attempting to develop an Mg alloy for bone fixation devices due to their superior biocompatibility. However, early resorption and insufficient strength remain the main problems that hinder their use. Heat treatment has previously been thoroughly studied as a post-shaping process, especially after the fabrication of complex parts (e.g. porous structures) by 3D-printing or powder metallurgy. In this work, the effect of heat treatment on Mg-1.2Zn-0.5Ca (wt%) alloy's microstructural, mechanical and corrosion properties was studied. The surface morphology of samples was characterized by optical microscopy, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and x-ray diffraction (XRD). Hardness, compression and tensile tests were conducted, while the in vitro corrosion characteristics of the prepared samples were determined using potentiodynamic polarization (PDP) and immersion tests. It was found that increasing the age hardening duration up to 2-5h increased the heat-treated Mg-1.2Zn-0.5Ca alloy's mechanical properties. Further increase in the age hardening duration did not result in further enhancement in mechanical properties. Similarly, heat treatment significantly altered the Mg-1.2Zn-0.5Ca alloy's in vitro corrosion properties. The corrosion rate of the Mg-1.2Zn-0.5Ca alloy after the heat treatment process was reduced to half of that for the as-cast alloy. XRD results showed the formation of biocompatible agglomerations of hydroxyapatite (HA) and magnesium hydroxide (Mg(OH)2) on the corroded surface of the heat-treated Mg-1.2Zn-0.5Ca alloy samples. The performed heat treatment process had a significant effect on both mechanical and corrosion properties of the prepared Mg-1.2Zn-0.5Ca alloy. The age hardening duration which caused the greatest increase in mechanical and the most slowed corrosion rate for Mg-1.2Zn-0.5Ca alloy material was between 2 and 5h.