Novel metal structures through powder metallurgy for biomedical applications

Biocompatible porous Ti-16Sn-4Nb alloys were synthesised in quest of a novel tissue engineering biomaterial for bone regeneration. The alloys were prepared from elemental powders via mechanical alloying followed by space-holder sintering. The effects of ball milling variables on the characteristics and mechanical properties of bulk and porous Ti-16Sn-4Nb alloy have been investigated.

Mechanically alloyed and spark plasma sintered aluminium/precious metal oxide composite materials

Air-atomised pure aluminium powder with additions of 10 at.% of AgO, PtO₂ or PdO was mechanically alloyed (MAed) by using a vibrational ball mill, and MAed powders were consolidated into bulk materials by a spark plasma sintering (SPS) process. Mechano-chemical reactions among pure Al, precious metal oxide and stearic acid, added as a process control agent, during the mechanical alloying (MA) process and subsequent heat treatments were investigated by X-ray diffraction. The mechanical properties of MAed powders obtained under various heat treatment conditions and those of the SPS materials were evaluated by hardness tests. Mechano-chemical reactions occurred in Al/precious metal oxide composite powders during 36 ks of the MA process to form AlAg₂, Pt and Al₃Pd₂ for the Al-AgO, Al-PtO₂ and Al-PdO systems, respectively. Further solid-state reactions in MAed powders have been observed after heating at 373 K to 873 K for 7.2 ks. The hardness of MAed powders initially increased significantly after heating at 373 K and then generally decreased with increasing heating temperatures. The full density was obtained for the SPS materials under the conditions of an applied pressure of 49 MPa at 873 K for 3.6 ks. All the SPS materials exhibited hardness values of over 200 HV in the as-fabricated state.

One-dimensional growth of TiO2 nanorods from ilmenite sands

Growth mechanisms of TiO₂ nanorods synthesized from mineral ilmenite using ball milling and annealing method have been systematically investigated. Two annealing processes are needed to grow the nanorods. The heating rate and gaseous environment in the first annealing step are critical to the formation of intermediate phases; these and the annealing atmosphere in the second heating play very important roles in nanorod growth. One-dimensional growth of the nanorods induced by low-temperature annealing in nitrogen plus hydrogen is possibly driven by atom vacancy diffusion in addition to surface diffusion.

Fabrication of nano-particle reinforced metal matrix composites

Nanoparticle reinforced metal matrix possess much better mechanical properties over microparticle reinforced metal matrix composites as well as corresponding monolithic matrix materials. However, the fabrication methods of nanoparticle reinforced metal matrix composites are complex and expensive. This paper investigates and discusses the mechanisms of all the fabrication process, such as powder metallurgy, liquid metallurgy, compocasting and hybrid methods, available in the literature. This gives an insight on challenges associated with different processes and ways to improve the fabrication processes. It is found that modified traditional fabrication processes are mainly applied for these materials. The main problem is to achieve reasonably uniform distribution of nanoparticle reinforcement in the methods other than mechanical alloying when the volume or weight percent of reinforcement is higher (> 1%).

Compressibility of a Ti-based alloy with varying amounts of surfactant prepared by high-energy ball milling

The combined effects of varying amounts of surfactant (ethylene bis-stearamide; EBS) and milling time on the compressibility of ball-milled Ti-10Nb-3Mo (wt.%) alloy were investigated. Ball milling process was performed on the elemental powders with different amounts of EBS (0-3. wt.%) for 5 and 10. h, and the ball-milled powders were consolidated by a uniaxial cold pressing in the range of 500-1100. MPa. Results indicated that the addition of surfactant in ball milling process lead to significant changes in particle packing density. The relative density was higher for powders ball milled with larger amounts of EBS and for the shorter milling time. The compressibility of powders was examined by the compaction equation developed by Panelli and Ambrosio Filho. The densification parameter (A) increased with the increasing amount of EBS, and decreased with increasing milling time.

Structural evolution of spark plasma sintered AlFeCuCrMgx (x = 0, 0.5, 1, 1.7) high entropy alloys

The present paper reports synthesis of novel AlFeCuCrMgx (x = 0, 0.5, 1, 1.7 mol) high entropy alloys (HEAs) by mechanical alloying (MA) followed by spark plasma sintering (SPS). Phase evolution, microstructure and phase transformation study of the sintered alloy were investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and differential scanning calorimetry (DSC). XRD of the sintered alloys revealed the formation of two BCC phases in the AlFeCuCr alloy and more complex structures in AlFeCuCrMgx (x = 0.5, 1, 1.7) alloys containing AlFe type, BCC, and Cu2Mg type phases. TEM bright field image and selected area diffraction pattern (SAED) revealed the formation of tetragonal closed packed Cr precipitates within the Cu2Mg phase of AlFeCuCrMgx alloys (x = 0.5, 1, 1.7). DSC study of the alloys revealed no substantial phase change up to 1000 °C for AlFeCuCr alloy. Although, for x = 0.5, 1 & 1.7 phase transformation occurs at 818 °C, 885 °C & 483 °C respectively. Mg content had a significant effect on hardness, increasing to a peak hardness of 853 HVN for AlFeCuCrMg0.5 alloy before decreasing to 533 HVN for the AlFeCuCrMg1.7 alloy. The phase evolution in these alloys has been considered using thermodynamic parameters, and the structure-property relationship has also been proposed by conventional strengthening mechanisms.

Effect of alloying and extrusion temperature on the microstructure and mechanical properties of Mg-Zn and Mg-Zn-RE alloys

Extruded Mg-Zn-RE alloys have been shown to exhibit excellent combinations of yield strength and ductility, but it is not completely clear how adding rare earth metals to Mg-Zn alters the microstructure and affects the mechanical properties. Microstructural changes and the resulting mechanical properties from changes in composition and extrusion temperature have been investigated for Mg-. x Zn-. y RE (. x=2.5 and 5. wt.%, y=0 and 1. wt. %, and RE=Gd and Y) alloys. Adding RE to Mg-Zn increased the strength and reduced the ductility, while increasing the zinc concentration in the Mg-Zn-RE alloys had the reverse effect.

Grain size in Mg alloys: recrystallization and mechanical consequences

The present paper examines the development of grain size during the recrystallization of magnesium alloys and the influence the grain size has on the mechanical response. In magnesium alloys grain refinement improves the strength-ductility balance. This simultaneous increase in both strength and ductility is ascribed to the impact the grain size has on deformation twinning. The mechanisms by which the grain size is established during hot working are shown to be conventional dynamic recrystallization followed by post-dynamic recrystallization. The role of alloying additionon both of these reactions is briefly considered.

Effect of alloying elements on the microstructure property relationship in thermomechanically processed C-Mn-Si TRIP steels

The effect of additions of Nb, Al and Mo to Fe-C-Mn-Si TRIP steel on the final microstructure and mechanical properties after simulated  thermomechanical processing (TMP) has been studied. The laboratory simulations of discontinuous cooling during TMP were performed using a hot rolling mill. All samples were characterised using optical microscopy and image analysis. The volume fraction of retained austenite was ascertained using a heat tinting technique and X-ray diffraction measurements. Room temperature mechanical properties were determined by a tensile test. From this a comprehensive understanding of the structural aspect of the bainite transformation in these types of TRIP steels has been developed. The  results have shown that the final microstructures of thermomechanically processed TRIP steels comprise 50 % of polygonal ferrite, 7 - 12 % of retained austenite, non-carbide bainitic structure and martensite. All steels exhibited a good combination of ultimate tensile strength and total elongation. The microstructure-property examination revealed the relationship between the composition of TRIP steels and their mechanical properties. It has been shown that the addition of Mo to the C-Si-Mn-Nb TRIP steel increases the ultimate tensile strength up to 1020 MPa. The stability of the retained austenite of the Nb-Mo steel was degraded, which led to a decrease in the elongation (24 %). The results have demonstrated that the addition of Al to C-Si-Mn-Nb steel leads to a good combination of strength (∼ 940 MPa) and elongation (∼ 30 %) due to the formation of refined acicular ferrite and granular bainite structure with ∼7 - 8 % of stable retained austenite. Furthermore, it has been found that the addition of Al increases the volume fraction of bainitic ferrite laths. The investigations have shown an interesting result that, in the Nb-Mo-Al steel, Al has a more pronounced effect on the microstructure in comparison with Mo. It has been found that the bainitic structure of the Nb-Mo-Al steel appears to be more granular than in the Nb-Mo steel. Moreover, the volume fraction of the retained austenite increased (12 %) with decreasing bainitic ferrite content. The results have demonstrated that this steel has the best mechanical properties (1100 MPa and 28 % elongation). It has been concluded that the combined effect of Nb, Mo, and Al addition on the dispersion of the bainite, martensite and retained austenite in the ferrite matrix and the morphology of these phases is different than effect of Nb, Mo and Al, separately.

Effect of alloying elements on the microstructure-property relationship in thermomechanically processed C-Mn-Si TRIP steels

The effect of additions of Nb, Al and Mo to Fe-C-Mn-Si TRIP steel on the final microstructure and mechanical properties after simulated thermomechanical processing (TMP) has been studied. The laboratory simulations of discontinuous cooling during TMP were performed using a hot rolling mill. All samples were characterised using optical microscopy and image analysis. The volume fraction of retained austenite was ascertained using a heat tinting technique and X-ray diffraction measurements. Room temperature mechanical properties were determined by a tensile test. From this a comprehensive understanding of the structural aspect of the bainite transformation in these types of TRIP steels has been developed. The results have shown that the final microstructures of thermomechanically processed TRIP steels comprise 50 % of polygonal ferrite, 7 - 12 % of retained austenite, non-carbide bainitic structure and martensite. All steels exhibited a good combination of ultimate tensile strength and total elongation. The microstructure-property examination revealed the relationship between the composition of TRIP steels and their mechanical properties. It has been shown that the addition of Mo to the C-Si-Mn-Nb TRIP steel increases the ultimate tensile strength up to 1020 MPa. The stability of the retained austenite of the Nb-Mo steel was degraded, which led to a decrease in the elongation (24 %). The results have demonstrated that the addition of Al to C-Si-Mn-Nb steel leads to a good combination of strength (∼ 940 MPa) and elongation (∼ 30 %) due to the formation of refined acicular ferrite and granular bainite structure with ∼7 - 8 % of stable retained austenite. Furthermore, it has been found that the addition of Al increases the volume fraction of bainitic ferrite laths. The investigations have shown an interesting result that, in the Nb-Mo-Al steel, Al has a more pronounced effect on the microstructure in comparison with Mo. It has been found that the bainitic structure of the Nb-Mo-Al steel appears to be more granular than in the Nb-Mo steel. Moreover, the volume fraction of the retained austenite increased (12 %) with decreasing bainitic ferrite content. The results have demonstrated that this steel has the best mechanical properties (1100 MPa and 28 % elongation). It has been concluded that the combined effect of Nb, Mo, and Al addition on the dispersion of the bainite, martensite and retained austenite in the ferrite matrix and the morphology of these phases is different than effect of Nb, Mo and Al, separately.

The effect of hydrogenation on the ECAP compaction of Ti–6Al–4V powder and the mechanical properties of compacts

The effect of hydrogen content on the compaction of Ti–6Al–4V powder at low temperatures, namely 500 °C, using equal channel angular pressing (ECAP) with back pressure has been investigated. The properties of the compacts before and after a heat treatment and de-hydrogenation cycle have been determined. Compaction of powder by ECAP (500 °C and 260 MPa) has shown maximum levels of relative density of 99.3% and 99.4% when charged with 0.05–0.1 wt.% and 0.61–0.85 wt.% of hydrogen, respectively. After the de-hydrogenation heat treatment the diffusion bonding between individual powder particles was completed and the microstructure was altered, depending on the level of hydrogen content. Two local maxima of 99.2% and 98.1% were observed in the measured density of consolidated compacts for hydrogen contents between 0.05 wt.% and 0.1 wt.% and between 0.61 wt.% and 0.85 wt.%, respectively. However, the mechanical properties of the compacts within these two ranges of hydrogen content were significantly different due to a difference in the observed microstructure. An exceptionally high ductility of 29%, in combination with a relatively high strength of ~560 MPa, was measured in a shear punch test on specimens which had a prior hydrogen level of 0.05 wt.% before the heat treatment. It was shown that material consolidated from powder hydrogenated to low levels of hydrogen before compaction has the potential to offer substantial improvements in mechanical properties after a suitable heat treatment.

Microstructure and mechanical properties of thermomechanically processed TRansformation Induced Plasticity (TRIP) steels

One of the main aims of steel research for the automotive industry is to develop materials with the optimum combination of relevant properties, cost and productivity. The introduction of new TRansformation Induced Plasticity steels has been driven by the requirements to increase the ductility without compromising the strength. The main phenomenon responsible for the unique mechanical properties in these steels has been proposed to be the formation of multiphase structure, which can contribute to an increase in elongation during straining. The thesis studied the effect of the different alloying additions on the structure-property relationship in the TRIP steels.

Effects of alloying elements on the corrosion behavior and biocompatibility of biodegradable magnesium alloys: a review

Magnesium (Mg) based alloys have been extensively considered for their use as biodegradable implant materials. However, controlling their corrosion rate in the physiological environment of the human body is still a significant challenge. One of the most effective approaches to address this challenge is to carefully select alloying compositions with enhanced corrosion resistance and mechanical properties when designing the Mg alloys. This paper comprehensively reviews research progress on the development of Mg alloys as biodegradable implant materials, highlighting the effects of alloying elements including aluminum (Al), calcium (Ca), lithium (Li), manganese (Mn), zinc (Zn), zirconium (Zr), strontium (Sr) and rare earth elements (REEs) on the corrosion resistance and biocompatibility of Mg alloys, from the viewpoint of the design and utilization of Mg biomaterials. The REEs covered in this review include cerium (Ce), erbium (Er), lanthanum (La), gadolinium (Gd), neodymium (Nd) and yttrium (Y). The effects of alloying elements on the microstructure, corrosion behavior and biocompatibility of Mg alloys have been critically summarized based on specific aspects of the physiological environment, namely the electrochemical effect and the biological behavior. This journal is © the Partner Organisations 2014.