Biomimetic porous titanium scaffolds for orthopaedic and dental applications

The development of artificial organs and implants for replacement of injured and diseased hard tissues such as bones, teeth and joints is highly desired in orthopedic surgery. Orthopedic prostheses have shown an enormous success in restoring the function and offering high quality of life to millions of individuals each year. Therefore, it is pertinent for an engineer to set out new approaches to restore the normal function of impaired hard tissues.

Over the last few decades, a large number of metals and applied materials have been developed with significant improvement in various properties in a wide range of medical applications. However, the traditional metallic bone implants are dense and often suffer from the problems of adverse reaction, biomechanical mismatch and lack of adequate space for new bone tissue to grow into the implant. Scientific advancements have been made to fabricate porous scaffolds that mimic the architecture and mechanical properties of natural bone. The porous structure provides necessary framework for the bone cells to grow into the pores and integrate with host tissue, known as osteointegration. The appropriate mechanical properties, in particular, the low elastic modulus mimicking that of bone may minimize or eliminate the stress-shielding problem. Another important approach is to develop biocompatible and corrosion resistant metallic materials to diminish or avoid adverse body reaction. Although numerous types of materials can be involved in this fast developing field, some of them are more widely used in medical applications. Amongst them, titanium and some of its alloys provide many advantages such as excellent biocompatibility, high strength-to-weight ratio, lower elastic modulus, and superior corrosion resistance, required for dental and orthopedic implants. Alloying elements, i.e. Zr, Nb, Ta, Sn, Mo and Si, would lead to superior improvement in properties of titanium for biomedical applications.

New processes have recently been developed to synthesize biomimetic porous titanium scaffolds for bone replacement through powder metallurgy. In particular, the space holder sintering method is capable of adjusting the pore shape, the porosity, and the pore size distribution, notably within the range of 200 to 500 m as required for osteoconductive applications. The present chapter provides a review on the characteristics of porous metal scaffolds used as bone replacement as well as fabrication processes of porous titanium (Ti) scaffolds through a space holder sintering method. Finally, surface modification of the resultant porous Ti scaffolds through a biomimetic chemical technique is reviewed, in order to ensure that the surfaces of the scaffolds fulfill the requirements for biomedical applications.

Fabrication and characterisation of microporous titanium

Microporous titanium was fabricated by a special powder metallurgy process and the microstructure and the mechanical properties of the material were characterised by scanning electron microscopy and quasi-static compression. The pore sizes and porosities of the samples are ranged of 10-50 μm and 40-65%, respectively. Macroporous Ti samples with the pore sizes ranged from 500 to 800 μm were also prepared by the similar process for comparison. The microporous Ti exhibits not only a very different deformation behaviour from the macroporous Ti but also lower flow stress than the latter, completely different from those observed in common porous metals.

In vitro behavior of human osteoblast-like cells (SaOS2) cultured on surface modified titanium and titanium–zirconium alloy

In this study, titanium (Ti) and titanium-zirconium (TiZr) alloy samples fabricated through powder metallurgy were surface modified by alkali-heat treatment and calcium (Ca)-ion-deposition. The alteration of the surface morphology and the chemistry of the Ti and TiZr after surface modification were examined. The bioactivity of the Ti and TiZr alloys after the surface modification was demonstrated. Subsequently, the cytocompatibility of the surface modified Ti and TiZr was evaluated via in vitro cell culture using human osteoblast-like cells (SaOS2). The cellular attachment, adhesion and proliferation after cell culture for 14 days were characterized by scanning electron microscopy (SEM) and MTT assay. The relationship between surface morphology and chemical composition of the surface modified Ti and TiZr and cellular responses was investigated. Results indicated that the surface-modified Ti and TiZr alloys exhibited excellent in vitro cytocompatibility together with satisfactory bioactivity. Since osteoblast adhesion and proliferation are essential prerequisites for a successful implant in vivo, these results provide evidence that Ti and TiZr alloys after appropriate surface modification are promising biomaterials for hard tissue replacement.

Titanium in biomedical applications—properties and fabrication: a review

Ti and Ti-based alloys have unique properties such as high strength, low density and excellent corrosion resistance. These properties are essential for the manufacture of lightweight and high strength components for biomedical applications. In this paper, Ti properties such as metallurgy, mechanical properties, surface modification, corrosion resistance, biocompatibility and osseointegration in biomedical applications have been discussed. This paper also analyses the advantages and disadvantages of various Ti manufacturing processes for biomedical applications such as casting, powder metallurgy, cold and hot working, machining, laser engineering net shaping (LEN), superplastic forming, forging and ring rolling. The contributions of this research are twofold, firstly scrutinizing the behaviour of Ti and Ti-based alloys in-vivo and in-vitro experiments in biomedical applications to determine the factors leading to failure, and secondly strategies to achieve desired properties essential to improving the quality of patient outcomes after receiving surgical implants. Future research will be directed toward manufacturing of Ti for medical applications by improving the production process, for example using optimal design approaches in additive manufacturing and investigating alloys containing other materials in order to obtain better medical and mechanical characteristics.

Effects of combined silicon and molybdenum alloying on the size and evolution of microalloy precipitates in HSLA steels containing niobium and titanium

The effects of combined silicon and molybdenum alloying additions on microalloy precipitate formation in austenite after single- and double-step deformations below the austenite no-recrystallization temperature were examined in high-strength low-alloy (HSLA) steels microalloyed with titanium and niobium. The precipitation sequence in austenite was evaluated following an interrupted thermomechanical processing simulation using transmission electron microscopy. Large (~ 105 nm), cuboidal titanium-rich nitride precipitates showed no evolution in size during reheating and simulated thermomechanical processing. The average size and size distribution of these precipitates were also not affected by the combined silicon and molybdenum additions or by deformation. Relatively fine (< 20 nm), irregular-shaped niobium-rich carbonitride precipitates formed in austenite during isothermal holding at 1173 K. Based upon analysis that incorporated precipitate growth and coarsening models, the combined silicon and molybdenum additions were considered to increase the diffusivity of niobium in austenite by over 30% and result in coarser precipitates at 1173 K compared to the lower alloyed steel. Deformation decreased the size of the niobium-rich carbonitride precipitates that formed in austenite.

Mechanical properties and microstructure of powder metallurgy Ti-xNb-yMo alloys for implant materials

In this study, a series of Ti-xNb-yMo (x = 5-40 wt.% in 5 wt.% increments; and y = 3, 5, 10 wt%) alloys were fabricated by powder metallurgy and studied with respect to their microstructures, compressive mechanical properties and hardness. Increases in Nb and Mo content led to decreases in compressive and yield strengths, elastic modulus and hardness of the sintered alloys. Among the studied alloys, Ti-10Nb-3Mo alloy exhibited the optimum combination of strength and ductility. Alloys with a lower amount of Nb (≤ 25 wt.%) and Mo (≤ 5 wt.%) developed Widmanstätten structure, while further increase in Nb and Mo additions led to the microstructure predominantly consisting of β phase with varying regions of α + β phase. The effects of sintering temperature on elastic modulus and hardness were also investigated for Ti-xNb-3Mo alloys.

Photocatalytic degradation of dye effluent by titanium dioxide pillar pellets in aqueous solution

Photocatalytic oxidation (PCO) process is an effective way to deal with organic pollutants in wastewater which could be difficult to be degraded by conventional biological treatment methods. Normally the TiO2 powder in nanometre size range was directly used as photocatalyst for dye degradation in wastewater. However the titanium dioxide powder was arduous to be recovered from the solution after treatment. In this application, a new form of TiO2 (i.e. pillar pellets ranging from 2.5 to 5.3 mm long and with a diameter of 3.7 mm) was used and investigated for photocatalytic degradation of textile dye effluent. A test system was built with a flat plate reactor (FPR) and UV light source (blacklight and solar simulator as light source respectively) for investigating the effectiveness of the new form of TiO2. It was found that the photocatalytic process under this configuration could efficiently remove colours from textile dyeing effluent. Comparing with the TiO2 powder, the pellet was very easy to recovered from the treated solution and can be reused in multiple times without the significant change on the photocatalytic property. The results also showed that to achieve the same photocatalytic performance, the FPR area by pellets was about 91% smaller than required by TiO2 powder. At least TiO2 pellet could be used as an alternative form of photocatalyst in applications for textile effluent treatment process, also other wastewater treatment processes.

Novel titanium foam for bone tissue engineering

Titanium foams fabricated by a new powder metallurgical process have bimodal pore distribution architecture (i.e., macropores and micropores), mimicking natural bone. The mechanical properties of the titanium foam with low relative densities of approximately 0.20-0.30 are close to those of human cancellous bone. Also, mechanical properties of the titanium foams with high relative densities of approximately 0.50-0.65 are close to those of human cortical bone. Furthermore, titanium foams exhibit good ability to form a bonelike apatite layer throughout the foams after pretreatment with a simple thermochemical process and then immersion in a simulated body fluid. The present study illustrates the feasibility of using the titanium foams as implant materials in bone tissue engineering applications, highlighting their excellent biomechanical properties and bioactivity.

Hydroxyapatite/titania sol-gel coatings on titanium-zirconium alloy for biomedical applications

A simple sol–gel method was developed for hydroxyapatite/titania (HA/TiO2) coatings on non-toxic titanium–zirconium (TiZr) alloy for biomedical applications. The HA/TiO2-coated TiZr alloy displayed excellent bioactivity when soaked in a simulated body fluid (SBF) for an appropriate period. Differential scanning calorimetry, thermogravimetric analysis, X-ray diffraction and scanning electron microscopy-energy dispersive spectrometry were used to characterize the phase transformations and the surface structures and to assess the in vitro tests. The HA/TiO2 layers were spin-coated on the surface of TiZr alloy at a speed of 3000 rpm for 15 s, followed by a heat treatment at 600 °C for 20 min in an argon atmosphere sequentially. The TiO2 layer exhibited a cracked surface and an anatase structure and the HA layer displayed a uniform dense structure. Both the TiO2 and HA layers were 25 μm thick, and the total thickness of the HA/TiO2 coatings was 50 μm. The TiZr alloy after the above HA/TiO2 coatings displayed excellent bone-like apatite-forming ability when soaked in SBF and can be anticipated to be a promising load-bearing implant material.

Micro-porous nickel produced by powder metallurgy

Micro-porous nickel (Ni) with an open cell structure was fabricated by a special powder metallurgical process, which includes the adding of a space-holding material. The average pore size of the micro-porous Ni samples approximated 30 μm and 150 μm, and the porosity ranged from 60 % to 80 %. The porous characteristics of the Ni samples were observed using scanning electron microscopy (SEM) and the mechanical properties were evaluated using compressive tests. For comparison, porous Ni samples with a macro-porous structure prepared by both powder metallurgy
(pore size 800 μm) and the traditional chemical vapour deposition (CVD) method (pore size 1300 μm) were also presented. Results indicated that the porous Ni samples with a micro-porous structure exhibited different deformation behaviour and dramatically increased mechanical properties,
compared to those of the macro-porous Ni samples.

Processing and mechanical properties of porous titanium-niobium shape memory alloy for biomedical applications

Ti-26 at.%Nb (hereafter Ti-26Nb) alloy foams were fabricated by space-holder sintering process. The porous structures of the foams were characterized by scanning electron microscopy (SEM). The mechanical properties of the Ti-26Nb foam samples were investigated using compressive test. Results indicate that mechanical properties of Ti-26Nb foam samples are influenced by foam porosity. The plateau stresses and elastic moduli of the foams under compression decrease with the increase of their porosities. The plateau stresses and elastic moduli are measured to be from 10~200 MPa and 0.4~5.0 GPa for the Ti-26Nb foam samples with porosities ranged from 80~50 %, respectively.

Sol-gel derived hydroxyapatite/titania biocoatings on titanium substrate

A simple sol–gel method was successfully developed for a hydroxyapatite (HA)/TiO₂ double layer deposition on a pure titanium substrate. Phase formation, surface morphology, and interfacial microstructure were investigated by differential scanning calorimetry analysis (DSC), X-ray diffraction (XRD) and scanning electron microscopy (SEM). The TiO₂ layer was coated by a spin coating method at a speed of 1500 rpm for 15 s, followed by a heat treatment at 560 °C for 20 min. The HA film was subsequently spin coated on the outer surface at the same speed and then heat-treated at difference temperatures. Results indicated that the HA phase began to crystallize after a heat treatment at 580 °C; and the crystallinity increased obviously at a temperature of 780 °C. The HA film showed a porous structure and a thickness of 5–7 μm after the heat treatment at 780 °C. SEM observations revealed no delamination and crack at the interfaces of HA/TiO₂ and TiO₂/Ti. The HA film with a porous structure is expected to be more susceptible to the natural remodeling processes when it is implanted in a living body.