Fabrication of novel metal alloy foams for biomedical applications

Degeneration of the weight bearing bones of the ageing population often requires the inception of metallic biomaterials. Research in this area is receiving increased attention globally. However, most of today's artificial bone materials are dense and suffer from problems of adverse reaction, biomechanical mismatch and lack of appropriate space for the regeneration of new bone tissues. In the present study, novel ZrTi alloy foams with a porous structure and mechanical properties that are very close to those of bone were fabricated. These ZrTi alloy foams are biocompatible, and display a porous structure permitting the ingrowth of new bone tissues.

Fabrication of novel TiZr alloy foams for biomedical applications

Bone injuries and failures often require the inception of implant biomaterial. Research in this area has received increasing attention recently. In particular, porous metals are attractive due to its unique physical, mechanical, and new bone tissue ingrowth properties. In the present study, TiZr alloy powders were prepared using mechanical alloying. Novel TiZr alloy foams with relative densities of approximately 0.3 were fabricated by a powder metallurgical process. The TiZr alloy foams displayed an interconnected porous structure resembling bone and the pore size ranged from 200 to 500 μm. The compressive plateau stress and the Young’s modulus of the TiZr foam were 78.4 MPa and 15.3 GPa, respectively. Both the porous structure and the mechanical properties of the TiZr foam were very close to those of natural bone.

Damping properties of open cell microcellular pure Al foams

Damping behaviours of the open cell microcellular pure Al foams fabricated by sintering and dissolution process with the relative density of 0·31-0·42 and the pore size of 112-325 μm were investigated. The damping characterisation was conducted on a multifunction internal friction apparatus. The internal friction (IF) was measured at frequencies of 1·0, 3·0 and 6·0 Hz over the temperature range of 298-725 K. The measured IF shows that the open cell pure Al foam has a damping capacity that is enhanced in comparison with pure Al. At a lower temperature (∼400 K), the IF of the open cell pure Al foams increases with decreasing relative density, with decreasing pore size and with increasing frequency. The IF peak was found at the temperature range of 433-593 K in the IF curves. It is clear that the IF peak is relaxational type and the activation energy associated with the IF peak is about 1·60 ± 0·02 eV. Defect effects can be used to interpret the damping mechanisms.

Mechanical properties and energy absorption of ceramic particulate and resin-impregnation reinforced aluminium foams

The mechanical properties of aluminium foams can be improved by matrix reinforcement and resin-impregnation methods. In the present study, aluminium foams were reinforced by both ceramic particulate reinforcing of the aluminium matrix and resin-impregnating pores. The mechanical properties and the energy absorption of the reinforced aluminium foams were investigated by dynamic and quasi-static compression. Results indicated that the ceramic particle additions of CBN, SiC and B4C in aluminium foams increase the peak stress, elastic modulus and energy absorption of the aluminium foams, under both conditions of dynamic and quasi-static compression. Moreover, the aluminium foams with and without ceramic particle additions exhibited obvious strain rate sensitivity during dynamic compression. Furthermore, the resin-impregnation improves the mechanic properties and energy absorption of aluminium foams significantly. However, aluminium foams with resin-impregnation showed negligible strain rate sensitivity under dynamic compression. It is reported that both the ceramic particle addition and resin-impregnation can be effective techniques to improve the mechanical and the energy absorption properties of aluminium foams.

TiNi shape memory alloy foams synthesized by spacer sintering and their properties

Titanium (Ti) and nickel (Ni) elemental powders were blened by ball milling and the ball milled powders were employed to fabricate NiNi shape memory alloy (SMA) foams by space sintering. Effect of ball milling time on phase constitutes of the sintered TiNi alloy foams was studied by X-ray diffraction (XRD) analysis.Scanning election microscopy (SEM) was used to characterize the porous structure, and compressive tests were carried out to evaluate the mechanical properties of the foams. Results indicate the porosities of the TiNi alloy foams can be controlled by using the spacer sincering method, and the porosities show a significant effect on the mechanical prperties and shape memory effect (SME).

Processing and mechanical properties of hollow sphere aluminum foams

Hollow sphere metallic foams are a new class of cellular material that possesses the attractive advantages of uniform cell size distribution and regular cell shape. These result in more predictable physical and mechanical properties than those of cellular materials with a random cell size distribution and irregular cell shapes. In the present study, single aluminum hollow spheres with three kinds of sphere wall thickness as 0.1 mm, 0.3 mm and 0.5 mm were processed by a new pressing method. Hollow sphere aluminum foam samples were prepared by bonding together single hollow spheres with simple cubic packing (SC) and body-centered cubic packing (BCC). Compressive tests were carried out to evaluate the deformation behaviors and mechanical properties of the hollow sphere aluminum foams. Effects of the sphere wall thickness and packing style on the mechanical properties were investigated.

Titanium–nickel shape memory alloy foams for bone tissue engineering

Titanium–nickel (TiNi) shape memory alloy (SMA) foams with an open-cell porous structure were fabricated by space-holder sintering process and characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis. The mechanical properties and shape memory properties of the TiNi foam samples were investigated using compressive test. Results indicate that 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 1.9 to 38.3 MPa and from 30 to 860 MPa for the TiNi foam samples with porosities ranged from 71% to 87%, respectively. The mechanical properties of the TiNi alloy foams can be tailored to match those of bone. The TiNi alloy foams exhibit shape memory effect (SME), and it is found that the recoverable strain due to SME decreases with the increase of foam porosity.

Anisotropic mechanical properties of nickel foams fabricated by powder metallurgy

In the present study, porous nickel foam samples with pore sizes of 20 μm and 150 μm and porosities of 60 % and 70 % were fabricated by the space-holding sintering method via powder metallurgy. Electron scanning microscopy (SEM) and Image-Pro Plus were used to characterise the morphological features of the porous nickel foam samples. The anisotropic mechanical properties of porous nickel foams were investigated by compressive testing loading in different directions, i.e. the major pore axis and minor pore axis. Results indicated that the nominal stress of the nickel foam samples increases with the decreasing of the porosity. Moreover, the foam sample exhibited significantly higher nominal stress for loading in the direction of the major pore axis than loading in direction of the minor pore axis. It is also noticeable that the nominal stress of the nickel foams increases with the decreasing of the pore size. It seems that the deformation behaviour of the foams with a pore size in the micron-order differs from those with a macro-porous structure.

Effect of pore size on mechanical properties of titanium foams

In the study, both experimental work and numerical modeling are performed to investigate the pore size effects on the mechanical properties and deformation behaviours of titanium foams. Cylindrical titanium foam samples with different pore sizes are fabricated through powder metallurgy. Scanning electron microscope (SEM) is used to determine the pore size, pore distribution and the ratios of the length to width of pores. Compressive tests are carried out to determine the mechanical properties of the titanium foams with different pore sizes. Finally, finite element modeling is attempted to simulate the deformation behaviour and the mechanical properties of the titanium foams. Results indicate that titanium foams with different pore sizes have different geometrical characteristics, which lead to different deformation behaviours of cell walls during compression, resulting in different mechanical properties of titanium foams.

Fracture toughness of titanium foams for medical applications

The fracture behavior of titanium open foam is characterized and the R-curves of crack propagation from pre-cracks are measured. The crack growth has been optically observed, the measured initiation toughness, J_IC, has been analyzed and the effect of material morphology on the J_IC is discussed. The fracture toughness was found to be dependent on the expanding crack bridging zone at the back of the crack tip. The compact tension specimens also have some plastic collapse along the ligaments and it has shown that the titanium foam with a higher relative density is tougher. The non-uniform stressing within the plastic zone at the crack tip and the plastic collapse of cell topology behind the tip was found to be the primary cause of the R-curve behavior in low relative density titanium foams.

Investigation of cell shape effect on the mechanical behaviour of open-cell metal foams

The mechanical behaviours of metal foams greatly depend on their cell topology, including cell shape, cell size etc. as well as relative density and material properties of the cell wall. However, the cell shape effect on the mechanical behaviours of such materials appears to be ignored in previous research. In this paper, both analytic and finite element models are developed and employed to investigate the effect of cell shape on the mechanical behaviour of open-cell magnesium alloy (AZ91) foams under compression, including deformation modes and failure modes. For numerical modelling, both two-dimensional (2-D) and three-dimensional (3-D) finite element models are developed to predict the compressive behaviours of typical open-cell metal foams and capture the deformation modes and failure mechanisms. Two typical cell shapes i.e. cubic and diamond are taken into consideration. To validate these models, the analytic and numerical results are compared to the experimental data. Both the numerical and experimental data indicate that the cell shape significantly affects the compression behaviour of open-cell metal foams. In general, numerical results from the three-dimensional solid-element model show better agreement with the experimental results than those from other finite element models.