Mechanical properties of micro-porous metals produced by space-holding sintering

Micro-porous nickel foams with an open cell structure were fabricated by the space-holding sintering. The average pore size of the micro-porous nickel specimens ranged from 30 μm to 150 μm, and the porosity ranged from 60 % to 80 %. The porous characteristics of the nickel specimens were observed using scanning electron microscopy (SEM). The mechanical properties were studied using compressive tests. For comparison, macro-porous nickel foams prepared by the chemical vapour deposition method with pore sizes of 800 μm and 1300 μm and porosity of 95 % were also presented. Results indicated that the ratio value of 6 and higher for the specimen length to cell size (L/d) is satisfying for obtaining stable compressive properties. The micro-porous nickel specimens exhibited different deformation behaviour and dramatically increased mechanical properties, compared to those of the macro-porous nickel specimens.

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.

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.

Mechanical properties of porous Ti-26NB alloy for regenerative medicine

Porous titanium-26at.%niobium (hereafter, Ti-26Nb) alloys with different porosities were prepared by space-holder sintering. The porous structure of the alloys was characterized by scanning electron microscopy (SEM). Mechanical properties of the porous alloys were investigated using compression test. Results indicate that the porous alloys with 60, 70 and 80% porosities exhibit interconnected porous structure with pore sizes of 100-300 µm. The porous structure has the potential to provide new bone tissue ingrowth ability. The mechanical properties of these porous alloys decrease with the increase of porosity. The mechanical properties of the porous Ti-26Nb alloys can be tailored to match those of human bone.

Ti6Ta4Sn alloy and subsequent scaffolding for bone tissue engineering

Porous titanium (Ti) and titanium alloys are promising scaffold biomaterials for bone tissue engineering, because they have the potential to provide new bone tissue ingrowth abilities and low elastic modulus to match that of
natural bone. In the present study, a new highly porous Ti6Ta4Sn alloy scaffold with the addition of biocompatible alloying elements (tantalum (Ta) and tin (Sn)) was prepared using a space-holder sintering method. The
strength of the Ti6Ta4Sn scaffold with a porosity of 75% was found to be significantly higher than that of a pure Ti scaffold with the same porosity. The elastic modulus of the porous alloy can be customized to match that of
human bone by adjusting its porosity. In addition, the porous Ti6Ta4Sn alloy exhibited an interconnected porous structure, which enabled the ingrowth of new bone tissues. Cell culture results revealed that human SaOS₂
osteoblast-like cells grew and spread well on the surfaces of the solid alloy, and throughout the porous scaffold. The surface roughness of the alloy showed a significant effect on the cell behavior, and the optimum surface
roughness range for the adhesion of the SaOS2 cell on the alloy was 0.15 to 0.35 mm. The present study illustrated the feasibility of using the porous Ti6Ta4Sn alloy scaffold as an orthopedic implant material with a special
emphasis on its excellent biomechanical properties and in vitro biocompatibility with a high preference by osteoblast-like cells.

Preparation of bioactive porous titanium-molybdenum alloy through powder metallurgy

Porous Ti-Mo alloy samples with different porosities from 52% to 72% were successfully fabricated by the space-holder sintering method. The pore size of the porous Ti-Mo alloy samples were ranged from 200 to 500 μm. The plateau stress and elastic modulus of the porous Ti-Mo alloy samples increases with the decreasing of the porosity. Moreover, an apatite coating on the Ti-Mo alloy after an alkali and heat treatment was obtained through soaking into a simulated body fluid (SBF). The porous Ti-Mo alloy provides promising potential for new implant materials with new bone tissue ingrowth ability, bioactivity and mechanical properties mimicking those of natural bone.

Degradation of the strength of porous titanium after alkali and heat treatment

Porous titanium with a porosity of 75% was fabricated by space-holder sintering through powder metallurgy. The effect of the alkali and heat treatment on the strength of the porous titanium was investigated. Results indicated that the alkali and heat treatment led to a significant decrease in the strength of the porous titanium, whichwas causedby the degradation due to corrosion of the struts of the porous titanium with a layer of the reaction products, grain pullout and micro-cracks.

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.

Biomimetic modification of porous TiNbZr alloy scaffold for bone tissue engineering

Porous titanium (Ti) and Ti alloys are important scaffold materials for bone tissue engineering. In the present study, a new type of porous Ti alloy scaffold with biocompatible alloying elements, that is, niobium (Nb) and zirconium (Zr), was prepared by a space-holder sintering method. This porous TiNbZr scaffold with a porosity of 69% exhibits a mechanical strength of 67MPa and an elastic modulus of 3.9GPa, resembling the mechanical properties of cortical bone. To improve the osteoconductivity, a calcium phosphate (Ca/P) coating was applied to the surface of the scaffold using a biomimetic method. The biocompatibility of the porous TiNbZr alloy scaffold before and after the biomimetic modification was assessed using the SaOS2 osteoblast–like cells. Cell culture results indicated that the porous TiNbZr scaffold is more favorable for cell adhesion and proliferation than its solid counterpart. By applying a Ca/P coating, the cell proliferation rate on the Ca/P-coated scaffold was significantly improved. The results suggest that high-strength porous TiNbZr scaffolds with an appropriate osteoconductive coating could be potentially used for bone tissue engineering application.

Titanium-based shape memory alloys and scaffolds for biomedical applications

Porous Ti-50.5Ni shape memory alloys with different porosities were produced using a space-holder sintering method. A new Ni-free Ti-based shape memory alloy, Ti-18Nb-5Mo-5Sn, was developed for potential biomedical applications, and a novel one-step hydrothermal process was applied to produce hydroxyapatite coatings on the surface of Ti alloy.

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 of Ti14Nb4Sn alloys for bone tissue engineering applications

In this paper, porous Ti14Nb4Sn alloys were fabricated using a space holder sintering method, resulting in a porosity of ~70%. Scanning electron microscopy (SEM) analyses revealed a combination of both macropore and micropore structures. The fabricated titanium alloy scaffolds exhibited a similar structure to that of natural bone, which is expected to improve bone implant longevity. Bacterial cells of Pseudomonas aeruginosa ATCC 9027 were employed for the in vitro test.

Porous TiNbZr alloy scaffolds for biomedical applications

In the present study, porous Ti–10Nb–10Zr alloy scaffolds with different porosities were successfully fabricated by a ‘‘space-holder” sintering method. By the addition of biocompatible alloying elements the porous TiNbZr scaffolds achieved significantly higher strength than unalloyed Ti scaffolds of the same porosity. In particular, the porous TiNbZr alloy with 59% porosity exhibited an elastic modulus and plateau stress of 5.6 GPa and 137 MPa, respectively. The porous alloys exhibited excellent ductility during compression tests and the deformation mechanism is mainly governed by bending and buckling of the struts. Cell cultures revealed that SaOS2 osteoblast-like cells grew on the surface and inside the pores and showed good spreading. Cell viability for the porous scaffold was three times higher than the solid counterpart. The present study has demonstrated that the porous TiNbZr alloy scaffolds are promising scaffold biomaterials for
bone tissue engineering by virtue of their appropriate mechanical properties, highly porous structure and excellent biocompatibility.

Mechanical properties of titanium foam for biomedical applications

Understanding the mechanical behaviour of pure titanium (Ti) foam is crucial for the design and development of Ti foam-based load-bearing implants. In this work, pure titanium foam is fabricated by a powder metallurgical process using the space-holder technique with a spacer size of 500 to 800 µm. Experimental data from static compression testing on the Ti foam are presented. The application of theoretical formulae to predict Young's modulus and yield strength of titanium foams is also discussed. A foam with 63% porosity, 87 ± 5 MPa yield strength, and 6.5 ± 1.3 GPa Young's modulus is found to be appropriate for a number of dental and orthopaedic applications.

Effects of pore morphology on the compressive behaviour of porous metals

In the present study, porous nickel foams with three different porosities (i.e. 50 %, 60 % and 70 %) were fabricated using the space-holding sintering method. Ammonium bicarbonate particles with sizes ranging from 1- 2 mm were chosen as the space-holding material. The anisotropic behaviours of the nickel foam samples were investigated by compressive testing loading at different directions, i.e., in both directions of the major and minor axis of ellipsoidal cells. Electron scanning microscopy (SEM) and Image-Pro Plus was used to characterise the morphological characteristics of the porous nickel foam samples. Results indicated that the porous nickel foam samples exhibited obvious anisotropic mechanical properties. The foam sample shows significantly higher nominal stress for loading in the direction of the major axis of the pores than loading in the direction of the minor axis of pores. The nominal stress increases with the decreasing of the porosity.