Selective Laser Melting of Novel Titanium-Tantalum Alloy as Orthopaedic Biomaterial (eBook)

Supervisors’ Foreword 6
Parts of this thesis have been published in the following journal articles: 8
Acknowledgements 9
Contents 10
Abbreviations 13
Symbols 14
1 Introduction to Additive Manufacturing for Orthopaedic Implants 16
1.1 Background 16
1.2 Motivations 18
1.3 Objectives 20
1.4 Scope 20
1.5 Organisation of Report 21
References 22
2 Concepts of Selective Laser Melting for Orthopaedic Implants 24
2.1 Orthopaedic Implants 24
2.2 Selective Laser Melting 27
2.3 Materials for Selective Laser Melting of Metallic Implants and Scaffolds 30
2.3.1 316L Stainless Steel 30
2.3.2 Cobalt Chromium 32
2.3.3 Titanium-6Aluminium-4Vanadium 32
2.3.4 New Materials 33
2.4 Design Consideration for Metallic Implants and Scaffolds Using Selective Laser Melting 35
2.4.1 Manufacturability of Metallic Scaffolds Using Selective Laser Melting 35
2.4.2 Biological Compatibility of Metallic Scaffolds Fabricated Using Selective Laser Melting 37
2.4.3 Mechanical Properties of Metallic Scaffolds Fabricated Using Selective Laser Melting 41
2.5 Summary 42
References 44
3 Formation of Titanium-Tantalum Alloy Using Selective Laser Melting 52
3.1 ? Stabilisers for Titanium 52
3.2 Powder Preparation 52
3.3 Powder Characterization 53
3.4 Parameters Optimization for Selective Laser Melting 56
3.5 Summary 61
References 62
4 Characterisation of Selective Laser Melted Titanium-Tantalum Alloy 63
4.1 Metallographic Analysis of Titanium-Tantalum Parts 63
4.1.1 X-Ray Diffraction Phase Analysis 64
4.1.2 Microstructure 65
4.2 Mechanical Analysis of Titanium-Tantalum Parts 71
4.2.1 Tensile Properties 71
4.2.2 Micro-Hardness 75
4.3 Summary 75
References 76
5 Statistical Modelling of Selective Laser Melting of Cellular Lattice Structures 78
5.1 Forming Mechanisms of Lattice Structures Using Selective Laser Melting 78
5.2 Design of Cellular Lattice Structures 79
5.3 Design of Experiment for Regression Analysis 79
5.4 Properties Modelling of Cellular Lattice Structures 82
5.4.1 Metrological Characterisation 82
5.4.2 Mechanical Characterisation 88
5.5 Summary 96
References 97
6 Characterisation of Titanium-Tantalum Lattice Structures Fabricated by Selective Laser Melting 99
6.1 Design of Cellular Lattice Structures 99
6.2 Metrological Characterisation 99
6.3 Mechanical Characterisation 104
6.4 Biocompatibility of Titanium-Tantalum 105
6.5 Summary 107
References 107
7 Future Trends in Titanium-Tantalum Formed by Selective Laser Melting 108
7.1 In-Situ Alloying of Titanium-Tantalum using Selective Laser Melting 108
7.1.1 Formation of Bulk Titanium-Tantalum Using Selective Laser Melting 108
7.1.2 Formation of Lattice Structures Using Selective Laser Melting 109
7.2 Future Work 110
7.2.1 Development of Titanium-Tantalum Using Selective Laser Melting 110
7.2.2 Thermal Modelling of Selective Laser Melting 110
7.2.3 In Vitro and In Vivo Biocompatibility Tests for Scaffolds Fabricated by Selective Laser Melting 110