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Porous titanium is used in many bioimplant and electrode applications because of its interconnected pore structure and good corrosion resistance. The purpose of this paper is to study the anodic polarization behavior of porous titanium in different electrolytes and clarify the influences of the porosity and macro‐pore size on the corrosion resistance.

The porous titanium with 10‐70% porosities and average macro‐pore sizes in the range of 100‐500 μm was prepared by the powder metallurgy method using polymethyl methacrylate (PMMA) as a space holder. Electrochemical corrosion tests were performed on porous titanium as well as solid titanium (with the same irregular and isolated micro‐pore structures as that on the interconnected spheroidal macro‐pore walls of porous titanium) in the 0.1 M H₂SO₄, 1 M NaOH and 0.9% NaCl (37 °C) solutions.

It was found that porous titanium exhibited an active‐passive transition behavior in the 1 M NaOH and 0.1 M H₂SO₄ solutions. In contrast, a self‐passivation transition behavior was observed in the 0.9% NaCl solution (37 °C).

The paper demonstrates that both the porosity and macro‐pore size of porous titanium play an important role in determining the corrosion rate, rather than the corrosion potential.

Human aging is becoming a common issue these days as it results in orthopaedic-related issues such as joints disorderness, bone-fracture. People with age = 60 years suffer more from these aforesaid issues. It is expected that these issues in human beings will ultimately reach 2.1 billion by 2050 worldwide. Furthermore, the increase in traffic accidents in young people throughout the world has significantly emerged the need for artificial implants. Their implantation can act as a substitute for fractured bones or disordered joints. Therefore, this study aims to focus on electron beam melted titanium (Ti)-based orthopaedic implants along with their recent trends in the field.

The main contents of this work include the basic theme and background of the metal-based additive manufacturing, different implant materials specifically Ti alloys and their classification based on crystallographic transus temperature (including α, metastable β, β and α + β phases), details of electron beam melting (EBM) concerning its process physics, various control variables and performance characteristics of EBMed Ti alloys in orthopaedic and orthodontic implants, applications of EBMed Ti alloys in various load-bearing implants, different challenges associated with the EBMed Ti-based implants along with their possible solutions. Recent trends and shortfalls have also been described at the end.

EBM is getting significant attention in medical implants because of its minor issues as compared to conventional fabrication practices such as Ti casting and possesses a significant research potential to fabricate various medical implants. The elastic modulus and strength of EBMed ß Ti-alloys such as 24Nb-4Zr-8Sn and Ti-33Nb-4Sn are superior compared to conventional Ti for orthopaedic implants. Beta Ti alloys processed by EBM have near bone elastic modulus (approximately 35–50 GPa) along with improved tribo-mechanical performance involving mechanical strength, wear and corrosion resistance, along with biocompatibility for implants.

Advances in EBM have opened the gateway Ti alloys in the biomedical field explicitly ß-alloys because of their unique biocompatibility, bioactivity along with improved tribo-mechanical performance. Less significant work is available on the EBM of Ti alloys in orthopaedic and orthodontic implants. This study is directed solely on the EBM of medical Ti alloys in medical sectors to explore their different aspects for future research opportunities.

This study aims to evaluate the melting process of the phase-change RT-35 material in a shell and tube heat exchanger saturated with a porous medium. Titanium porous media with isotropic and inhomogeneous structures are studied. The considered tubes in the shell and tube exchanger are made of copper with specific thicknesses. The phase-change material has a non-Newtonian behavior and follows the endorsed Carreau–Yasuda Model.

The enthalpy–porosity method is used for modeling of the melting process. The governing equations were transferred to their dimensionless forms. Finally, the equations are solved by applying the Galerkin finite element method.

The findings for different values of the relative permeability (K*) and permeability deviation angle (λ) are represented in the forms of charts, streamlines and constant temperature contours. The considerable effects of the relative permeability (K*) and deviation angle (λ) on the flow line patterns of the melting phase-change material are some of the significant achievements of this works.

This study was conducted using data from relevant research articles provided by reputable academic sources. The data included in this manuscript have not been published previously and are not under consideration by any other journal.

The purpose of this paper is to verify the feasibility and evaluate the compressive properties of Ti6Al4V implants with controlled porosity via electron beam melting process. This process might be a promising method to fabricate orthopedic implants with suitable pore architecture and matched mechanical properties.

Ti6Al4V implants with controlled porosity are produced using an electron beam melting machine. A scanning electron microscope is utilized to examine the macro‐pore structures of the Ti6Al4V implants. The compressive test is performed to investigate the mechanical properties of the porous implants.

The fabricated samples show a fully interconnected open‐pore network. The compressive yield strength of the Ti6Al4V implants with the porosity of around 51 percent is higher than that of human cortical bone. The Young's modulus of the implants is similar to that of cortical bone.

The surface of samples produced by electron beam melting process is covered with loosely spherical metal particles. Polishing and ultrasonic cleaning have to be used to remove the loose remnants.

This paper presents the potential application in the fabrication of orthopedic or dental implants using electron beam melting process.

With technology advances, metallic implants claim to improve the quality and durability of human life. In the recent decade, Ti-6Al-4V biomaterial has been additively manufactured via selective laser melting (SLM) for orthopedic applications. This paper aims to provide state-of-the-art on mechanobiology of these fabricated components.

A literature review has been done to explore the potential of SLM fabricated Ti-6Al-4V porous lattice structures (LS) as bone substitutes. The emphasize was on the effect of process parameters and porosity on mechanical and biological properties. The papers published since 2007 were considered here. The keywords used to search were porous Ti-6Al-4V, additive manufacturing, metal three-dimensional printing, osseointegration, porous LS, SLM, in vitro and in vivo.

The properties of SLM porous biomaterials were compared with different human bones, and bulk SLM fabricated Ti-6Al-4V structures. The comparison was also made between LS with different unit cells to find out whether there is any particular design that can mimic the human bone functionality and enhance osseointegration.

The implant porosity plays a crucial role in mechanical and biological characteristics that relies on the optimum controlled process variables and design attributes. It was also indicated that although the mechanical strength (compressive and fatigue) of porous LS is not mostly close to natural cortical bone, elastic modulus can be adjusted to match that of cortical or cancellous bone. Porous Ti-6Al-4V provide favorable bone formation. However, the effect of design variables on biological behavior cannot be fully conclusive as few studies have been dedicated to this.

Selective laser melting (SLM) is an additive manufacturing process suitable for fabricating metal porous scaffolds. The unit cell topology is a significant factor that determines the mechanical property of porous scaffolds. Therefore, the purpose of this paper is to evaluate the effects of unit cell topology on the compression properties of porous Cobalt–chromium (Co-Cr) scaffolds fabricated by SLM using finite element (FE) and experimental measurement methods.

The Co-Cr alloy porous scaffolds constructed in four different topologies, i.e. cubic close packed (CCP), face-centered cubic (FCC), body-centered cubic (BCC) and spherical hollow cubic (SHC), were designed and fabricated via SLM process. FE simulations and compression tests were performed to evaluate the effects of unit cell topology on the compression properties of SLM-processed porous scaffolds.

The Mises stress predicted by FE simulations showed that different unit cell topologies resulted in distinct stress distributions on the bearing struts of scaffolds, whereas the unit cell size directly determined the stress value. Comparisons on the stress results for four topologies showed that the FCC unit cell has the minimum stress concentration due to its inclined bearing struts and horizontal arms. Simulations and experiments both indicated that the compression modulus and strengths of FCC, BCC, SHC, CCP scaffolds with the same cell size presented in a descending order. These distinct compression behaviors were correlated with the corresponding mechanics response on bearing struts. Two failure mechanisms, cracking and collapse, were found through the results of compression tests, and the influence of topological designs on the failure was analyzed and discussed. Finally, the cell initial response of the SLM-processed Co-Cr scaffold was tested through the in vitro cell culture experiment.

A focus and concern on the compression properties of SLM-processed porous scaffolds was presented from a new perspective of unit cell topology. It provides some new knowledge to the structure optimization of porous scaffolds for load-bearing bone implants.

The requirements of open cell porous regular interconnected metallic structure (OCPRIMS) in applications such as heat exchangers, sound absorption, fluid flow control, spark arresters and biocompatible inserts have been increased. As per available technology in the present scenario, only the metallic-based rapid prototyping (RP) machines can guarantee fabrication of OCPRIMS. Metal-based RP machines are capital-intensive. So, this study aims to develop a technique for fabrication of OCPRIMS economically using three-dimensional printing (3 DP) and pressureless sintering.

Three computer-aided design (CAD) models of varying designed interconnected porosity 73, 70 and 60 per cent were modeled to target metallic porosity 27, 30 and 40 per cent. The same were fabricated with ceramic-based powder using 3 DP. Thereafter, spherical bronze powder with average size of 200 µm was filled and sintered in pressureless manner under inert atmosphere of argon. After sintering, the specimens were cleaned with the help of pricking needles and high-pressure water. It flushed the burnt ceramic powder and allowed metallic portion to remain intact. The obtained specimens were inverse of CAD/3 DP models. The dimensional measurement at different stages of fabrication was carried out to find shrinkage. Sintered density and interconnected porosity were measured using Archimedes’ principle. The characterization of the fabricated specimens was done with the help of microstructure analysis, scanning electron microscopy and energy dispersive x-ray analysis. Mechanical properties were assessed using compressive, tensile and Charpy tests.

The feasibility has been explored successfully to fabricate OCPRIMS of phosphor bronze using 3 DP and pressureless sintering process. Interconnected porosity of 51.45, 56.45, 64.09 per cent of final metallic specimens has been observed against the targeted 27, 30 and 40 per cent. The increase in pore dimensions up to 19.13 per cent and shrinkage up to 5.44 per cent of outer dimensions were found to be the main causes of increase in interconnected porosity level. The characterization results exhibit the behavior of pressureless sintering process and stability of the fabricated specimens. Mechanical properties of fabricated structures are found to be dependent on porosity and strut diameter. Compressive and tensile strength decrease with the increase in porosity for strut diameter less than 1 mm, whereas they increase with the increase in strut diameter of 1 mm or more. A similar trend has been observed for impact strength also.

This paper explores the feasibility to fabricate OCPRIMS economically using 3 DP and pressureless sintering process.

Ti6Al4V alloy has received a great deal of attention in medical applications due to its biomechanical compatibility. However, the human bone stiffness is between 10 and 30 GPa while solid Ti6Al4V is several times stiffer, which would cause stress shielding with the surrounding bone, which can lead to implant and/or the surrounding bone’s failure.

In this work, the effect of selective laser melting (SLM) process parameters on the characteristics of Ti6Al4V samples, such as porosity level, surface roughness, elastic modulus and compressive strength (UCS), has been investigated using response surface method. The examined ranges of process parameters were 35-50 W for laser power, 100-400 mm/s for scan speed and 35-120 µm for hatch spacing. The process parameters have been optimized to obtain structures with properties very close to that in human bones.

The results showed that the porosity percentage of a SLM component could be increased by reducing the laser power and/or increasing the scan speed and hatch spacing. It was also shown that there was a reverse relationship between the porosity level and both the modulus of elasticity and UCS of the SLM part. In addition, the increased laser power was resulted into a substantial decrease of the surface roughness of SLM parts. Results from the optimization study revealed that the interaction between laser process parameters (i.e. laser power, laser speed, and the laser spacing) have the most significant influence on the mechanical properties of fabricated samples. The optimized values for the manufacturing of medical implants were 49 W, 400 mm/s and 99 µm for the laser power, laser speed and laser spacing, respectively. The corresponding porosity, surface roughness, modulus of elasticity and UCS were 23.62 per cent, 8.68 µm, 30 GPa and 522 MPa, respectively.

Previous investigations related to additive manufacturing of Ti alloys have focused on producing fully dense and high-integrity structures. There is a clear gap in literature regarding the simultaneous enhancement and adjustment of pore fraction, surface and mechanical properties of Ti6Al4V SLM components toward biomedical implants. This was the objective of the current study.