Review of the Powder Metallurgical Production of Net-Shaped Titanium Implants

Abstract:

The paper gives a short review of P/M routes which were developed or adapted by the authors for the net-shape manufacturing of titanium implants. Special attention is paid to the production of highly porous bone implants, where the porosity is achieved by the application of temporary space holder particles, which are removed before or during sintering by decomposition or dissolution. In this case, shaping was done either by machining of powder compacts in the green and sintered state or by metal injection moulding (MIM). The challenges of these shaping technologies and current solutions are discussed. To complete the review, two promising new technologies for the net-shape production of highly porous titanium implants, the replica technique and additive manufacturing are briefly introduced.

• Periodical: Key Engineering Materials (Volume 704)
• Pages: 311-317
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.704.311
• Online since: August 2016
• Authors: Alexander Laptev*, Ana Paula Cysne Barbosa, Natália Daudt, Martin Bram
• Keywords: Additive Manufacturing, Green Machining, Metal Injection Moulding, Net-Shape Manufacturing, Porous Titanium, Powder metallurgy, Replica Technique, Titanium Implant

References

[1] G. Lütjering, J.C. Williams, Titanium, second ed., Springer, Berlin, Heidelberg, New York, (2007).

[2] T. Imwinkelried, Mechanical properties of open-pore titanium foam, J. Biomed. Mater. Res. Part A 81 (2007) 964-970.

DOI: 10.1002/jbm.a.31118

[3] G. Ryan, A. Pandit, D.P. Apatsidis, Fabrication methods of porous metals for use in orthopedic applications, Biomaterials 27 (2006) 2651–2670.

DOI: 10.1016/j.biomaterials.2005.12.002

[4] A. Laptev, M. Bram, H.P. Buchkremer, D. Stöver, Study of production route for titanium parts combining very high porosity and complex shape, Powder Metall. 47 (2004) 85-92.

DOI: 10.1179/003258904225015536

[5] A. Laptev, O. Vyal, M. Bram, H.P. Buchkremer, D. Stöver, Green strength of powder compacts provided production of highly porous titanium parts, Powder Metall. 48 (2005) 358-364.

DOI: 10.1179/174329005x73838

[6] M. Bram, A. Laptev, H.P. Buchkremer, D. Stöver, Herstellung von hochporösen, endkonturnahen Titan-Formkörpern für biomedizinische Anwendungen, Materialwiss. Werkst. 35 (2004) 213-218.

DOI: 10.1002/mawe.200400731

[7] A. Laptev, M. Bram, Manufacturing hollow titanium parts by powder metallurgy route and space holder technique, Mater. Lett. 160 (2015) 101-103.

DOI: 10.1016/j.matlet.2015.07.094

[8] H. Schiefer, M. Bram, H.P. Buchkremer, D. Stöver, Mechanical examination on demntal implants with porous coating, J. Mater. Sci.: Mater. Med. 20 (2009), 1763-1770.

DOI: 10.1007/s10856-009-3733-1

[9] M. Bram, C. Kempmann, A. Laptev, D. Stöver, K. Weinert, Investigation on the machining of sintered titanium foams using face milling and peripheral grinding, Adv. Eng. Mater. 5 (2003) 441-447.

DOI: 10.1002/adem.200300356

[10] ASM Handbook v. 7. Powder metal technologies and applications. ASM International, (1998).

[11] M. Bram, A. Laptev, D. Stöver and H.P. Buchkremer, BRD Patent 10224671. (2003).

[12] N. Tuncer, M. Bram, A. Laptev, T. Beck, A. Moser, H.P. Buchkremer, Study of metal injection molding of highly porous titanium by physical modeling and direct experiments, J. Mater. Process. Technol. 214 (2014) 1352-1360.

DOI: 10.1016/j.jmatprotec.2014.02.016

[13] A.P. Cysne Barbosa, M. Bram, D. Stöver, H.P. Buchkremer, Realization of a titanium spinal implant with a gradient in porosity by 2-component metal injection moulding, Adv. Eng. Mater. 15 (2013) 510-521.

DOI: 10.1002/adem.201200289

[14] N.F. Daudt, M. Bram, A.P. Cysne Barbosa, C. Alves Jr., Surface modification of porous titanium by plasma treatment, Mater. Lett. 141 (2015) 194-197.

DOI: 10.1016/j.matlet.2014.11.083

[15] A.M. Laptev, N.F. Daudt, O. Guillon, M. Bram, Increase of shape stability and porosity of injection molded highly porous titanium parts, Adv. Eng. Mater. 17 (2015) 1579-1587.

DOI: 10.1002/adem.201500061

[16] J.P. Li, S.H. Li, K. de Groot, P. Layrolle, Preparation and characterization of porous titanium, Key Eng. Mater. 218-220 (2002) 51-54.

DOI: 10.4028/www.scientific.net/kem.218-220.51

[17] P. Quadbeck, K. Kümmel, R. Hauser, G. Standke, J. Adler, G. Stephani, B. Kieback, Structural and material design of open-cell powder metallurgical foams, Adv. Eng. Mater. 13 (2011) 1024-1030.

DOI: 10.1002/adem.201100023

[18] P. Heinl, A. Rottmair, C. Körner, R.F. Singer, Cellular titanium by selective electron beam melting, Adv. Eng. Mater. 9 (2007) 360-364.

DOI: 10.1002/adem.200700025

[19] Information on http: /www. arcam. com.

[20] ASTM F67-13, Standard specification for unalloyed titanium, for surgical implant applications (UNS R50250, UNS R50400, UNS R50550, UNS R50700), ASTM International, West Conshohocken, PA, (2013).

DOI: 10.1520/f0067

[21] Implants for surgery, metallic materials. Part 2: Unalloyed titanium, ISO 5832-2: 1999, ISO, Geneva, Switzerland.

[22] ASTM F2989-13, Standard specification for metal injection molded unalloyed titanium components for surgical implant applications, ASTM International, West Conshohocken, PA, (2013).

DOI: 10.1520/f2989-21

[23] A.T. Sidambe, Biocompatibility of advanced manufactured titanium implants. A review, Materials 7 (2014) 8168-8188.

DOI: 10.3390/ma7128168