High-current pulsed electron-beam (PEB) treatment was applied as a surface finishing procedure for Ti–35Nb–7Zr–5Ta (TNZT) alloy produced by electron beam melting (EBM). According to the XRD results the TNZT alloy samples before and after the PEB treatment have shown mainly the single body-centered cubic (bcc) β-phase microstructures. The crystallite size, dislocation density, and microstrain remain unchanged after the PEB treatment. The investigation of the texture coefficient at the different grazing angle revealed the evolution of the crystallite orientations at the re-melted zone formed at the top of the bulk samples after the PEB treatment. The top-view SEM micrographs of the TNZT samples treated by PEB exhibited the bcc β-phase grains with an average size of ~85 μm. TEM analysis of as-manufactured TNZT alloy revealed the presence of the equiaxed β-grains with the fine dispersion of nanocrystalline α and NbTi4 phases together with β-Ti twins. Meanwhile, the β phase regions free of α phase precipitation are observed in the microstructure after the PEB irradiation. Nanoindentation tests revealed that the surface mechanical properties of the melted zone were slightly improved. However, the elastic modulus and microhardness in the heat-affected zone and the deeper regions of the sample were not changed after the treatment. Moreover, the TNZT alloy in the bulk region manufactured by EBM displayed no significant change in the corrosion resistance after the PEB treatment. Hence, it can be concluded that the PEB irradiation is a viable approach to improve the surface topography of EBM-manufactured TNZT alloy, while the most important mechanical parameters remain unchanged.
Targeting biomedical applications, Triply Periodic Minimal Surface (TPMS) gyroid sheet-based structures were successfully manufactured for the first time by Electron Beam Melting in two different production Themes, i.e., inputting a zero (Wafer Theme) and a 200 µm (Melt Theme) wall thickness. Initial assumption was that in both cases, EBM manufacturing should yield the structures with similar mechanical properties as in a Wafer-mode, as wall thickness is determined by the minimal beam spot size of ca 200 µm. Their surface morphology, geometry, and mechanical properties were investigated by means of electron microscopy (SEM), X-ray Computed Tomography (XCT), and uniaxial tests (both compression and tension). Application of different manufacturing Themes resulted in specimens with different wall thicknesses while quasi-elastic gradients for different Themes was found to be of 1.5 GPa, similar to the elastic modulus of human cortical bone tissue. The specific energy absorption at 50% strain was also similar for the two types of structures. Finite element simulations were also conducted to qualitatively analyze the deformation process and the stress distribution under mechanical load. Simulations demonstrated that in the elastic regime wall, regions oriented parallel to the load are primarily affected by deformation. We could conclude that gyroids manufactured in Wafer and Melt Themes are equally effective in mimicking mechanical properties of the bones.
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