As an important metal three-dimensional printing technology, electron beam melting (EBM) is gaining increasing attention due to its huge potential applications in aerospace and biomedical fields. EBM processing of Ti-6Al-4V as well as its microstructure and mechanical properties were extensively investigated. However, it is still lack of quantitative studies regarding its microstructural evolution, indicative of EBM thermal process. Here, we report α′ martensitic transformation and α/β interface evolution in varied printing thicknesses of EBM-printed Ti-6Al-4V block samples by means of atom probe tomography. Quantitative chemical composition analysis suggests a general phase transformation sequence. By increasing in-fill hatched thickness, elemental partitioning ratios arise and β volume fraction is increased. Furthermore, we observe kinetic vanadium segregation and aluminum depletion at interface front and the resultant α/β interface widening phenomenon. It may give rise to an increased α/β lattice mismatch and weakened α/β interfaces, which could account for the degraded strength as printing thickness increases.

Micro/nano hot-embossing and injection molding are two promising manufacturing processes for the mass production of workpieces bearing micro/nanoscale features. However, both the workpiece and micro/nano-mold are susceptive to structural damage due to high thermal stress, adhesion and friction, which occur at the interface between the workpiece and the mold during these processes. Hence, major constraints of micro/nano-molds are mainly attributed to improper replication and their inability to withstand a prolonged sliding surface contact because of high sidewall friction and/or high adhesion. Consequently, there is a need for proper surface coating as it can improve the surface properties of micro/nano-molds such as having a low friction coefficient, low adhesion and low wear rate. This review deals with the physical, mechanical and tribological properties of various surface coatings and their impact on the replication efficiency and lifetime of micro/nano-molds that are used in micro/nano hot-embossing and injection molding processes.

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Ti-6Al-4V (Ti64) parts of varying thicknesses were additively manufactured (AM) by the powder-bed-based electron beam melting (EBM) technique. Microstructure and wear properties of these EBM-built Ti-6Al-4V parts have been investigated in comparison with conventionally cast Ti64 samples. Sliding wear tests were conducted using a ball-on-disc micro-tribometer under ambient conditions. Experimental results reveal that EBM-built Ti64 samples exhibited higher microhardness and an overall larger coefficient of friction as compared to the as-cast counterpart. Of interest is that the corresponding specific wear volumes were lower for EBM-built Ti64 samples, while the as-cast Ti64 showed the poorest wear resistance despite its lower coefficient of friction. Wear mechanisms were provided in terms of quantitative microstructural characterization and detailed analysis on coefficient of friction (COF) curves.

Orthopedic implants first started out as an all-metal hip joint replacement. However, poor design and machinability as well as unsatisfactory surface finish subjected the all-metal joint replacement to being superseded by a polyethylene bearing. Continued improvement in manufacturing techniques together with the reality that polyethylene wear debris can cause hazardous reactions in the human body has brought about the revival of metal-on-metal (MOM) hip joints in recent years. This has also led to a relatively new research area that links tribology and corrosion together. This article aims at reviewing the commonly used tribochemical methods adopted in the analysis of tribocorrosion and putting forward some of the models and environmental factors affecting the tribocorrosive behavior of CoCrMo alloys, a widely-used class of biomaterial for orthopedic implants.