Porous Titanium by Additive Manufacturing: A Focus on Surfaces for Bone Integration

Additive manufacturing (AM) is gaining increasing interest for realization of customized porous titanium constructs for biomedical applications and, in particular, for bone substitution. As first, the present review gives a short introduction on the techniques used for additive manufacturing of Ti/Ti-Alloys (Direct Energy Deposition—DED, Selective Laser Melting—SLM and Electron Beam Melting—EBM) and on the main bulk properties of additively manufactured titanium porous structures. Then, it discusses the main advancements in surface modifications of additively manufactured titanium constructs for bone contact applications. Even if specific surface modifications of constructs from AM are currently not widely explored, it is a critical open issue for application in biomedical implants. Some thermal, chemical, electrochemical, and hydrothermal treatments as well as different coatings are here described. The main aim of these treatments is the development of surface micro/nano textures, specific ion release, and addition of bioactivity to induce bone bonding and antibacterial activity. Physicochemical characterizations, in vitro bioactivity tests, protein absorption, in vitro (cellular/bacterial) and in vivo tests reported in the literature for bare and surface modified AM Ti-based constructs are here reviewed. Future perspectives for development of innovative additively manufactured titanium implants are also discussed

Surface Activation and Characterization of Aluminum Alloys for Brazing Optimization

Brazing of Al-alloys is of interest in many application fields (e.g., mechanical and automotive). The surface preparation of substrates and the in depth investigation of the interface reaction between aluminum substrates and brazing materials is fundamental for a proper understanding of the process and for its optimization. The interaction between two aluminum based substrates (Al5182 and Al6016) and two studied brazing materials (pure Zn and for the first time ZAMA alloy) has been studied in simulated brazing condition in order to define the best surface preparation conditions and combination substrate-brazing material to be used in real joining experiments. Three different surface preparations were considered: polishing and cleaning, application of flux and vacuum plasma etching (Ar) followed by sputtering coating with Zn. Macroscopic observation of the samples surface after “brazing”, optical microscopy, and microhardness measurements on the cross-section and XRD measurements on the top surface gave a comprehensive description of the phenomena occurring at the interface between the substrate and the brazing alloy which are of interest to understand the brazing process and for the detection of the best conditions to be used in brazing. Plasma etching (Ar) followed by sputtering coating with Zn resulted a promising solution in case of Al5182 brazed with Zn, while the addition of flux was more effective in case of Al6016 substrate. ZAMA alloy demonstrated good interface reactivity with both Al6016 and Al5182 alloys, particularly on only cleaned surfaces

Fatigue resistance of light alloy sheets undergoing eco-friendly chemical milling: metallurgical and chemical aspects

Abstract Component lightening is a key issue for automotive and aerospace industries. Lightening processes on design profile are not always possible by means of traditional machining processes. Then, chemical milling processes are used, often by acid etching. The effect on fatigue behavior is related on many factors, such as chemical surface composition and surface roughness. Material removal through chemical milling is in particular interesting for Additive manufactured components where surface finish still remains a parameter difficult to be controlled and repeated. The environmental aspects related to alkaline and acid processing are still an important issue. In the present paper, an overview on chemical milling for component lightening is presented with focus of the effects on mechanical and chemical resistance of materials. Then, the results of an experimental campaign on an aluminum alloy is presented. In particular, high cycle fatigue tests results are presented on specimens subjected or not subjected to an eco-friendly alkaline chemical milling process (called " Green Etching") and chemical, profilometric and metallographic analyses are presented and related to fatigue resistance results. Wettability and surface charge results will be presented

Natural Polyphenols and the Corrosion Protection of Steel: Recent Advances and Future Perspectives for Green and Promising Strategies

Corrosion is recognized as an unavoidable phenomenon and steel, particularly carbon steel, is strongly susceptible to corrosion. Corrosion damages cause serious material, energy, and economic losses as well as negative impacts on the environment. As a result, research interest has been focused on the development of effective corrosion prevention strategies. However, some of the most commonly used corrosion inhibitors, such as chromates and pyridines, are harmful to human and environmental health. Polyphenols are natural, non-toxic, and biodegradable compounds from plant sources or agricultural by-products. Polyphenols’ chelating capacity has been acknowledged since the 1990s, and tannins, in particular, have been widely exploited as green rust converters in phosphoric acid-based formulations to recover rusty steel. Polyphenolic compounds have recently been investigated as a method of corrosion prevention. This review overviews not only the polyphenolic rust converters, but also the application of green anticorrosive coatings containing polyphenols. Moreover, polyphenols were discussed as an active component in corrosion-inhibiting primers to also promote strong adhesion between the steel surface and the topcoat layer. Finally, an overview of the use of polyphenolic additives in coatings as sustainable systems to improve corrosion resistance is provided

Tannic Acid Coatings to Control the Degradation of AZ91 Mg Alloy Porous Structures

Porous structures of magnesium alloys are promising bioimplants due to their biocompatibility and biodegradability. However, their degradation is too rapid compared to tissue regeneration and does not allow a progressive metal substitution with the new biological tissue. Moreover, rapid degradation is connected to an accelerated ion release, hydrogen development, and pH increase, which are often causes of tissue inflammation. In the present research, a natural organic coating based on tannic acid was obtained on Mg AZ91 porous structures without toxic reagents. Mg AZ91 porous structures have been prepared by the innovative combination of 3D printing and investment casting, allowing fully customized objects to be produced. Bare and coated samples were characterized using scanning electron microscopy equipped with energy dispersive spectroscopy (SEM-EDS), fluorescence microscopy, Fourier transformed infrared spectroscopy (FTIR), tape adhesion test, Folin– Ciocalteu, and degradation tests. Different parameters (solvent, dipping time) were compared to optimize the coating process. The optimized coating was uniform on the outer and inner surfaces of the porous structures and significantly reduced the material degradation rate and pH increase in physiological conditions (phosphate-buffered saline—PBS)

UV-Cured Chitosan-Based Hydrogels Strengthened by Tannic Acid for the Removal of Copper Ions from Water

In this work, a new environmentally friendly material for the removal of heavy metal ions was developed to enhance the adsorption efficiency of photocurable chitosan-based hydrogels (CHg). The acknowledged affinity of tannic acid (TA) to metal ions was investigated to improve the properties of hydrogels obtained from natural and renewable sources (CHg-TA). The hydrogel preparation was performed via a simple two-step method consisting of the photocrosslinking of methacrylated chitosan and its subsequent swelling in the TA solution. The samples were characterized using ATR-FTIR, SEM, and Folin–Ciocalteu (F&C) assay. Moreover, the mechanical properties and the ζ potential of CHg and CHg-TA were tested. The copper ion was selected as a pollutant model. The adsorption capacity (Qe) of CHg and CHg-TA was assessed as a function of pH. Under acidic conditions, CHg-TA shows a higher Qe than CHg through the coordination of copper ions by TA. At an alkaline pH, the phenols convert into a quinone form, decreasing the Qe of CHg-TA, and the performance of CHg was found to be improved. A partial TA release can occur in the copper solution due to its high hydrophilicity and strong acidic pH conditions. Additionally, the reusability of hydrogels was assessed, and the high number of recycling cycles of CHg-TA was related to its high mechanical performance (compression tests). These findings suggest CHg-TA as a promising green candidate for heavy metal ion removal from acidic wastewater

Exploitation of tannic acid as additive for the adhesion enhancement of UV-curable bio-based coating

The interest in environmentally friendly coatings is rising to substitute for the oil-derived materials in the coating industry. In the present study, natural tannic acid (TA) is investigated as an additive to an epoxidized soybean oil-based (ESO) coating. TA solutions in propylene carbonate at two different concentrations were prepared and added to an ESO matrix with different weight ratios. The UV-curing process of the coatings was deeply assessed through real-time Fourier Transform Infrared (FTIR) spectroscopy and Differential Scanning photo Calorimetry (photo-DCS). A significant increase in high epoxy group conversion, around 90 %, was achieved thanks to the activated monomer mechanism, which involves the TA polyphenols. This mechanism accelerated the photocrosslinking process, but reduced the coatings' crosslinking density, as demonstrated by the dynamic thermal mechanical analysis. The hardness of coatings containing the TA additive decreased, while the hydrophobicity of the surface coatings remained unchanged after the TA incorporation. Lastly, the adhesion of the UV-cured coating was evaluated on low-carbon steel substrates. An outstanding enhancement in adhesion property was provided by the TA additive, whose phenols not only participate in the photocrosslinking reaction but also coordinate iron on the steel surface. Moreover, the influence of two different steel surface pre-treatments, the pickling and plasma processes, on the coatings' adhesion strength was studied