Bending behavior of superplastic titanium alloy for denture base

The mechanical behavior of the Ti-6A1 4V alloy denture base made by superplastic forming was studied using various bending tests. The bending strength of the Ti-6A1-4V alloy plate made by superplastic forming was as strong as that of the casting Co-Cr alloy plate with the same thickness. The bending strength of the superplastic forming plate with channels was higher than that of the plain plate. Increase in the arch curvature of the plate decreased the strength, because increase in the arch curvature of the plate decreased the thickness of the superplastic forming plate. Similar results were obtained for the clinical models. The appropriate original thickness for superplastic forming denture base was derived empirically from the experimental values for depth of palate.     

Mechanical property and adaptability of super-plastic titanium alloy denture base]

The purpose of this study is to investigate the mechanical property and the adaptability of the upper complete denture bases made by superplastic forming of Ti-6A1-4V alloy plates which have various thicknesses. The strength of the denture base made by superplastic forming using the 0.55 mm thickness plate was lower than that of the base made by Co-Cr alloy casting in the standard form when loaded on the hard metal board. But by increasing the thickness by partial or full diffusion bonding of two Ti-6A1-4V alloy plates, the denture base became stronger than the Co-Cr alloy base. With resin occlusion rims, all the denture bases were reinforced. Moreover, when loaded on the mastermodel covered with rubber in the residual ridge and palate area, the difference of the strain between the thin and the thick bases became small. However, the strain of the thin base increased particularly when the base had a contact with the mastermodel on a small area in the palate. The superplastic forming denture bases revealed a high adaptability with the space less than 0.13 mm on the average between the base and the mastermodel. And increasing the thickness of the base prevented the worsening of the adaptability after curing resin for the denture.     

Use of metal conditioners to improve bond strengths of autopolymerizing denture base resin to cast Ti-6Al-7Nb and Co-Cr

OBJECTIVE: The shear bond strengths of an autopolymerizing denture base resin to cast Ti-6Al-7Nb and Co-Cr alloys using three metal conditioners were investigated. METHODS: Ti-6Al-7Nb alloy and Co-Cr alloy discs were cast. The disc surfaces were air-abraded with 50 microm alumina particles and treated with three metal conditioners (Alloy Primer; Cesead II Opaque Primer; Metal Primer II). An autopolymerizing denture base resin was applied on the discs within a hole punched in a piece of sticky tape and a Teflon ring to define the bonding area. All specimens were immersed in 37 degrees C water for 24 h. Half of the specimens were thermocycled up to 20,000 cycles. The shear bond strengths were determined at a crosshead speed of 1.0 mm/min. RESULTS: Specimens treated with the three metal conditioners had significantly (p<0.05) improved shear bond strengths of the autopolymerizing denture base resin to both Ti-6Al-7Nb and Co-Cr. Although the bond strengths of the bonded Ti-6Al-7Nb specimens were higher than those of the Co-Cr alloy before thermocycling, the decrease in the bond strength of Ti-6Al-7Nb was considerably greater than that of the Co-Cr after thermocycling. CONCLUSION: Significant improvements in bond strength of the autopolymerizing denture base resin to cast Ti-6Al-7Nb alloy and Co-Cr alloy were achieved through the application of Alloy Primer, Cesead II Opaque Primer and Metal Primer II. The bond durability to Ti-6Al-7Nb alloy was inferior to that to Co-Cr.     

牙科用Ti-Zr合金铸造后挠度的研究

目的：研究Ti-Zr合金铸造后的挠度,为选择Ti-Zr合金临床应用的合理厚度提供依据。方法：参照美国ADA关于义齿基托树脂材料挠度的标准,测量不同厚度的Ti-Zr合金的挠度,并对Ti及Ti-6Al-4V合金以及临床常用的Co-Cr合金进行对比研究,结果：Ti-Zr合金,纯钛及Ti-6Al04V合金在厚度为0．65mm左右时能够达到义齿基托挠度的标准,钴铬合金在0．57mm左右即可达到标准要求,结论：临床制作Ti-Zr合金基托时,厚度应选择0.65mm左右。     

Comparative study on torsional strength, ductility and fracture characteristics of laser-welded alpha+beta Ti-6Al-7Nb alloy, CP Titanium and Co-Cr alloy dental castings.

OBJECTIVES: The purpose of this study was to compare torsional strength, ductility and fracture behaviors of Ti-6Al-7Nb, CP Ti and Co-Cr alloy castings after laser welding. METHODS: Dumbbell-shaped castings of three metal alloys (Ti-6Al-7Nb alloy, CP Ti, Co-Cr alloy) were cut in half and laser welded with a Nd:YAG pulse laser-welding machine at either 220V or 260V of laser voltage. After being laser welded, all cast specimens were tested with a multi-axial hydraulic testing machine (MTS 858 Mini Bionix) using a torsional test. The fracture surfaces were investigated with a scanning electron microscope. RESULTS: None of the laser-welded Ti-6Al-7Nb alloy and CP Ti castings was broken within the welded joint, showing torsional strength as high as the unwelded castings. Unlike the other groups, the laser-welded Co-Cr alloy castings exhibited brittle fracture appearance and provided substantially less torsional strength. SIGNIFICANCE: The torsional strength of the laser-welded Ti-6Al-7Nb alloy and CP Ti castings was as high as that of the unwelded castings while this finding could not apply to the Co-Cr alloy castings. This indicates that the mechanical strength of the laser-welded Ti-6Al-7Nb alloy dental casting is sufficient for clinical applications.     

Shear bond strengths of polymethyl methacrylate to cast titanium and cobalt-chromium frameworks using five metal primers

STATEMENT OF PROBLEM: Poor chemical bonding of a denture base resin to cast titanium frameworks often introduces adhesive failure and increases microleakage. PURPOSE: This study examined the shear bond strengths of a denture base resin to cast pure titanium, Ti-6Al-4V, and a cobalt-chromium alloy using various adhesive primers. MATERIAL AND METHODS: Disks (6.0 mm diameter, 2.5 mm thick) were cast of the 3 alloys. The disk surfaces were grit-blasted with 50 microm alumina and treated with 5 different metal primers (Metal Primer II ?MP]; Cesead Opaque primer ?OP]; Meta Base ?MB]; experimental primer ?EP]; Siloc bonding system ?SI]). A denture base resin (Palapress Vario) was then applied on the disks with hole-punched sticky tape (bonding area of 5.0 mm) and a Teflon (PTFE, New Age Industries Inc, Willow Grove, Pa.) ring (6.0 mm diameter x 2.0 mm thick). Specimens without primer were also prepared as controls. All specimens were immersed in 37 degrees C water and thermocycled up to 2,000 cycles. Shear bond strength values were determined at a crosshead speed of 0.5 mm/min. Data were statistically analyzed using 3-way ANOVA, followed by 1-way ANOVA and the Scheffé multiple range test. RESULTS: Primers significantly (P <.05) improved shear bond strengths of denture base resin to all metals, among which no significant differences were found. Specimens primed with OP, MP, and EP showed higher bond strengths than did those primed with MB. After thermocycling, the bond strengths of MB and SI decreased substantially; MB showed the least durability (22.8% to 35.5% decrease) among the primers. CONCLUSION: The application of 5 primers significantly improved the shear bond strengths of a denture base resin to cast CP titanium, Ti-6Al-4V, and Co-Cr alloy. OP and MP primers exhibited greater bond strength and durability than did MB and SI.     

Bending properties of strengthened Ti-6Al-7Nb alloy major connectors compared to Co-Cr alloy major connectors

STATEMENT OF PROBLEM: Although Ti-6Al-7Nb alloy has several excellent mechanical properties, its poor rigidity has limited its clinical use as a material for the fabrication of a removable partial denture (RPD) major connector. PURPOSE: The purpose of this study was to develop and evaluate strengthening designs of Ti-6Al-7Nb RPD major connectors in an effort to increase rigidity. MATERIAL AND METHODS: Four strengthening designs of Ti-6Al-7Nb alloy major connectors were developed using finite element analysis modeling: wide, thick, thick at the middle, and thick at the anterior and posterior borders. The designs had similar rigidity values to a conventional Co-Cr alloy major connector, as measured by the maximum deformation when a simulated load was applied. Next, 30 Kennedy Class II maxillary RPD specimens, using 6 different major connector designs (n = 5), were fabricated. These 6 designs included Ti-6Al-7Nb alloy RPDs with 4 different strengthening designs, a Ti-6Al-7Nb alloy RPD without strengthening designs, and a conventional Co-Cr alloy RPD as a control. The rigidity of the RPDs was evaluated by measuring strains on the major connector and force on the intaglio surface of a denture base under a 30 N loading condition. The data obtained from the 6 different RPD designs were compared using a repeated measures analysis of variance and the Bonferroni correction (alpha=.05). RESULTS: The strains on the major connectors and the force on the denture bases measured from the Ti-6Al-7Nb RPD without strengthening designs were significantly larger than those of the standard Co-Cr alloy RPD. The strains measured from the 4 strengthening designs were not significantly larger than those of the Co-Cr alloy RPD. CONCLUSION: The results suggest that the strengthening designs tested may improve the rigidity of the Ti-6Al-7Nb alloy major connectors and, hence, may promote clinical application for RPDs.     

Bonding properties of heat-polymerized denture base resin to Ti-6Al-7Nb alloy

The purpose of this study was to evaluate the shear bonding strength and leakage of heat-polymerized denture base resin to titanium-aluminum-niobium (Ti-6Al-7Nb) and cobalt-chromium (Co-Cr) castings using four adhesive systems; three adhesive primers (Metal Primer II, Metal Link, MR. Bond) and one heat-polymerized adhesive resin containing 4-META (Metadent). The resin tab was heat-polymerized directly with or without the primer. Shear bonding strengths and dye penetration distances were determined before and after 10,000 times of thermocycling. The results were analyzed with three-way ANOVA and Tukey's comparison (p<0.05). Thermocycling significantly decreased bonding strength and promoted dye penetration. However, with the application of adhesive systems, post-thermocycling bond strength was significantly improved and dye penetration was inhibited. The bonding strength of Ti-6Al-7Nb was significantly smaller than that of Co-Cr, but the difference was marginal. These results suggested that the examined adhesive systems significantly improved the bonding efficiency of heat-polymerized resin to Ti-6Al-7Nb and Co-Cr alloys.     

An initial study of diffusion bonds between superplastic Ti-6Al-4V for implant dentistry applications

STATEMENT OF PROBLEM: Production of precisely fitting fixed partial denture implant superstructures with titanium alloys is limited by casting techniques that introduce distortion. After alignment of the framework with existing implants, the remaining misfit may generate stresses that cause screw loosening and adversely affect the implant/bone interface. PURPOSE: The purpose of this study was to prepare diffusion-bonded joints between superplastic (SP) Ti-6Al-4V plates and indenters (representing analogs to implant-supported fixed frameworks and abutments) and determine if this process has potential for producing strong, dimensionally precise prostheses. MATERIAL AND METHODS: Seven sets of trial indenter and plate specimens with dimensions of 6.4 mm x 6.4 mm x 5 cm and 8.5 mm x 1.5 cm, respectively, were prepared. Several indenter designs were used (35- or 45-degree half-angle, presence or absence of a notch, and SP versus no SP condition for Ti-6Al-4V); all plates were prepared from SP Ti-6Al-4V. For the results-guided experimental design, there was 1 trial indenter/plate combination for each design/processing condition. Diffusion bonding was performed at 10(-6) Torr, while the temperature was increased 10 degrees C/min to 900 degrees or 920 degrees C. Following 10 minutes of equilibration, the indenter was pressed 2.5 mm into the plate at 0.13 mm/min. Joint strength was evaluated in tension, and the ductile or brittle character of fracture surfaces was assessed by the presence or absence of a dimpled rupture surface from secondary electron SEM observations. Fractured specimens were cross-sectioned and examined with an optical microscope to evaluate overall joint integrity and quality, and used for Vickers hardness measurements to gain insight into the variation in mechanical properties of the indenter and plate with distance from the joint. One-way ANOVA (alpha=.05) was used to compare hardness at the joint for the trial specimen with highest joint strength with hardness values for adjacent regions at 125-mum intervals in the indenter and plate. The Ryan-Einot-Gabriel-Welsch (REGW) multiple range test was used to identify any specific location having significantly (alpha=.05) different hardness. Backscattered electron SEM observations were also performed on the cross-sectioned specimens to investigate whether a layer of alpha-stabilized titanium, which would decrease joint strength, was present. Fits of Ti-6Al-4V implant analogs prepared by this diffusion-bonding process were assessed qualitatively from visual observation. RESULTS: The maximum joint strength of 820 MPa was achieved for a diffusion bonding temperature of 900 degrees C for an SP Ti-6Al-4V indenter with a 35-degree half-angle and no notch. This joint strength is nearly 90% of the maximum tensile strength of the parent Ti-6Al-4V, which can range from approximately 930 to 1015 MPa. The hardness at the joint was significantly higher (P<.05) than the hardness of the indenter and plate at 125-mum distances from the joint. The mean hardness of the indenter at 125 mum from the joint was significantly greater (P<.05) than the mean hardness of the plate at a distance of 500 mum from the joint. All other mean hardness values at the different measurement distances from the joint were not significantly different. Ductile fracture occurred for all superplastic processing conditions, and no alpha-titanium layer was present. Minimal asperities were observed with the optical microscope, and fits of implant prosthesis analogs were considered acceptable. CONCLUSIONS: A 900 degrees C processing condition for diffusion-bonding an SP Ti-6Al-4V indenter with a 35-degree half-angle and no notch to a Ti-6Al-4V SP plate yielded a joint with nearly the same strength as the parent alloy. Use of this processing temperature with a 0.13 mm/min rate of pressing the indenter into the plate yielded minimal distortions for implant prosthesis analogs when observed visually.     

Mechanical strength and microstructure of laser-welded Ti-6Al-7Nb alloy castings

Mechanical properties of laser-welded castings of Ti-6Al-7Nb alloy, CP Ti, and Co-Cr alloy were investigated and compared to the unwelded castings using a tensile test. Dumbbell-shaped specimens were cut at the center, and two halves of the specimens were welded with an Nd:YAG laser welding machine at 220 or 260 V of laser voltage. The mechanical strength of 260 V groups was higher than that of 220 V groups for Ti-6Al-7Nb and Co-Cr alloys except for CP Ti. All 260 V laser-welded castings of Ti-6Al-7Nb alloy and CP Ti, which fractured outside the welded joints, exhibited ductile characteristics, while all laser-welded Co-Cr alloy castings, which fractured within the welded joints, showed brittle characteristics. This study proved that the mechanical strength of laser-welded Ti-6Al-7Nb alloy and CP Ti castings was as high as that of unwelded castings, while the mechanical properties of laser-welded alloy joints were influenced by microstructural changes.     

Deformation properties of Ti-6A1-7Nb alloy castings for removable partial denture frameworks

Ti-6Al-7Nb alloy was cast into three differently designed, removable partial denture frameworks: Palatal strap (PS), Anterior-posterior bar (AP), and Horseshoe-shaped bar (HS). The vertical displacement and local strain of Ti-6Al-7Nb alloy frameworks were investigated to compare against those of Co-Cr alloy frameworks. Vertical loading force of 19.6 N was applied at two locations, 10 and 20 mm, from the distal end of the framework. Although higher vertical displacement and local strain were observed for Ti-6Al-7Nb alloy frameworks than those for Co-Cr alloy frameworks, the PS framework appeared to show the least deformation. In addition, the strain at 10-mm location was higher than that at 20-mm location for AP and HS frameworks. This study thus proved that design had a significant influence on the deformation properties of denture frameworks. The PS design was evaluated to be a suitable design for the removable denture framework with Ti-6Al-7Nb alloy.     

Castability of Ti-6Al-7Nb alloy for dental casting

Castability of Ti-6Al-7Nb alloy, CP Ti, and Co-Cr alloy was examined for mesh type and plate type specimens. The casting was carried out with a pressure type casting machine and commercial molding material. The castability of the mesh type specimen was evaluated in terms of the number of cast segments (castability index), and that of the plate type was evaluated by the area of the specimen (casting rate). X-ray images processed by a digital imaging technique were used to identify the casting porosity. The casting rate of the specimens increased with increasing thickness of the specimens. It was concluded that the castability index and the casting rate of Ti-6Al-7Nb alloy was slightly lower than that of CP Ti, and higher than that of Co-Cr alloy, were as Ti-6Al-7Nb alloy showed fewer casting porosities than CP Ti and smaller ones than Co-Cr alloy, which was advantageous for increasing the reliability of the casting properties.     

The effect of thermal cycling on the bond strength of low-fusing porcelain to commercially pure titanium and titanium–aluminium–vanadium alloy

OBJECTIVES: Titanium-ceramic restorations are currently used in spite of the pending problem of titanium-ceramic bonding, which has only been partially solved. In addition, some titanium-ceramic systems appear to be susceptible to thermal cycling, which can cause weaker bond strength. The objective of this study was to evaluate the bonding characteristics of titanium porcelain bonded to commercially pure titanium (Ti-Cp) or titanium-aluminum-vanadium (Ti-6Al-4V) alloy as well as the effect of thermal cycling on bond strength. METHODS: A three-point-flexure-test was used to evaluate the bond strength of titanium porcelain bonded to commercially pure titanium and Ti-6Al-4V alloy according to DIN 13.927. To evaluate the effect of thermal cycling on the samples, half were thermal cycled in temperatures ranging from 4 degrees C (+/-2 degrees C) to 55 degrees C (+/-2 degrees C). Results were compared with palladium-silver (Pd-Ag) alloy bonded to conventional porcelain (control). Scanning electron microscope (SEM) photomicrographs were taken to characterize the failed surfaces in the metal-ceramic interface. Anova and Tukey's multiple comparison tests were used to analyze the data at a 5% probability level. RESULTS: Thermal cycling did not significantly weaken the bond strength of porcelain to titanium interfaces. There was no significant difference in bond strength between commercially pure titanium (23.60 MPa for thermal cycled group and 24.99 MPa for non-thermal cycled group) and Ti-6Al-4V groups (24.98 and 25.60 MPa for thermal cycled and non-thermal cycled groups, respectively). Bond strength values for the control group (47.98 and 45.30 MPa, respectively) were significantly greater than those for commercially pure titanium and Ti-6Al-4V combinations. SIGNIFICANCE: The bond strength of low fusing porcelain bonded to cast pure titanium or Ti-6Al-4V alloy was significantly lower than the conventional combination of porcelain-Pd-Ag alloy. Thermal cycling did not affect the bond strength of any group.     

铸模温度对牙科用Ti-Zr合金铸流率影响的研究

目的：通过对Ti-Zr合金铸流率的研究,为Ti-Zr合金临床应用提供合理的铸造参数,方法：采用网状试样法, 测量Ti-Zr合金,纯钛及Ti-6Al-4V合金在3种铸模温度（室温,300度,600度）下的铸流率,结果：Ti-Zr合金在室温铸造时其铸流率明显低于纯钛及T-6A-4V合金,并且Ti-Zr合金的铸流率也明显低于300度及600度组,结论：为保证 临床义齿铸造的完整性,Ti-Zr合金铸造时模温度应在300度以上。     

Effect of surface reaction layer on grindability of cast titanium alloys.

OBJECTIVE: The purpose of this study was to investigate the effect of the cast surface reaction layer on the grindability of titanium alloys, including free-machining titanium alloy (DT2F), and to compare the results with the grindability of two dental casting alloys (gold and Co-Cr). METHODS: All titanium specimens (pure Ti, Ti-6Al-4V and DT2F) were cast using a centrifugal casting machine in magnesia-based investment molds. Two specimen sizes were used to cast the titanium metals so that the larger castings would be the same size as the smaller gold and Co-Cr alloy specimens after removal of the surface reaction layer (alpha-case). Grindability was measured as volume loss ground from a specimen for 1 min using a handpiece engine with a SiC abrasive wheel at 0.1 kgf and four circumferential wheel speeds. RESULTS: For the titanium and gold alloys, grindability increased as the rotational speed increased. There was no statistical difference (p>0.05) in grindability for all titanium specimens either with or without the alpha-case. Of the titanium metals tested, Ti-6 Al-4V had the greatest grindability at higher speeds, followed by DT2F and CP Ti. The grindability of the gold alloy was similar to that of Ti-6 Al-4V, whereas the Co-Cr alloy had the lowest grindability. SIGNIFICANCE: The results of this study indicated that the alpha-case did not significantly affect the grindability of the titanium alloys. The free-machining titanium alloy had improved grindability compared to CP Ti.     

Effect of Denture Cleansers on the Surface Roughness and Hardness of a Microwave-Cured Acrylic Resin and Dental Alloys

PURPOSE: This study evaluated the effect of denture cleansers on the surface hardness of a denture base resin, and on the surface roughness of the resin and Co-Cr and Ti-6Al-4V alloys. MATERIALS AND METHODS: Forty-eight disc-shaped specimens were fabricated of a microwave-cured acrylic resin, each having one of the alloys attached to its surface. The specimens were randomly divided into 6 groups, each consisting of 8 samples. Specimens were exposed to one of the three cleansing treatments (polident, manipulation pharmacy cleanser, and water) as follows. Group I: Co-Cr + polident; Group II: Co-Cr + manipulation; Group III: Co-Cr + water; Group IV: Ti-6Al-4V + polident; Group V: Ti-6Al-4V + manipulation; and Group VI: Ti-6Al-4V + water. Three exposures lasting 5 minutes each were conducted daily, and repeated after storage periods of 1, 14, and 29 days in artificial saliva at 37 degrees C. Hardness and roughness measurements were undertaken immediately after specimen preparation (T0) and on the 1st (T1), 15th (T15), and 30th (T30) day following the beginning of storage. Three roughness and hardness evaluations were carried out for each sample and testing time, and mean values were calculated. Results were analyzed using ANOVA and linear regression. RESULTS: The Knoop hardness test demonstrated differences (p < 0.05) between Groups I and IV at T1 and T30 (14.30 +/- 2.78; 14.06 +/- 1.76) and between Groups II and V at T15 (16.99 +/- 2.24). Significant differences (p < 0.05) in resin roughness (in microm) were observed between Groups I and IV at T15 and T30 (0.14 +/- 0.06; 0.21 +/- 0.38). With regard to Co-Cr, roughness data showed differences (p < 0.05) for all groups at T30 (Group I: 0.15 +/- 0.07; Group II: 2.43 +/- 0.66; Group III: 4.05 +/- 1.03), for Group II at T1 (0.10 +/- 0.03), and for Group I at T15 (0.15 +/- 0.02). There were significant differences (p < 0.05) in titanium roughness for Group IV at T15 (0.12 +/- 0.01) and T30 (0.11 +/- 0.04). CONCLUSIONS: Manipulated cleanser containing sodium perborate increased surface roughness and hardness, probably due to its incapacity to remove the pellicle formed on the acrylic resin and dental alloys.     

纯钛铸造可摘义齿的临床应用

目的　评估整体铸造纯钛基托义齿的临床应用情况。方法　分别检测患者戴整体铸造纯钛基托义齿 2年后义齿性口炎发生率以及满意度 ,并和传统的整体铸造钴铬合金基托义齿相比较。结果　患者戴整体铸造纯钛基托义齿半年和 2年后均比铸造钴铬合金基托义齿的舒适性、语音功能、咀嚼功能好 (P <0 .0 5 ) ,而前者的义齿性口炎发生率却远低于后者 (P <0 .0 0 1)。结论　提示整体铸造纯钛基托义齿可能比传统的整体铸造钴铬合金基托义齿更适用于临床。     

Laser Welding of Cast Titanium and Dental Alloys Using Argon Shielding

PURPOSE: This study investigated the effect of argon gas shielding on the strengths of laser-welded cast Ti and Ti-6Al-7Nb and compared the results to those of two dental casting alloys. MATERIALS AND METHODS: Cast plates of Ti, Ti-6Al-7Nb, gold, and Co-Cr alloy were prepared. After polishing the surfaces to be welded, two plates were abutted and welded using Nd:YAG laser at a pulse duration of 10 ms, spot diameter of 1 mm, and voltage of 200 V. Five specimens were prepared for each metal by bilaterally welding them with three or five spots either with or without argon shielding. The failure load and percent elongation were measured at a crosshead speed of 1.0 mm/min. RESULTS: The factor of argon shielding significantly affected the failure load and elongation of the laser-welded specimens. The failure loads of argon-shielded laser-welded CP Ti and Ti-6Al-7Nb were greater compared with the failure loads of specimens welded without argon shielding for both three- and five-spot welding. Regardless of argon shielding, the failure loads of the laser-welded gold alloy were approximately half that of the control specimens. In contrast, the failure loads of the nonshielded laser-welded Co-Cr alloy were greater. The percent elongations positively correlated with the failure loads. CONCLUSIONS: The use of argon shielding is necessary for effective laser-welding of CP Ti and Ti-6Al-7Nb but not for gold and Co-Cr alloy.     

Optimisation of the superplastic forming of a dental implant for bone augmentation using finite element simulations.

OBJECTIVES: The phenomenon of superplasticity has made it possible to form complex shapes that require extremely high degrees of ductility in titanium alloy with minimal internal stresses. Combined with the use of an investment casting material as the die material, which makes possible the forming of re-entrant angles, it is possible to produce membranes for ridge augmentation. The aim is to characterise the metal alloy sheet and simulate the superplastic forming process in three dimensions to produce process parameters, namely gas pressure as a function of time, to accurately adapt the titanium sheet to the bone surface. METHOD: The surface of the die was digitised using a 3D laser scanning system (UBM-Keyence LC2450). Ti-6Al-4V sheet of 140 mm diameter was modelled using a grid of triangular membrane elements. This mesh was automatically refined during the simulations. Finite element simulation was carried out using the Superflag software program (University of Wales Swansea) Three different options for gas pressure control were adopted, namely, target flow stress, target strain rate and target energy dissipation. The pressure cycles produced from the simulation were used to form titanium alloy sheet at 900 degrees C using argon gas. The deformed regions of the formed sheet were then examined to determine the regions of contact with the die and to characterise surface damage. RESULTS: Comparison of the simulations with experiment showed that there was good agreement between simulated and experimental thickness distributions in most parts of the sheet that were examined. Interrupted tests showed that in the intermediate positions of the forming sheet the simulations were slightly ahead of the experiment. The target stress option was found to produce the best degree of adaptation and the sheet formed using this cycle showed good surface quality, whereas in highly deformed regions using the other target options, the sheet was found to have formed microcracks. The use of a solid lubricant on the surface of the forming sheet was not found to have a significant influence on the adaptation of the titanium alloy sheet except in areas of high deformation where the sheet perforated. SIGNIFICANCE: The finite element membrane formulation is well adapted to the superplastic forming of a ridge augmentation membrane prosthesis. The simulation accurately describes the evolution of the shape of the prosthesis and its thickness distribution with time, which allows the manufacturer to select an appropriate initial thickness of titanium alloy sheet prior to attempting to form the component. The investment dies are found to have sufficient strength to withstand the forming operation if a suitable orientation of the titanium sheet with respect to the die is adopted. A metal surface of good quality can be produced in the formed prosthesis using the appropriate gas control option.     

Mechanical properties of cast Ti-6Al-4V-XCu alloys

The mechanical properties of Ti-6Al-4V-XCu (1, 4 and 10 wt% Cu) alloys were examined. The castings for each alloy were made in a centrifugal titanium casting machine. Two shapes of specimens were used: a dumbbell (20 mm gauge length x 2.8 mm diameter) for mechanical property studies, and a flat slab (2 mm x 10 mm x 10 mm) for metallography, microhardness determination and X-ray diffractometry. Tensile strength, yield strength, modulus of elasticity, elongation and microhardness were evaluated. After tensile testing, the fracture surfaces were observed using scanning electron microscopy. The tensile strengths of the quaternary alloys decreased from 1016 MPa for the 1% Cu alloy to 387 MPa for the 10% Cu alloy. Elongation decreased with an increase in the copper content. The 1% Cu alloy exhibited elongation similar to Ti-6Al-4V without copper (3.0%). The results also indicated that the copper additions increased the bulk hardness of the quaternary alloy. In particular, the 10% Cu alloy had the highest hardness and underwent the most brittle fracture. The mechanical properties of cast Ti-6Al-4V alloy with 1 and 4% Cu were well within the values for existing dental casting non-precious alloys.