Fabrication of ultra-thin porous titanium alloys by electron beam selective melting: Porosity and mechanical properties

Abstract

Titanium alloys are widely regarded as ideal biomaterials due to their superior mechanical properties and resistance to corrosion. Additive manufacturing offers a novel approach for fabricating porous structures, enabling the production of titanium alloys with intricate geometries and varied dimensions. In this study, porous titanium alloys were produced using the Ti-6Al-2Zr-2V-1Mo alloy via electron beam selective melting (EBSM). Thin-wall structures with thicknesses ranging from 360 μm to 600 μm demonstrated exceptional mechanical performance near the forming threshold. An increase in porosity from 22 % to 32 % was observed, resulting in a reduction in tensile strength from 350 MPa to 250 MPa. Tensile testing and microstructural analyses revealed that precise control of the electron beam spot diameter facilitated effective metallurgical bonding between powder particles, with residual pores comparable in size to the original powder. This work highlights a promising strategy for fabricating titanium alloys tailored for biomedical applications.