Ti-6Al-4V anterior cervical plates (ACP) are used in spinal fusion surgeries to fixate cervical vertebrae during graft adhesion. However, documented cases of implant failure and the potential for ACP corrosion raise concerns regarding any degradation of material resulting from extended implantation. In addition, abrasion during implantation may damage a section of the protective oxide layer, potentially exposing surrounding tissues to the harmful effects of bare titanium, aluminum, and vanadium. Thermal oxidation has been shown to improve corrosion-resistance and wear-resistance, depending on temperature and time. To quantify the attributes of the thermally grown oxide layer, Ti-6Al-4V coupons underwent thermal oxidation treatments in an atmosphere environment at 600 and 675 ˚C for 1, 4, 8, and 16 hours. Two sample types were produced: non-abraded and abraded. Non-abraded samples underwent potentiodynamic polarization according to ASTM F2129, which included open circuit potential tests. Open circuit potentials (EOC) increased with increasing treatment time, indicating that longer treatment time resulted in thicker oxides. All samples treated at 675˚C displayed higher EOC than samples treated at 600˚C, indicating an increase in oxide thickness with higher temperature. During the first hour of treatment at 675˚C, the rate of oxide growth was greater than the rate of oxide growth of all samples treated at 600˚C. Samples treated at 600˚C for 4 and 8 hours displayed pitting during potentiodynamic polarization, but all other samples withstood the applied potentials and surfaces were further passivated. To simulate damage during surgery, a single abrasion was made across samples in the abraded group with a diamond-tip indenter under a load of 471g at 4.4 mm/s. Abraded samples were subjected to potential-step tests to assess repassivation ability after abrasion. All samples displayed repassivation ability, except for the sample treated at 600˚C for 4 hours. Surface roughness was measured with atomic force microscopy before and after thermal oxidation treatments. Lower surface roughness was desired to discourage osseointegration, or the growth of bone cells. No isothermal surface roughness trends were observed, as high surface roughness outliers were seen in samples treated at 675˚C for 8 hours and 600˚C for 4 hours. Rockwell hardness and Vickers microhardness were also measured to assess bulk changes in mechanical properties and hardness of the oxidized surfaces. No statistical change was seen in Rockwell hardness. Vickers hardness increased with increasing temperature and time, with the exception of the sample treated at 600˚C for 4 hours. Metallography of the thermally oxidized samples was analyzed to determine if a change in microstructure had occurred due to thermal processing. No major change in grain size or the amount of alpha and beta grains was seen in samples treated at 600˚C, but samples treated for extended times at 675˚C showed equiaxed enlarged alpha grains and a reduction in beta grains. The breakdown of samples treated at 600˚C exemplified possible differences in the alpha-beta oxide behavior during thermal oxidation and corrosion. Outlying surface roughness and microhardness values related to the thermal oxidation treatments and resulting oxide structure. Due to delamination of oxides grown at 675˚C for 4, 8, and 16 hours, the treatment parameters would not be effective in the ACP application. Therefore, through corrosion resistance, repassivation ability, low surface roughness, increased microhardness, and no microstructural change, thermal oxidation treatments at 600˚C for more than 16 hours, and 675˚C for 1 hour or less would be suitable treatments for anterior cervical plates.

When testing forgings for specifications, it was found that some parts did not meet the requirements for mechanical properties. This triggered an investigation into two of the parts from the lot that did not meet specification. The ultimate reason for failure was due to lower than necessary yield strength and ultimate tensile strength values, as well as unwanted variability between regions of the part. Therefore, samples of the regions were tensile tested to determine the differences that existed in yield strength, ultimate tensile strength, and elongation. After tensile testing, quantitative metallography and fractography were conducted to identify aspects of the microstructure and fracture surfaces that may have caused the variability. Three aspects of the microstructure that were identified as characteristics that may affect the mechanical properties were: grain size, Widmanstätten colony size, and volume fraction of the β phase. Based on measurements it was determined that a smaller Widmanstätten colony size found to be roughly 120 microns/colony was associated with a larger yield strength and UTS than larger colony sizes of roughly 170 microns/ colony. Grain size also played a role with smaller grain sizes of roughly 1550 microns/grain being associated with a higher yield strength and UTS than the larger grains of roughly 2000 microns/grain. Fractography also suggested that the presence of interlamellar decohesion and trans-lamellar failure may have created sites of further crack initiation, resulting in a lower ultimate tensile strength. These differences were theorized to be caused by a temperature gradient created during the heat treatment that created non-uniform cooling rates, resulting in the differences in microstructural characteristics.

In this work, the influence of different cooling rates (5, 20, 50 and 100 °C/s) on the microstructure and mechanical properties of Laser Metal Wire Deposited (LMwD) Ti-6Al-4V was investigated, this was done using a thermal-mechanical physical simulation system (Gleeble 3800, DSI). Two different soak times above β transus (held at 1100 °C), 5 and 40 s, were used and after cooling to 150 °C, the samples were tensile tested. The samples were characterized with optical microscopy (OM) and scanning electron microscopy (SEM) and hardness testing. The results were then compared, both with each other and with two reference samples, that were only heated to 150 °C and then tensile tested. It was found that for the lowest cooling rate, 5 °C/s, the microstructure had transformed from a basketweave α microstructure to a colony α microstructure in the center of the specimen waist where heating was most efficient. Ultimate tensile strength (UTS) was found to be in the range of 858 – 977 MPa, with the highest average being recorded for the reference samples, similar results were noted for the strain, with a range of  ⁓5 – 14 %, where the highest recorded average was for the reference samples. However, the extensometer used was not optimized for this kind of test, therefore percent reduction of area (RA) measurements were performed. The RA measurements produced a significantly different result than that obtained from the testing, a large scatter in the ductility was found, possibly due to thermal instability that occurred during testing. Overall, the microstructure appears to be relatively stable over the cooling range of 20 - 100 °C/s, no major differences were observed, the microstructure consisted of a homogeneous basketweave α microstructure, with little to no change in the measured average α lath thickness.

The present work aims to reveal the microstructural evolution and post-processing mechanical behavior of difficult-to-work alloys upon severe plastic deformation. Severe plastic deformation is applied using equal channel angular extrusion (ECAE) where billets are pressed through a 90o corner die achieving simple shear deformation. Three different materials are studied in this research, namely Ti-6Al-4V, Ti-6Al-4V reinforced with 10% TiC and AISI 316L stainless steel. Microstructure and mechanical properties of successfully extruded billets were reported using light microscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), tension and compression experiments and microhardness measurements. The effects of extrusion conditions (temperature and processing route) on the microstructure and mechanical properties are investigated. The underlying mechanisms responsible for observed mechanical behaviors are explored. It is seen that ECAE shear deformation leads to refinement in α plates and elimination of prior β boundaries in Ti-6Al-4V. Decreasing extrusion temperature and increasing number of passes decreases α plate size and grain size. Refined α grain size leads to a significant increase in tensile and compressive flow stresses at room temperature. Texture produced by ECAE has a pronounced effect on mechanical properties. Specifically it leads to tension/compression asymmetry in flow strengths and strain hardening coefficients may be described by the activation of differing slip systems under tension and compression loading. ECAE of Ti-6Al-4V+10%TiC samples also improved mechanical properties due to α plate size refinement. Nevertheless, further extrusion passes should be carried out for tailoring reinforcement size and distribution providing optimum strength and ductility. ECAE deformation of AISI 316L stainless steel at high homologous temperatures (0.55 to 0.60 Tm) results in deformation twinning as an effective deformation mechanism which is attributed to the effect of the high stress levels on the partial dislocation separation. Deformation twinning gives rise to high stress levels during post-processing room temperature tension and compression experiments by providing additional barriers to dislocation motion and decreasing the mean free path of dislocations. The highest tensile flow stress observed in the sample processed at 700 oC following one pass route A was on the order of 1200 MPa which is very high for 316L stainless steel. The ultimate goal of this study is to produce stabilized end microstructures with improved mechanical properties and demonstrate the applicability of ECAE on difficult-to-work alloys.

This research investigates the mechanical properties and performance of structural materials at a small volume scale. In situ observation was made possible through the Small Punch Test (SPT) method as well as tribological testing. Experimentally, aluminum and titanium alloys were examined using those two techniques. Analysis of their behavior in comparison with their published mechanical properties made it possible to establish connections between test parameters and conventional uniaxial tensile test properties. Connections were generated between SPT parameters and tribological performance. This research used experimental approaches to develop an understanding of the material behaviors during small punch testing and apply them to hydrogen embrittlement. The SPT for such alloys were highly repeatable and specimen surface roughness did not have visible impacts on repeatability. Analysis indicated that there is a link between the SPT and conventional mechanical properties. The relationship between the applied force and the slop of the FvE curve is associated with the tensile strength and elastic modulus. It was found that the SPT can be used to qualitatively gage wear resistance. The SPT was used to analyze hydrogen effects, and no significant effects were seen on 3003-H14 and 2618-T61 aluminum alloys; however, effects were seen on a Ti-6Al-4V alloy. It was also found that hydrogen showed no visible effects on friction and wear. The SPT can now be applied more accurately to the testing of aluminum alloys and new doors for the potential of small punch testing in the application of hydrogen embrittlement and surface characterization have been opened. This thesis consists of six chapters. The first chapter serves as an introduction to the background necessary to understand the rational and motivation for the present research. The second chapter will go into detail about the motivation and the objects of the research while the third chapter will explain the experimental procedures that were conducted to fulfill these objectives. The fourth chapter will present the results of these experiments, and they will be discussed in the fifth chapter. Finally, in the sixth chapter, conclusions will be stated and future work will be discussed.

Porous Ti-6Al-4V alloys are widely used in the biomedical applications for hard tissue implantation due to its biocompatibility and elastic modulus being close to that of bone. In this study, porous Ti-6Al-4V alloys were produced with a powder metallurgical process, space holder technique, where magnesium powders were utilized in order to generate porosities in the range of 50 to 70 vol. %. In the productions of Ti-6Al-4V foams, first, the spherical Ti-6Al-4V powders with an average size of 55 &mu / m were mixed with spherical magnesium powders sieved to an average size of 375 &mu / m, and then the mixtures were compacted with a hydraulic press under 500 MPa pressure by using a double-ended steel die and finaly, the green compacts were sintered at 1200

The present work aims to reveal the microstructural evolution and post-processing mechanical behavior of difficult-to-work alloys upon severe plastic deformation. Severe plastic deformation is applied using equal channel angular extrusion (ECAE) where billets are pressed through a 90o corner die achieving simple shear deformation. Three different materials are studied in this research, namely Ti-6Al-4V, Ti-6Al-4V reinforced with 10% TiC and AISI 316L stainless steel. Microstructure and mechanical properties of successfully extruded billets were reported using light microscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), tension and compression experiments and microhardness measurements. The effects of extrusion conditions (temperature and processing route) on the microstructure and mechanical properties are investigated. The underlying mechanisms responsible for observed mechanical behaviors are explored. It is seen that ECAE shear deformation leads to refinement in α plates and elimination of prior β boundaries in Ti-6Al-4V. Decreasing extrusion temperature and increasing number of passes decreases α plate size and grain size. Refined α grain size leads to a significant increase in tensile and compressive flow stresses at room temperature. Texture produced by ECAE has a pronounced effect on mechanical properties. Specifically it leads to tension/compression asymmetry in flow strengths and strain hardening coefficients may be described by the activation of differing slip systems under tension and compression loading. ECAE of Ti-6Al-4V+10%TiC samples also improved mechanical properties due to α plate size refinement. Nevertheless, further extrusion passes should be carried out for tailoring reinforcement size and distribution providing optimum strength and ductility. ECAE deformation of AISI 316L stainless steel at high homologous temperatures (0.55 to 0.60 Tm) results in deformation twinning as an effective deformation mechanism which is attributed to the effect of the high stress levels on the partial dislocation separation. Deformation twinning gives rise to high stress levels during post-processing room temperature tension and compression experiments by providing additional barriers to dislocation motion and decreasing the mean free path of dislocations. The highest tensile flow stress observed in the sample processed at 700 oC following one pass route A was on the order of 1200 MPa which is very high for 316L stainless steel. The ultimate goal of this study is to produce stabilized end microstructures with improved mechanical properties and demonstrate the applicability of ECAE on difficult-to-work alloys.

Superplastic forming (SPF) is a near net-shape forming process which offers many advantages over conventional forming operations including low forming pressure due to low flow stress, low die cost, greater design flexibility, and the ability to shape hard metals and form complex shapes. However, low production rate due to slow forming process and limited predictive capabilities due to lack of accurate constitutive models for superplastic deformation, are the main obstacles to the widespread use of SPF. Recent advancements in finite element tools have helped in the analysis of complex superplastic forming operations. These tools can be utilized successfully in order to develop optimized superplastic forming techniques. In this work, an optimum variable strain rate scheme developed using a combined micromacro stability criterion is integrated with ABAQUS for the optimization of superplastic forming process. Finite element simulations of superplastic forming of Ti-6Al-4V sheet into a hemisphere and a box are carried out using two different forming approaches. The first approach is based on a constant strain rate scheme. The second one is based on the optimum variable strain rate scheme. It is shown that the forming time can be significantly reduced without compromising the uniformity of thickness distribution when using the proposed optimum approach. Further analysis is carried out to study the effects of strain rate, microstructural evolution and friction on the formed product. Finally the constitutive equations and stability criterion mentioned above are used to analyze the forming of dental implant superstructure, a modern industrial application of superplastic forming.

Additive manufacturing (AM) offers reduced material waste and energy usage, as well as an increase in precision. Direct metal AM is used not only for prototyping, but to produce final production parts in the aerospace, medical, automotive and other industries. Process mapping is an approach that represents process outcomes in terms of process input variables. Solidification microstructure process maps are developed for single bead and thin wall deposits of Ti-6Al-4V via an electron beam wire feed and electron beam powder bed AM process. Process variable combinations yielding constant beta grain size and morphology are identified. Comparison with the process maps for melt pool geometry shows that by maintaining a constant melt pool cross sectional area, a constant grain size will also be achieved. Additionally, the grain morphology boundaries are similar to curves of constant melt pool aspect ratio. Experimental results are presented to support the numerical predictions and identify a proportional size scaling between beta grain widths and melt pool widths. Results demonstrate that in situ, indirect control of solidification microstructure is possible through direct melt pool dimension control. The ability to control solidification microstructure can greatly accelerate AM process qualification potentially allow for tailored microstructure to the desired application.

With an increasingly aging population, a significant challenge in implantology is the creation of biomaterials that actively promote and accelerate tissue integration while offering excellent mechanical properties. Engineered surfaces with superimposed micro and nanoscale topographies showed great potential to control and direct biomaterial-host tissue interactions. However, these modified surfaces require a careful assessment to prevent potential adverse effects on the fatigue resistance, a factor which may ultimately cause premature failure of biomedical implants. In this context, the surfaces of two widely used biocompatible metals, namely CP Ti and Ti-6Al-4V, were engineered through simple yet efficient chemical treatments which demonstrated the ability to confer exciting new bioactive capacities. The qualitative and quantitative assessments of the fatigue resistance of polished and treated metals were carried out. Results from this study highlight the importance of mechanical considerations in the development and evaluation of nanoscale surface treatments for metallic biomedical implants.