Thesis (Ph.D.)--University of Western Australia, 2005.

Thesis (M.Sc.(Metallurgy)--University of Pretoria, 2000. / Summaries in Afrikaans and English. Includes bibliographical references (leaves 108-112).

Thesis (Ph. D.)--University of Alabama at Birmingham, 1996. / eContent provider-neutral record in process. Description based on print version record. Includes bibliographical references.

Thesis (Ph. D.)--University of Alabama at Birmingham, 1996. / eContent provider-neutral record in process. Description based on print version record. Includes bibliographical references.

Metallic materials have gained much attention recently from the areas of medical devices and orthopaedics. Artificial organs, dental implants, prostheses and implants that replace damaged or malfunctioning parts in the body are, or contain, metal components. Our ageing society poses an increased demand to provide devices and implants that can demonstrate better performance than those presented by traditional solutions. Matching the mechanical properties (i.e. stiffness and strength) of the device to those of the host tissue is a major challenge for the design and manufacture of engineered metal materials for biomedical applications. Failure in doing so provokes implant loosening, patient discomfort and repeated surgeries. Therefore, tailoring physical properties and biocompatibility of those materials is the main final aim of this research programme. This PhD study has focused on the tailoring of the mechanical properties of titanium-based materials and titanium-based alloys. Titanium inertness and the selection of biocompatible alloying elements were set as the baseline. Two approaches were employed to decrease stiffness (i.e. Young s modulus): one, by introducing porosity in a titanium matrix and therefore, reduce its Young s modulus, and two, by designing and manufacturing beta-titanium-based alloys with a reduced Young s modulus. Titanium scaffolds were manufactured using powder metallurgy with space holder technique and a sintering process. Different space holder sizes were used in four different categories to study the effect of pore size and porosity on the mechanical properties of the porosity engineered Ti scaffolds. Ti-based alloys were manufactured using manufacturing techniques such as sintering and arc-melting. The effect of different fabrication processes and the addition of beta-stabilising elements were studied and investigated. The obtained results of mechanical properties for pore size and porosity were within the values that match bone properties. This means these materials are suitable for biomedical application and the beta-Ti alloys results show that the mechanical properties can be decreased via tailoring the crystal structures. The characterisation of the Ti-based alloys helps to develop this material for its use in biomedical application.

Os implantes dentários de titânio comercialmente puro (Ticp) grau 4 e os de titânio-alumínio-vanádio (Ti6Al4V) grau 5, possuem boas propriedades mecânicas. No entanto, algumas situações clínicas com restrição de espessura óssea impedem a utilização dos implantes com 3.75mm de diâmetro tradicionalmente fabricados em titânio 4 e que apresentam resistência mecânica testada em profusão. Como a liga de grau 5 possui superior resistência à tração e à fadiga, este estudo objetiva analisar a resposta óssea do titânio grau 4 e grau 5 em implantes curtos e estreitos através da análise do contato osso-implante (BIC) e da área de neoformação óssea. Para este fim, o presente estudo utilizou 15 coelhos da raça New Zealand, que receberam um total de trinta implantes divididos em suas tíbias direita e esquerda. Os implantes de grau 4 e de grau 5, com dimensões de 3.5x8mm e 2.9x7mm, respectivamente, foram fornecidos pela empresa NEODENT® (Curitiba-Brasil). Neste estudo, dois grupos foram formados, um com implantes de titânio grau 4 e outro com implantes de titânio grau 5, ambos contendo quinze implantes curtos e estreitos. Cortes histológicos foram realizados após duas semanas de osseointegração. Mensurações no analisador de imagens ImageJ foram feitas para verificar o BIC e a área de osso neoformado. Para a análise dos dados estatísticos, utilizou-se o teste t de Student para amostras independentes com nível de significância de p<0.05. Os resultados mostraram que não houve diferença estatisticamente significante entre os grupos nos dois tipos de análises. A média dos valores de BIC do titânio grau 4 obteve o valor médio mais alto de 56,53%, variando de 95,74% a 9,4%. O grupo de titânio grau 5 apresentou média de 50,63%, variando entre 84,3% e 13,12%. Com base em imagens com fluorescência, realizou-se análise da área óssea. O grupo de titânio grau 5 apresentou valor de 46,3% (variando entre 79% a 14,21%) em fluorescência, número ligeiramente maior do que o verificado no grupo de titânio grau 4 (44,73%, com variância entre 78,93% e 18,36%). Com isso, concluiu-se que implantes de titânio de grau 4 e de grau 5 obtiveram respostas biológicas equivalentes, quando avaliados o BIC e a área óssea neoformada. / Commercially pure titanium implants (Ticp) of degree IV and of titanium-aluminum-vanadium degree V have good mechanical properties. However some clinical situations with limited bone thickness preclude the use of traditionally implants with 3.75mm diameter made from titanium IV and present strength tested in profusion. In addition, degree V alloy shows higher resistance to traction and fatigue, this study aims to analyze the bone response to degree IV and degree V titanium in short and narrow implants with the same surface treatment through the analysis of the bone-to-implant contact (BIC) and the area of the new bone formation. For such purpose, this study used15 New Zealand white rabbits which had a total of thirty implants inserted in their right and left tibiae. Both degree IV and degree V implants, measuring 3.5x8mm and 2.9x7mm, respectively, were provided by dental implant manufacturer NEODENT® (Curitiba-Brazil). The implants were allocated into two distinct groups. Fifteen short and narrow implants of degree IV were utilized in a group, whereas fifteen short and narrow implants of degree V were employed in the other group. Histological sections samples were carried out after a two-week period of osseointegration. Subsequently, measurements were calculated using ImageJ software in order to verify the BIC and the area of the newly grown bone. Analysis of statistical data of independent samples with significance level p<0.05 was carried out via Student\'s t-test. Results showed no statistically substantial difference between both groups regarding both measurement activities. The media values BIC for the degree IV titanium group reached the highest average value of 56,53%, varying from 95,74% to 9,4%. The degree V titanium group averaged 50,63%, oscillating between 84,3% and 13,12%. The bone areas were analyzed based on images with fluorescence. The degree V titanium group reached the percentage of 46,3% (varying from 79% to 14,21%) in fluorescence whereas the degree IV titanium group had a percentage of 44,73% (varying between 78,93% and 18,36%). Therefore, both degree IV and degree V implants had equivalent biological responses based on the analysis of BIC and newly grown bone areas.

M.Ing. (Mechanical Engineering) / High strength alloys such as titanium are widely used within applications that require specific material properties. These include high strength, high temperature as well as low weight applications. Thus a need arises to investigate the fundamental to understand the mechanics of how these materials are machined. Titanium alloys are known for the difficulties that arise during the machining thereof. Complexities arise due to its inherent material properties, the most important property being the retention of strength at high temperatures. In addition to maintaining its strength, it becomes highly chemically reactive with other materials at increased temperatures. All these factors contribute to extreme temperatures at the tool chip interface contributing to increased tool wear and shortened tool life. The aim of the research is to investigate the effect of machining on various cutting process parameters including cutting force, temperature, tool wear and surface finish for grade 2 and grade 5 titanium alloys during high speed turning. Grade 2 titanium is a commercially grade with lower mechanical properties, while Grade 5 is titanium alloy with substantially higher mechanical properties and is the most widely used titanium alloy. In addition an experimental setup was developed and verified to conduct fundamental research on the high speed machining of titanium alloys. A literature review was concluded with focus on the machining of titanium alloys. This was followed by the development of the experimental setup, measurement and compilation of data. The data was compiled into graphs and compared with the current research available. The research found that for the cuts performed, that cutting forces are independent of cooling applied and that no substantial variation was noted between the two grades. When temperatures were evaluated, dramatic drops in temperature were noted when coolant was applied. As temperatures increased, specifically during un-cooled cutting, the inserts deteriorated having an effect on the quality of the surfaces obtained. When coolant was applied, substantial temperature drops were achieved, improving tool life and directly improving surface finishes. The best surface finish was achieved for higher cutting speeds as and lower feed rates. This phenomenon was found for both grades of titanium evaluated. The largest amount of tool wear was noted for the highest cutting speeds, with increased values noted for Grade 5 in comparison with Grade 2. This phenomenon is noted for crater as well as flank wear.

This dissertation involves the experimental investigation of commercially pure titanium (CP Ti) which was subjected to laser forming and mechanical forming processes. Commercially pure titanium grade 2 was formed to a radius of curvature of approximately 120 mm using three forming procedures, i.e. i) laser forming; ii) mechanical forming (stretched forming) and iii) a combined forming process (laser-mechanical forming). Fatigue testing revealed, for all the forming processes, that samples produced by laser forming performed the best at high load settings. However, mechanically formed specimens performed the best at low load settings, whereas the laser-mechanical process resulted in midway performance between laser and mechanical processing. Considering microstructure vs fatigue; impact vs fatigue; and residual stress vs fatigue; at high load settings it is evident that the microstructure is the dominant contributor to crack initiation and growth. Crack morphology of fatigue samples revealed that secondary cracks (parallel to main crack front) followed the grain boundaries of the Widmanstätten microstructure, whereas irregular secondary cracks grew parallel and through the twinning planes and along the grain boundaries of the equiaxed microstructure. Laser forming resulted in microstructural changes from equiaxed grains to a Widmanstätten structure due to fast cooling rates. Excessive twinning is developed within the equiaxed microstructure after the mechanical forming procedure. This is due to cold working / strain hardening. The combined process shows a combination of equiaxed grains and Widmanstätten microstructure. Residual stress relieved for all forming processes revealed an increase in the magnitude of the residual stress compared to the parent plate and that the maximum values were obtained at the inner radius of curvature (i.e. 118.4 mm). Laser forming revealed the highest values in residual stress whereas the other two processes i.e. mechanical and laser-mechanical forming exhibited an increase midway between the parent plate and laser forming. The second most influential factor with regards to fatigue was the magnitude of the residual stress, especially at medium to low load settings. When considering theoretical models to predict fatigue life it was found that the Goodman model showed the closest relation to the actual fatigue data when considering the entire theoretical curve. Vickers microhardness profiling was applied to the thickness of the samples for the parent plate and all forming processes. No significant hardening occurred due to the forming processes and differences in hardness were considered negligible. Charpy impact testing revealed that the laser formed specimens exhibited the most brittle behaviour when compared to the parent plate results. Mechanical formed specimens showed a slight increase in brittleness compared to parent plate whereas the combined process yielded results midway between the laser and mechanically formed specimens. Mathematical equations are formulated and presented for predicting the fatigue life of CP Ti grade 2 for the parent plate and the three forming processes. This study proved that the laser forming process can be successfully used as a production stage in the forming of CP Ti grade 2.

M.Ing. / Grade 4 titanium is a commercially pure grade titanium alloy extensively used in various industries including the chemical industry and more recently in the biomedical industry. Grade 4 has found a niche as a biomedical material for production of components such as orthopaedic and dental implants. Its physical properties such as high corrosion resistance, low thermal conductivity and high strength make it suitable for these applications. These properties also make it hard-to-machine similar to the other grades of titanium alloys and other metals such as nickel based alloys. During machining of titanium, elevated temperatures are generated at the tool-workpiece interface due to its low thermal conductivity. Its high strength is also maintained at these high temperatures. These tend to impair the cutting tool affecting its machinability. Various investigations on other grades of titanium and other hard-to-machine materials have shown that machining at high cutting speeds may improve certain aspects of their machinability. High speed machining (HSM) is used to improve productivity in the machining process and to therefore lower manufacturing costs. HSM may, however, change the surface integrity of the machined material. Surface integrity refers to the properties of the surface and sub-surface of a machined component which may be quite different from the substrate. The properties of the surface and sub-surface of a component may have a marked effect on the functional behaviour of a machined component. Fatigue life and wear are examples of properties that may be significantly influenced by a change in the surface integrity. Surface integrity may include the topography, the metallurgy and various other mechanical properties. It is evaluated by examination of surface integrity indicators. In this investigation the three main surface integrity indicators are examined. These are surface roughness, sub-surface hardness and residual stress. White layer thickness and chip morphology were also observed as results of the machining process used. The effect of HSM on the surface integrity of grade 4 is largely unknown. This investigation therefore aims to address this limitation by conducting an experimental investigation on the effect of HSM on selected surface integrity indicators for grade 4. Two forged bars of grade 4 alloy were machined using a CNC lathe at two depths of cut, 0.2mm and 1mm. Each bar was machined at varying cutting speeds ranging from 70m/min to 290m/min at intervals of approximately 20m/min. Machined samples were prepared from these cutting speeds and depths of cut. The three surface integrity indicators were then evaluated with respect to the cutting speed and depth of cut (DoC). iv Results show that a combination of intermediate cutting speeds and low DoC may have desirable effects on the surface integrity of grade 4. Highest compressive stresses were obtained when machining with these conditions. High compressive stresses are favourable in cases where the fatigue life of a material is an important factor in the functionality of a component. Subsurface hardening was noticed at 0.2mm DoC, with no subsurface softening at all cutting speeds. Surface hardness higher than the bulk hardness tends to improve the wear resistance of the machined material. Though surface roughness values for all depths of cut were below the standard fine finish of 1.6μm, roughness values of samples machined at 0.2mm DoC continued to decrease with increase in cutting speed. Low surface roughness values may also influence the improvement of fatigue life of the machined components. These machining conditions, (intermediate cutting speeds and low DoC), seem to have promoted mechanically dominated deformation during machining rather than thermal dominated deformation. Thermal dominated deformation was prominent on titanium machined at DoC of 1mm.

M.Eng. (Mechanical Engineering) / High speed machining (HSM) has the potential to greatly increase productivity and to lower manufacturing costs if workpiece surface integrity can be controlled. The surface fmish of a biomaterial is vitally important for proper implant functioning, and is the focus of this study. Grade 4 titanium was turned on a lathe with cutting speeds increasing from the conventional to the high speed range. The surface finish was assessed using profilometry, atomic force microscopy, and contact angle measurement. The ability of the material to bond directly with bone was predicted by cell adhesion studies. Results indicate that there is a general relationship between cutting speed, surface roughness, contact angle, and cell adhesion. Turning grade 4 titanium at cutting speeds between 150m/min and 200m/min may provide an optimal surface for osseointegration.