This study developed a non-equiatomic Ti_28.33Zr_28.33Hf_28.33Nb_6.74Ta_6.74Mo_1.55 super-solid solutionized BioHEA using laser powder bed fusion (LPBF) to reach the full potential as BioHEA. We succeeded in significant suppression of elemental segregation, thus, resulting in a single crystalline-like texture by activating layer-to-layer epitaxial growth. Relatively low Young’s modulus was achieved in the single crystalline-like BioHEA. Moreover, LPBF-fabricated BioHEA exhibited significantly higher yield stress (1355–1426 MPa) due to the effective solid solution hardening compared to as-cast counterpart with marked segregation (949 MPa), and good biocompatibility. This is first report achieving BioHEA with low modulus, excellent strength-ductility balance, and good biocompatibility via LPBF. GRAPHICAL ABSTRACT IMPACT STATEMENT This study achieved super-solid-solutionized and single crystalline-like TiZrHfNbTaMo bio-high entropy alloy using laser powder bed fusion, resulting in low Young’s modulus along oriented direction, excellent strength-ductility balance, and good cytocompatibility.

The additive manufacturing of titanium–niobium–tantalum alloys with nominal chemical compositions Ti–xNb–6Ta (x = 20, 27, 35) by means of laser beam powder bed fusion is reported, and their potential as implant materials is elaborated by mechanical and biological characterization. The properties of dense specimens manufactured in different build orientations and of open porous Ti–20Nb–6Ta specimens are evaluated. Compression tests indicate that strength and elasticity are influenced by the chemical composition and build orientation. The minimum elasticity is always observed in the 90° orientation. It is lowest for Ti–20Nb–6Ta (43.2 ± 2.7 GPa) and can be further reduced to 8.1 ± 1.0 GPa for open porous specimens (p < 0.001). Furthermore, human osteoblasts are cultivated for 7 and 14 days on as-printed specimens and their biological response is compared to that of Ti–6Al–4V. Build orientation and cultivation time significantly affect the gene expression profile of osteogenic differentiation markers. Incomplete cell spreading is observed in specimens manufactured in 0° build orientation, whereas widely stretched cells are observed in 90° build orientation, i.e., parallel to the build direction. Compared to Ti–6Al–4V, Ti–Nb–Ta specimens promote improved osteogenesis and reduce the induction of inflammation. Accordingly, Ti–xNb–6Ta alloys have favorable mechanical and biological properties with great potential for application in orthopedic implants.

Multifunctional materials have been described to meet the diverse requirements of implant materials for femoral components of uncemented total knee replacements. These materials aim to combine the high wear and corrosion resistance of oxide ceramics at the joint surfaces with the osteogenic potential of titanium alloys at the bone-implant interface. Our objective was to evaluate the biomechanical performance of hybrid material-based femoral components regarding mechanical stress within the implant during cementless implantation and stress shielding (evaluated by strain energy density) of the periprosthetic bone during two-legged squat motion using finite element modeling. The hybrid materials consisted of alumina-toughened zirconia (ATZ) ceramic joined with additively manufactured Ti-6Al-4V or Ti-35Nb-6Ta alloys. The titanium component was modeled with or without an open porous surface structure. Monolithic femoral components of ATZ ceramic or Co-28Cr-6Mo alloy were used as reference. The elasticity of the open porous surface structure was determined within experimental compression tests and was significantly higher for Ti-35Nb-6Ta compared to Ti-6Al-4V (5.2 ± 0.2 GPa vs. 8.8 ± 0.8 GPa, p < 0.001). During implantation, the maximum stress within the ATZ femoral component decreased from 1568.9 MPa (monolithic ATZ) to 367.6 MPa (Ti-6Al-4V/ATZ), 560.9 MPa (Ti-6Al-4V/ATZ with an open porous surface), 474.9 MPa (Ti-35Nb-6Ta/ATZ), and 648.4 MPa (Ti-35Nb-6Ta/ATZ with an open porous surface). The strain energy density increased at higher flexion angles for all models during the squat movement. At ∼90° knee flexion, the strain energy density in the anterior region of the distal femur increased by 25.7 % (Ti-6Al-4V/ATZ), 70.3 % (Ti-6Al-4V/ATZ with an open porous surface), 43.7 % (Ti-35Nb-6Ta/ATZ), and 82.5% (Ti-35Nb-6Ta/ATZ with an open porous surface) compared to monolithic ATZ. Thus, the hybrid material-based femoral component decreases the intraoperative fracture risk of the ATZ part and considerably reduces the risk of stress shielding of the periprosthetic bone.

Many applications among aerospace, defense and energy generation require materials being capable to perform in high temperature environments. Nb-base alloys are becoming particularly interesting if the temperatures exceed ~1050°C as they are outperforming even the most advanced Ni- and Co-base alloys. Notably, conventional production methods for Nb-base alloys are challenging, especially if parts with complex shapes are to be manufactured. The use of powder-based processes e.g. AM or HIP, opens up new opportunities to economically produce complex-shaped parts. However, for these processes the application of suitable high-quality powders is mandatory. In this context, the production of Nb-base alloys as powder feedstock using the electrode induction-melting gas atomization (EIGA) is reported. Powders and additively manufactured parts were investigated by X-ray diffraction, scanning electron microscopy, mechanical tests, and electro-thermal mechanical testing (ETMT). The mechanical performance, i.e., strength of parts processed by laser beam powder bed fusion (PBF-LB) clearly outperforms that of conventionally manufactured parts.