This study aims to achieve in situ-formed pure Ti and Ti6Al4V coatings on 316L stainless steel through hot pressing and examine their wear and corrosion properties thoroughly in two simulated body fluids: physiological serum (0.9% NaCl) and Hanks’ solution. The sintering and diffusion bonding process was conducted at 1050 °C under a uniaxial pressure of 40 MPa for 30 min in a vacuum environment of 10⁻⁴ mbar. Following sintering, in situ-formed pure Ti and Ti6Al4V coatings, approximately 1000 µm thick, were produced on 316L substrates approximately 3000 µm in thickness. The mean hardness of 316L substrates, pure Ti, and Ti6Al4V coatings are around 165 HV, 170 HV, and 420 HV, respectively. The interface of the stainless steel substrate and the pure Ti and Ti6Al4V coatings exhibited no microstructural defects, while the interface exhibited significantly higher hardness values (ranging from 600 to 700 HV). The coatings improved corrosion resistance in both electrolytes compared to the 316L substrate. Wet wear tests revealed reduced friction coefficients in 0.9% NaCl relative to Hanks’ solution, highlighting the chemical interactions between the material surface and the electrolyte type and the significance of tribocorrosion in biocoatings.

In this article, the process of creating calcium phosphate coatings through plasma electrolytic oxidation was investigated. Calcium phosphate coatings were deposited onto titanium substrates fabricated via the selective laser melting (SLM) method. The correlation between the characteristics of the coating and the applied voltage (200, 250, and 300 V) of PEO was studied. The surface morphology analysis indicates that an increase in applied voltage results in a larger pore size. It was discovered that, when a voltage of 300 V was applied, a layer of hydroxyapatite formed. However, at 300 V, the coating cracked, producing a significantly rough surface. Our analysis of the elemental composition of sample cross sections indicates the presence of TiO₂ layers that are enriched with calcium (Ca) and phosphorus (P). The coefficient of friction and wear rate are primarily influenced by the morphology, pore size, and density of the titanium dioxide layer. Furthermore, a rise in the quantity of the beta phase of the titanium on the surface can be noticed as the applied voltage increases. As a result, it also affects the mechanical and tribological characteristics of the coating. The sample treated to a voltage of 250 V demonstrates a higher resistance to wear and a lower elastic modulus in comparison to the other two coatings.

The reconstruction of segmental bone defects requires patient-specific scaffolds that combine mechanical safety, biological functionality, and rapid manufacturing. We converted CT-derived mandibular geometry into a functionally graded Ti-6Al-4V lattice and optimised porosity, screw layout, and strut thickness through a cyber-physical loop that joins high-fidelity FEM, millisecond ANN, and a BN for uncertainty quantification. Fifteen candidate scaffolds were fabricated by direct metal laser sintering and hot isostatic pressing and were mechanically tested. FEM predicted stress and stiffness with 98% accuracy; the ANN reproduced these outputs with 94% fidelity while evaluating 10,000 designs in real time, and the BN limited failure probability to <3% under worst-case loads. The selected 55–65% porosity design reduced titanium use by 15%, shortened development time by 25% and raised multi-objective optimisation efficiency by 20% relative to a solid-plate baseline, while resisting a 600 N bite with a peak von Mises stress of 225 MPa and micromotion < 150 µm. Integrating physics-based simulation, AI speed, and probabilistic rigour yields a validated, additively manufactured scaffold that meets surgical timelines and biomechanical requirements, offering a transferable blueprint for functional scaffolds in bone and joint surgery.

Plasma electrolytic oxidation (PEO) is often used to improve the physical and mechanical properties of valve metals. This method allows for the formation of thicker and denser metal oxide coatings, which helps to improve physical and mechanical properties, especially the wear and corrosion resistance of the surface. The PEO process is widely used in areas such as mechanical engineering, aerospace, biomedical, and others. This review aims to summarize and explain the fundamental principles of the PEO process, with a focus on the influence of waveform types and their parameters on the properties of PEO coatings. This study found that a sinusoidal waveform promotes the generation of more stable discharges compared to a rectangular waveform, thereby enhancing the corrosion resistance of the coatings. Furthermore, it was demonstrated that using a rectangular waveform with adjustable parameters enables the production of thicker and more wear-resistant coatings. Meanwhile, the application of sawtooth and trapezoidal waveforms reduces sharp current spikes during the onset of discharges, minimizing defect formation and positively influencing the coating formation process. In addition, bipolar and unipolar modes are analyzed, and the promising future directions are discussed.

This study investigates the fabrication, characterization, and computational analysis of a Ti6Al4V porous scaffold for bone tissue engineering (BTE). The main objective is to address the stress-shielding effect caused by the mismatch in the mechanical properties between the scaffold and surrounding bone. An octet-truss architecture was considered to design a highly porous scaffold (with 80.5% porosity) and fabricated using selective laser melting (SLM). The scaffold was then treated with post-processing chemical etching in oxalic acid to remove surface defects and tailor topography. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) revealed that etching effectively removed adhered unmelted powder particles and created a distinct micro-textured strut surface (with increased roughness) that is conducive to osseointegration. The etching process also uniformly thinned down the struts and resulted in 10% mass loss. A compression test gave the scaffold’s compliance-corrected elastic moduli of 4.54 ± 0.18 GPa (pre-etching) and 3.53 ± 0.06 GPa (post-etching). These values closely match with the stiffness of human trabecular bone reported in the literature. The experimental modulus results were validated with a finite element model that predicted 4.188 GPa, which agrees well with the experiment. Furthermore, computational fluid dynamic simulations evaluated a permeability of 8 × 10^–9 m², consistent with transport in bone-like structures.

This article provides a comparative analysis of pendulum and radial micro-hydropower plants. The novelty of this study lies in the comparative analysis of units that are fundamentally different in design to achieve the most rational option for low-speed rivers. It has been established that a pendulum micro-hydropower plant has a high torque with relatively small dimensions but operates cyclically. At a diameter of 1 m and a blade area of 0.3 m², the peak torque was 140 N·m. At the same time, the design is sensitive to the blade area and at 0.6 m² and a lever length of 1.5 m, the torque reached 430 N·m. A radial micro-hydropower plant has lower torque but operates constantly. At an area of 1.23 m² and a diameter of 1 m, the torque was 40.4 N·m. Accordingly, in terms of specific area with a diameter of 1 m, a pendulum micro-hydropower plant has up to 12 times more torque. It has been established that the pendulum hydropower plant best satisfies the requirements for converting a low river speed into high revolutions of a current generator.