The Ti-6Al-4V alloy is widely used in the manufacture of components that must have low density and high corrosion resistance and fatigue strength. The fatigue strength can be improved by surface modification. The aim of this study was to determine the influence of plasma nitriding on the fatigue behavior of a Ti-6Al-4V alloy with a lamellar microstructure (Widmanstätten type). Nitriding was executed at 720 °C for 4 h in an atmosphere with N₂, Ar, and H₂. Microstructure characterization of the samples was carried out by X-ray diffraction analysis, optical microscopy, and scanning electron microscopy. The average roughness of the specimens was determined, and fatigue tests were executed in a bending–rotating machine with reverse tension cycles (R = −1). X-ray diffraction analysis of the nitrided alloy revealed the following matrix phases: α, β, ε-Ti₂N, and δ-TiN. A nitrogen diffusion layer was formed between the substrate and the titanium nitrides. Plasma nitriding resulted in an increase in low-cycle fatigue strength, whereas at high cycles of 200 MPa, both conditions exhibited similar behaviors. The fracture surface of the fatigue-tested specimens clearly revealed the lamellar microstructure. The fracture mechanism in the non-nitrided specimens appears to be due to cracking at the interface of the α and β phases of the lamellar microstructure.

AlSi10Mg has been one of the most studied and employed aluminum alloys for additive manufacturing via laser powder-bed fusion (L-PBF). The optimization of manufacturing parameters is important for reducing internal defects, including porosity and inadequate surface finishes. In addition, heat treatments, such as T6, are often applied to this alloy, but they degrade the characteristic microstructure obtained via L-PBF additive manufacturing—the fine cellular structures—which may, in turn, detrimentally affect the material’s properties. In this context, a new alternative to this treatment, direct aging (DA), has shown promise in improving the mechanical properties of AlSi10Mg parts produced via L-PBF, since it preserves the cellular microstructure, precipitating silicon-rich nanoparticles within the cells. Understanding how different temperatures and heat treatment times influence the microstructure and, consequently, the properties remains a field to be explored in order to optimize the treatment conditions and achieve better mechanical properties. Thus, the objective of this study was to evaluate the influence of manufacturing parameters and heat treatments on the microstructure and mechanical properties of AlSi10Mg alloy. The optimized manufacturing conditions were 300 W power, 800 mm/s scan speed, 30 µm layer thickness, and an argon atmosphere, which led to lower porosity and better finishing. Samples were heat-treated via DA at 150 °C and 170 °C for different times, as well as undergoing a T6 treatment (solution at 520 °C followed by aging at 150 °C and 170 °C). Initially, the aging curves show higher hardness values for the direct aging condition, compared to the T6 and as-built conditions, reaching a peak hardness of 195 HV for 6h of direct aging. In this way, it was followed with microstructural characterization, which demonstrated that DA maintained the fine cell microstructure of L-PBF and promoted the precipitation of Si nanoparticles, which certainly contributed to the increase in hardness compared to T6, which promoted a structure with coarser precipitates. DA at 170 °C for 6 h increased the tensile strength to 430 MPa, compared to the as-built condition, with a slight loss of ductility.

Nickel superalloy Inconel 718 (IN718) is widely employed in harsh environments with prolonged cyclic stresses in the aerospace and energy sectors, due to its corrosion/oxidation resistance and mechanical strength obtained by precipitation hardening. This work investigates the mechanical behavior in fatigue of IN718 manufactured by Additive Manufacturing (AM), specifically by Laser Powder Bed Fusion (PBF-LB), and compares its results with the material produced by forging and rolling. Samples from both processes were subjected to heat treatments of solution and double aging to increase their mechanical strength. Then, tensile, microhardness, microstructural characterization, and uniaxial fatigue tests were performed (with loading ratio R = −1). The results showed that, although the IN718 produced by AM had higher microhardness and a higher tensile strength limit than the forged and rolled material, its fatigue performance was lower. The S–N curve (stress vs. number of cycles) for the material obtained by PBF-LB demonstrated shorter fatigue life, especially under low and medium stresses. The analysis of the fracture surfaces revealed differences in the regions where the crack initiated and propagated. The shorter fatigue life of the material obtained by PBF-LB was attributed to typical process defects and microstructural differences, such as the shape of the grains, which act as points of crack nucleation.

Combining metallic additive manufacturing with laser texturing could be an alternative in obtaining parts with functional hydrophilic surfaces, which improves osteointegration. Careful study of the corrosion behavior of the surfaces obtained is necessary, because the evolution of this phenomenon can influence the osteointegration of the implant, causing the release of metal ions in the body and even the rejection of the component. This study compared the corrosion behavior of laser texturing Ti6Al4V components with components manufactured using laser power bed fusion of the same alloy followed by laser texturing. Their microstructure, roughness, wettability, and electrochemical behavior were analyzed, and different morphologies and microtopographies were observed comparing both samples. The electrochemical tests obtained indicate that Ti6Al4V showed higher corrosion resistance than L-PBF Ti6Al4V after laser texturing. The results suggest that laser texturing can encourage cell proliferation and osseointegration on the surface of Ti6Al4V biomedical implants.

Ti alloys are widely used in severe corrosion environments where corrosion resistance is required, as biomedical industry. Additive manufacturing produces customized and complexes products. Laser texturing is a process of structuring surfaces using laser pulses, that allows the creation of periodic patterns on the surfaces of materials, to modify them, functionally and/or aesthetically, in a precise and direct way, allowing parameterization, versatility and repeatability. Consequently, bringing together metallic additive manufacturing with laser texturing process could be an alternative to obtain parts with functional hydrophilic surfaces, which improves osteointegration and reduces bacteria adhesion. Thus, the aim of this work is to characterize and evaluate the influence of LASER parameters in as-built additive manufactured potential biomedical components. Ti6Al4V specimens were produced by L-PBF, using Ytterbium LASER with maximum power of 500 W, varying the laser power from 61 W to 244 W. The samples were characterized by SEM, Microhardness, and wettability. After that, some specimens were Laser textured using an Ytterbium optical fiber laser, and then evaluated by SEM, wettability, and 3D roughness. It was possible to observe that the surface of all studied samples was flattened after Laser texturing in comparison with as-built condition, due to the melting of the powder particles.

Additive manufacturing using laser powder bed fusion (LPBF) has been widely used to produce nickel-based superalloy components with complex shapes for high-temperature applications requiring creep resistance. In this research, the creep behavior of LPBF Inconel 718 under solution and double-aging heat treatments, performed at 590–650 °C under stresses of 450–550 MPa, is studied. The characterization included optical microscopy, scanning electron microscopy (SEM), porosity analysis, Vickers microhardness tests, and fracture surface examination. The findings revealed that even after heat treatment, the material maintained a mainly directional, columnar microstructure, with an average porosity below 1%, which was unevenly distributed and contained critical defects related to lack-of-fusion (LOF) and trapped powder. Fracture after creep presents regions of ductile failure alongside facets indicative of quasi-cleavage. Kinetic analysis revealed a high stress exponent (n = 18.26) and an activation energy (Qc = 410–538 kJ/mol), indicating that the deformation operates within the power-law breakdown (PLB) regime, where dislocation–precipitate interactions govern the creep rate in this precipitation-strengthened superalloy. Overall, the results highlight that the directional microstructure and residual defects typical of LPBF can reduce the creep resistance of Inconel 718, underscoring the importance of post-processing methods and internal defect control specifically tailored for additively manufactured materials.