This study focuses on the control of density and grain structure of a superelastic Ti-18Zr-14Nb (at. %) alloy subjected to laser powder bed fusion. It starts with the production and characterization of a Ti-18Zr-14Nb powder feedstock and printing of a series of calibration specimens. These specimens are next subjected to chemical, structural, phase and texture analyses in order to collect experimental data needed to build simulation-driven processing maps in the laser energy density–material build rate coordinates. The results of this study prove that, once calibrated, the simulation-driven processing maps can be used to relate the main LPBF parameters (laser power, scanning speed, hatching distance and layer thickness) to the density and grain structure of the printed material, and the process productivity (build rate). Even though this demonstration is made for a specific material–system combination (TiNbZr & TruPrint 1000), such a process mapping is feasible for any material–system combination and can, therefore, be exploited for the process optimization purposes and for manufacturing of functionally graded materials or parts with intentionally seeded porosity.

In this work, the microstructure, phase state, texture, superelastic and mechanical properties of a Ti–18Zr–15Nb (at. %) shape memory alloy subjected to a combined thermomechanical treatment, including hot rotary forging with either air cooling or water quenching and post-deformation annealing are studied. It was revealed that the main structural component of the deformed and annealed alloy is BCC β-phase. With an increase in the forging temperature from 600 to 700 °C, the average grain size increases from 5.4 to 17.8 µm for the air-cooled specimens and from 3.4 to 14.7 µm for the water-quenched specimens. Annealing at 525 °C after forging at 700 °C with water quenching leads to the formation of a mixed statically and dynamically polygonized substructure of β-phase. In this state, the alloy demonstrates the best combination of functional properties in this study: a Young’s modulus of ~33 GPa, an ultimate tensile strength of ~600 MPa and a superelastic recovery strain of ~3.4%.

The Ti-18Zr-15Nb shape memory alloys are a new material for medical implants. The regularities of phase transformations during heating of this alloy in the coarse-grained quenched state and the nanostructured state after high-pressure torsion have been studied. The specimens in quenched state (Q) and HPT state were annealed at 300–550 °C for 0.5, 3, and 12 h. The α-phase formation in Ti-18Zr-15Nb alloy occurs by C-shaped kinetics with a pronounced peak near 400–450 °C for Q state and near 350–450 °C for HPT state, and stops or slows down at higher and lower annealing temperatures. The formation of a nanostructured state in the Ti-18Zr-15Nb alloy as a result of HPT suppresses the β→ω phase transformation during low-temperature annealing (300–350 °C), but activates the β→α phase transformation. In the Q-state the α-phase during annealing at 450–500 °C is formed in the form of plates with a length of tens of microns. The α-phase formed during annealing of nanostructured specimens has the appearance of nanosized particle-grains of predominantly equiaxed shape, distributed between the nanograins of β-phase. The changes in microhardness during annealing of Q-specimens correlate with changes in phase composition during aging.

Ti-Zr-Nb shape memory alloys exhibit a unique combination of properties that make them suitable for bone implants: low Young’s modulus, superelastic behavior, superior corrosion resistance, and non-toxicity of all the constitutive elements.