Microstructures and mechanical properties of electron beam-rapid manufactured Ti-6Al-4V biomedical prototypes compared to wrought Ti-6Al-4V

This study represents an exploratory characterization and comparison of electron-beam melted (EBM) or rapid manufacturing (RM) of Ti-6Al-4V components (from nominal 30 μm diameter powder) with wrought products. Acicular α and associated β microstructures observed by optical metallography and electron microscopy (SEM and TEM) are compared along with corresponding tensile test and hardness data; including the initial powder particles where the Vickers microindentation hardness averaged 5.0 GPa in comparison with the fully dense, EB manufactured product with an average microindentation hardness ranging from 3.6 to 3.9 GPa. This compared with wrought products where the Vickers microindentation hardness averaged 4.0 GPa. Values of UTS for the EBM samples averaged 1.18 GPa for elongations ranging from 16 to 25%. Biomaterials/biomedical applications of EBM prototypes in direct prosthesis or implant manufacturing from CT or MRI data are discussed in the context of this work, especially prospects for tailoring physical properties through EB control to achieve customized and optimized implant and prosthetic products direct from CT-scans.