Evaluation of corrosion behaviour of advanced beta-titanium alloy: a comparison between 3D printing and conventional manufacturing methods

This study investigates the influence of various manufacturing processes on the corrosion behaviour of the Ti-25Nb-4Ta-8Sn beta titanium alloy, focusing on methods such as casting, powder metallurgy, and additive manufacturing (3D printing). The research aims to evaluate the material's microstructure and corrosion resistance, particularly in simulated body environments and fluoride-enriched solutions relevant to dental applications. The 3D-printed samples exhibited distinctive microstructural features, including melt pools and partially melted particles, which contributed to the presence of crevices and influenced their mechanical properties. Corrosion testing revealed that, while 3D-printed alloys displayed greater susceptibility to localized corrosion in neutral environments, they demonstrated improved corrosion resistance under aggressive conditions with fluoride ions. This improved performance was attributed to the formation of a more stable passive oxide layer. Comparative analysis of casting and powder metallurgy samples showed similar corrosion resistance, with differences primarily seen in more aggressive environments. These findings highlight the potential of 3D-printed beta titanium alloys in biomedical applications, particularly where exposure to aggressive conditions is expected. Further optimization of the additive manufacturing process could enhance the long-term durability and reliability of these alloys.