The impact of post manufacturing treatment of functionally graded Ti6Al4V scaffolds on their surface morphology and mechanical strength

An ultrasonic vibration post-treatment procedure was suggested for additively manufactured lattices. The aim of the present research was to investigate mechanical properties and the differences in mechanical behavior and fracture modes of Ti6Al4V scaffolds treated with traditional powder recovery system (PRS) and ultrasound vibration (USV). Scanning electron microscopy (SEM) was used to investigate the strut surface and the fracture surface morphology. X-ray computed tomography (CT) was employed to evaluate the inner structure, strut dimensions, pore size, as well as the surface morphology of additively manufactured porous scaffolds. Uniaxial compression tests were conducted to obtain elastic modulus, compressive ultimate strength and yield stress. Finite element analysis was performed for a body-centered cubic (BCC) element-based model and for CT-based reconstruction data, as well as for a two-zone scaffold model to evaluate stress distribution during elastic deformation. The scaffold with PRS post treatment displayed ductile behavior, while USV treated scaffold displayed fragile behavior. Double barrel formation of PRS treated scaffold was observed during deformation. Finite element analysis for the CT-based reconstruction revealed the strong impact of surface morphology on the stress distribution in comparison with BCC cell model because of partially molten metal particles on the surface of struts, which usually remain unstressed.