Ti-Ta-Cu Biocompatible Alloy System Development via Selective Laser Melting for Prosthetic Applications

This study investigated the development of Ti-Ta-Cu alloys via selective laser melting (SLM) for potential prosthetic applications. Ti-Ta-Cu alloys with 10, 15, and 20 wt.% Ta were fabricated using in situ alloying of elemental powders. We examined the effects of Ta content and SLM processing parameters on microstructure, phase composition, mechanical properties, and corrosion resistance. X-ray diffraction analysis revealed an increase in β-phase content with increasing Ta concentration. Microstructural analysis showed a dendritic structure in Ta-rich areas, with remelting strategies improving chemical homogeneity and Ta dissolution. The Ti-20Ta-5Cu alloy exhibited the best balance of strength and ductility, with an ultimate tensile strength of 1011 MPa and elongation of 5.7%. All compositions demonstrated lower elastic moduli (103–109 GPa) compared to traditional titanium alloys. Microhardness values were highest for Ti-15Ta-5Cu, ranging from 359 to 410 HV0.5 depending on SLM parameters. Corrosion testing in Hank’s solution showed improved pitting resistance for Ti-15Ta-5Cu and Ti-20Ta-5Cu compared to Ti-10Ta-5Cu. The study demonstrates the feasibility of producing Ti-Ta-Cu alloys with tailored properties via SLM, offering potential for customized prosthetic applications with improved biomechanical compatibility and functionality.