Microstructural and fatigue properties of dental structures produced via selective laser melting: comparing Co-Cr-Mo, Co-Cr-Mo-W and Co-Cr-W alloys

Purpose The primary goal of this research is to explore the microstructural characteristics and fatigue properties of dental metallic structures produced from Co-Cr-Mo, Co-Cr-Mo-W and Co-Cr-W alloys using selective laser melting (SLM). This study aims to provide a deeper understanding of how different alloy compositions impact the microstructure and mechanical properties post-manufacture and heat treatment. Design/methodology/approach This study uses a comparative analysis where dental metallic frameworks made from three distinct Co-Cr alloy variations are manufactured using SLM. The samples are subjected to identical post-processing heat treatments to evaluate changes in microstructure, microhardness and fatigue strength. The methodology incorporates microstructural analysis techniques, fatigue resistance testing and statistical assessments to draw meaningful conclusions. Findings The findings indicate that heat treatment significantly alters the microstructure of these alloys, promoting the formation of precipitates that enhance mechanical properties. Specifically, the Co-Cr-W alloy displayed superior fatigue resistance, attributed to the presence of W-rich precipitates at grain boundaries. This study highlights the critical influence of alloy composition on the performance of dental alloys produced via SLM. Originality/value This research contributes original insights into the fatigue behavior of Co-Cr alloys used in dental applications, a topic that has not been extensively studied before. The comparative analysis of three alloy systems provides valuable data that could influence future material selection and processing conditions in dental alloy manufacturing. The study’s findings could potentially lead to improved durability and performance of dental prosthetics, offering significant value to materials science and dental engineering fields.