Laser Powder Bed Fusion of a Ti-16Nb-Based Alloy: Processability, Microstructure, and Mechanical Properties

Titanium alloys, especially Ti6Al4V, are widely used in biomedical implants due to their biocompatibility and mechanical strength. However, their high elastic modulus (>100 GPa), compared to that of human bone (10–30 GPa), often causes stress shielding, reducing implant lifespan. To address this, titanium alloys with lower elastic modulus are under development. In this study, Ti-based multi-element alloy with 16 wt.% Nb samples were fabricated using laser powder bed fusion (L-PBF) from a premixed powder blend of Ti6Al4V and Nb-Hf-Ti. Processing high-melting Nb-based alloys via L-PBF poses challenges, which were mitigated through optimized parameters, including a maximum laser power of 100 W. Eleven parameter sets were employed to evaluate printability, microstructure, and mechanical properties. Microstructural analysis revealed Widmanstätten structures composed of α and β phases, along with isolated spherical pores. Reduced hatch spacing and slower laser speed led to increased hardness. The highest hardness (~43 HRC) was observed at the highest energy density (266 J/mm3), while the lowest (~28 HRC) corresponded to 44 J/mm3. Elastic modulus values ranged from 30 to 35 GPa, closely matching that of bone. These results demonstrate the potential of the developed Ti-based alloy containing 16 wt.% Nb as a promising candidate for load-bearing biomedical implants.