Metal Ion Release from PEO-Coated Ti6Al4V DMLS Alloy for Orthopedic Implants

This study investigates the influence of plasma electrolytic oxidation (PEO) on corrosion resistance of Ti6Al4V alloys produced by direct metal laser sintering (DMLS) for orthopedic implants. PEO (300 s) and flash-PEO (60 s) coatings containing Si, Ca, P, Mg and Zn were applied on both DMLS and wrought Ti6Al4V alloys. Samples, coated and uncoated, were characterized for microstructure, morphology and composition. Electrochemical behaviour was assessed by potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) in simulated body fluid (SBF) at 37 °C. Ion release was quantified by inductively coupled plasma optical emission spectroscopy (ICP-OES). DMLS alloy was more passive than wrought Ti6Al4V, releasing ~60% less Ti and ~25% less Al, but ~900% more V. For both alloys, correlation of corrosion current and ion release indicated that 98-99% of oxidized Ti remained in the passive layer. Flash-PEO produced uniform porous coatings composed of anatase and rutile with ~50% amorphous phase, while PEO yielded heterogeneous layers due to soft sparking. In both cases, coatings were the main source of ions. For the DMLS alloy, the best protection was afforded by flash-PEO, releasing 0.01 μg cm^-2 d^-1 Ti, 26 μg cm^-2 d^-1 Al, and 0.25 μg cm^-2 d^-1 V over 30 days.