Effect of Iron on the Microstructure, Mechanical Properties, Corrosion Behavior, and Biocompatibility of Mechanically Alloyed Zn-3Ag Biodegradable Alloys

Novel pure Zn and Zn-3Ag-xFe (x = 0, 1, 3, 5) (wt.%) nanocrystalline powders were synthesized for potential use as implants and stent materials by the mechanical alloying (MA) technique. The morphological and structural alterations of the powders milled for 5, 10, and 20 h were examined. SEM research revealed that during MA, the original elemental powder particles were subjected to a cold-welding process, subsequently fracturing in a brittle manner. The EDX spectra of the powders milled for 20 h indicated a uniform distribution of components. Laser diffraction particle size examination proved that the Zn-3Ag-1Fe alloy had the smallest particle size at 58.8 µm. XRD examination indicates the existence of AgZn₃ and Fe₃Zn₁₀ intermetallic phases. The crystallite size diminishes with prolonged milling time, decreasing from 130 nm to 30 nm. The porosity rose from 11.62% for pure Zn to 15.35% in the Zn-3Ag-5Fe alloy, suggesting that the incorporation of Ag and the higher Fe ratio diminished the compressibility of the milled powders, as evidenced by density tests. The Zn-3Ag-5Fe alloy exhibited the maximum corrosion current density of 164.65 µA/cm², attributed to the microgalvanic effect and reduced relative density induced by the Fe₃Zn₁₀ phase, which escalated with higher Fe doping. The hardness of the Zn-3Ag-5Fe alloy rose from 34.5 ± 2.8 HV to 132.2 ± 4.6 HV compared to the pure Zn sample, while the wear coefficient decreased from 0.029 ± 0.003 mm³/Nm to 0.005 ± 0.001 mm³/Nm, corresponding with the hardness test results. In contrast to <i>S. aureus</i>, which exhibited an 87.8% susceptibility to antibacterial activity from 3% silver and iron additions, <i>E. coli</i> demonstrated over 85% susceptibility to antibacterial activity from silver addition alone. The Zn-3Ag and Zn-3Ag-1Fe samples demonstrated high biocompatibility, attaining cell survival rates of 99.2% ± 3.01% and 99.2% ± 4.02% for the 12.5% extract, respectively. This study demonstrates that the newly developed Zn-Ag-xFe alloys have exceptional mechanical properties and excellent biocompatibility. Furthermore, the variable biodegradation rate dependent on alloy type presents an avenue for further research.