Predicting the onset of shear localization is among the most challenging problems in machining. This phenomenon affects the process outputs, such as machining forces, surface quality, and machined part tolerances. To predict this phenomenon, analytical, experimental, and numerical methods (especially finite element analysis) are widely used. However, the limitations of each method hinder their industrial applications, demanding a reliable and time-saving approach to predict shear localization onset. Additionally, since this phenomenon largely depends on the type and parameters of the constitutive material model, any change in these parameters requires a new set of simulations, which puts further restrictions on the application of finite element modeling. This study aims to overcome the computational efficiency of the finite element method to predict the onset of shear localization when machining Ti6Al4V using machine learning methods. The obtained results demonstrate that the FCM (fuzzy c-means) clustering ANFIS (adaptive network-based fuzzy inference system) has given better results in both training and testing when it is compared to the ANN (artificial neural network) architecture with an R2 of 0.9981. Regarding this, the FCM-ANFIS is a good candidate to calculate the critical cutting speed. To the best of the authors’ knowledge, this is the first study in the literature that uses a machine learning tool to predict shear localization.

Electrochemical treatments, such as electropolishing on titanium alloys, are used to promote the formation of nanostructured surfaces, which can contribute to the bone regeneration process. However, sterilization methods can change the superficial and physicochemical properties of the biomaterials. The objective of this work was to evaluate the effect of three sterilization methods (air plasma, ethanol + PBS, and autoclave sterilizations) on nanostructured Ti6Al4V surfaces properties obtained by electrochemical treatment. These methods, especially the first two, have been widely used in literature, yet few studies in the literature highlight the changes on the surface of the samples. The nanostructures were obtained by electropolishing in a H2SO4/HF/glycerine solution, at 25 V and at 7 °C for 4 min. Samples were characterized by atomic force microscopy (AFM), profilometry, and wettability. Samples were seeded with hESC-MPs, and the cell number was measured. The air plasma sterilization did not promote changes in nanometric morphology and roughness of the Ti6Al4V nanostructured samples. Unlike air plasma sterilization, the ethanol + PBS and the autoclave sterilizations, which strongly affected the nanostructured surface morphology and properties, and, consequently, the cellular viability after 7 days of contact with human embryonic stem cell-derived mesenchymal progenitors (hESC-MPs).

Seeking to improve the wear resistance of the Ti6Al4V (Ti64) alloy for biomedical applications, carbon nanotubes (CNTs) and calcium phosphate (CaP) ceramics were added to Ti64 powder and successfully 3D-printed using a commercial laser engineered net shaping (LENS™) system. It was hypothesized that CNTs would allow for in situ carbide formation during laser processing, resulting in increased surface hardness. It was also hypothesized that CaPs would allow for protective tribofilm formation during wear, reducing material loss from wear-induced damage. Scanning electron microscopy images reveal defect-free microstructures with fine carbides evenly distributed, while X-ray diffraction confirms the presence of carbides without additional unwanted intermetallic phases. Vickers microhardness shows an increase in surface hardness in coatings containing both CNTs and CaPs. In vitro tribological studies found reduced coefficient of friction, reduced wear rates, and reduced metal ion-release concentrations in coatings containing both CNTs and CaPs. This study demonstrates the efficacy of CNTs and CaPs to improve wear resistance of Ti64 for potential applications in articulating surfaces of load-bearing implants.

Sterilization is one of the last stages prior to the implantation of a biomaterial. Therefore, the method should be chosen carefully as this is determinant not to compromise the properties of the material. In this context, three sterilization processes were evaluated as to their effect on the properties of a silane hybrid coating: steam autoclave, ethylene oxide, and hydrogen peroxide plasma. The coating was obtained from a sol consisting of alkoxysilane Tetraethoxysilane and organoalcoxysilane Methyltriethoxysilane (MTES), applied to the Ti6Al4V substrate, to increase its corrosion resistance and biocompatibility. After sterilization, the samples were characterized by scanning electron microscopy, atomic force microscopy, profilometry, wetabillity, and Fourier transform infrared spectroscopy. The electrochemical behavior was monitored by open circuit potential and potentiodynamic polarization curves. The cytocompatibility was evaluated by adhesion, viability, and morphological alterations in the MG-63 cells. The results showed that the protective behavior of the hybrid coating was compromised regardless of the sterilization method. However, the steam autoclave caused more morphological changes on the silane hybrid coating as well as on the Ti6Al4V substrate than the other two sterilization methods. Although the sterilized hybrid coating did not show cytotoxicity, the hybrid coating sterilized by hydrogen peroxide plasma showed a higher percentage of viable cells. The ethylene oxide presented the lowest percentage of viability and the highest cell death rate.

Ti6Al4V alloys usually need to undergo some kind of surface treatment to enable good bone growth and implant integration. In this work, three treatments that modify the titanium alloy surface were studied with the aim of promoting osteogenic differentiation of human-embryonic-stem-cell-derived mesenchymal progenitors (hESC-MPs). The surface treatments used were mechanical polishing and electropolishing for 4 or 12 min in an H2SO4/HF/glycerine solution. The samples were characterised by atomic force microscopy, profilometry, X-ray photoelectron spectroscopy, and wettability. Samples were seeded with hESC-MPs in osteogenic media, and the cell number and alkaline phosphatase activity were measured. The electropolishing surface treatments influenced the nanometric morphology and wettability. However, the electropolished surfaces contributed in the same way as the mechanically polished surface to osteogenic differentiation, indicating that differentiation was strongly influenced by microroughness, which did not differ among the treatments used in the present work.

Interaction of a Nd:YAG laser, operating at wavelengths of 1064 nm (23.6 J cm−2 fluence) or 532 nm (25.9 J cm−2 fluence), and pulse duration of 40 ps, with a titanium-based medical implant Ti6Al4V alloy was studied. Surface damage thresholds were estimated to be 0.9 J cm−2 and 0.25 J cm−2 at laser wavelengths 1064 nm and 532 nm, respectively. At both laser wavelengths, the energy absorbed was mostly converted into thermal energy, forming craters, albeit about 50 times deeper at 1064 nm than at 532 nm. Periodic surface structures (PSS) were also formed with both laser wavelengths, concentric, and radial at micrometer scale (3 µm to 15 µm period), parallel at nanometer scale (800 nm period with the 1064 nm laser, 400 nm with the 532 nm laser). In the case of the 532 nm laser, the concentric structures enlarge their period with accumulating laser pulse count. These features can help roughening of the implant surface and improve bio-compatibility.