Finite Element Analysis and Mechanical Testing of Titanium Alloy (Ti-6Al-4V) and Silicon Carbide (SiC) for Hip Implants

Resumo

Orthopedic surgical implants have traditionally been produced using conventional manufacturing techniques, with the output of these methods depending on the weight of the fabricated component and its biologically sourced materials. These hip implant composites, when exposed to physiological conditions over extended periods, particularly blood and adjacent soft tissues, are susceptible to gradual material degradation, manifesting as corrosion-induced damage and structural compromises. To address these challenges, this study focused on the development of titanium-containing composite material devices, primarily incorporating silicon carbide as a supporting component. The devices were cast via high-temperature sintering, facilitated by a specialized die assembly. The geometric design, material composition, and dimensional precision of these die sets are critical factors that determine the compressing efficiency and, consequently, the quality of the resulting sintered products. Therefore, this study emphasizes the design and application of a sintering die set optimized for cold uniaxial compression to produce cylindrical green packs characterized by a consistent layout and sufficient mechanical strength before the heated compression process. The compaction die set is a crucial component of the powder metallurgy method, which is responsible for shaping loose powder into the intended form. The die set was designed in accordance with the ASTM standards, and AISI D3 steel was used for its fabrication. This study also elaborates on the design factors, calculations, 2-D drawings, and 3-D models related to the die set. The die was manufactured using processes such as facing, turning, drilling, grinding, wire-cut electrical discharge machining (EDM), and heat treatment. The design was analyzed using SolidWorks 14 and ANSYS 2023R1. Following the evaluation of the safe load and production of the die set, the specimens were characterized. Scanning electron microscopy (SEM) evaluation identified the grain boundaries and porosity of the material, and mechanical tests demonstrated satisfactory hardness and biocompatibility.