LAUSR

To reduce the wear related damage of medical grade Ti-6Al-4V alloy, laser engineered net shaping (LENS™) based in situ reactive multi-material additive manufacturing was employed to process a mixed coating of Ti-6Al-4V powder and calcium phosphate (CaP) in an oxygen free, nitrogen-argon environment. The resultant coatings were composite materials of titanium nitrides and calcium titanate in an α-Ti matrix. Hardness was increased by up to ~148% to 868 ± 9 HV as compared to the untreated Ti-6Al-4V substrate. Similarly, when tribological properties were evaluated in deionized (DI) water medium against alumina counter material, the wear damage was reduced by ~91% as compared to the untreated Ti-6Al-4V substrate. Furthermore, the untreated Ti-6Al-4V substrate released Ti ions of ~12.45 ppm concentration during wear whereas the Ti6Al4V-5%CaP coating processed in an argon-nitrogen environment released ions of ~3.17 ppm concentration under similar testing conditions. The overall coefficient of friction was also found to decrease due to the addition of CaP and processing the Ti6Al4V-CaP mixture in an argon-nitrogen environment. Our results indicate that this reactive multi-material additive manufacturing of metal-ceramic composites is an effective way of enhancing the tribological performance of metallic materials.