Behaviour of novel low-cost blended elemental Ti-5Fe-xAl alloys fabricated via powder metallurgy.

Ti alloys, generally made via wrought metallurgy, are commonly used as biomedical materials. The manufacturing of such alloys via powder metallurgy offers the possibility to reduce the cost as well as to develop innovative compositions not otherwise achievable. The aim of this study is to understand the effect that the progressive addition of Al has on the physical and mechanical behaviour of the low-cost powder metallurgy Ti-5Fe alloy for structural biomedical implants. Specifically, Ti-5Fe-xAl (x = 1-6 w.%) alloys were developed combining blending elemental and cold pressing plus vacuum sintering to further limit the manufacturing costs as Al is lighter and cheaper than Ti. This investigation demonstrates that the amount of Al added significantly changes the thermodynamics of the sintering process and induces microstructural modifications such as grain refinement. These effects jointly with the Al solid solution strengthening leads to progressively stronger and harder (but less ductile) α+β Ti alloys characterised by the typical α+β lamellar microstructure with mechanical behaviour suitable for a variety of structural biomedical implants.