The effect of build orientation on the microstructure and properties of selective laser melting Ti-6Al-4V for removable partial denture clasps

Abstract Statement of problem Selective laser melting (SLM) Ti-6Al-4V has been used for removable partial dentures, but the impact of SLM Ti-6Al-4V build orientation is not evident. Purpose The purpose of this in vitro study was to investigate the microstructure and properties of SLM Ti-6Al-4V clasps with different build orientations compared with cast Ti-6Al-4V clasps. Material and methods Forty-eight clasps were made from Ti-6Al-4V alloys—by SLM with 3 different build orientations (SLM0, SLM45, and SLM90) and cast (CAST) as a control. The microstructure was investigated by using a metallographic microscope and a confocal laser scanning microscope. The fit and surface roughness of the clasps were measured, and the physical properties were evaluated. In addition, the von Mises stresses in the clasps were calculated by finite element analysis. All specimens were then subjected to insertion and removal tests in artificial saliva to model 5 years of clinical use. After these tests, 3-point bend tests were used to analyze the fracture surface of the clasp arms, which were observed by using a scanning electron microscope. All data were statistically analyzed (α=.05). Results The microstructure of the Ti-6Al-4V specimens was a comixture of α+β phases. In addition, growth directions of β grains were approximately parallel to the build orientation, with acicular α grains present between β grains. SLM0 and SLM45 had significantly higher roughness than SLM90. Even though the fit was inferior to that of SLM90, SLM0 and SLM45 still performed better than cast specimens ( P P Conclusions The microstructure of SLM Ti-6Al-4V affected the properties of clasps by changing the anisotropy of specimens. Among the tested groups, SLM90 clasps had the best fit, the lowest surface roughness, and the best fatigue resistance. Furthermore, SLM Ti-6Al-4V clasps could be engaged into 0.50-mm undercuts.