Use of mechanical alloying to develop novel titanium alloy powders suitable for the selective laser melting process

Over recent years there has been a push to develop Titanium (Ti) implants with a customised compressive modulus that would mimic that of load bearing bones (i.e. 10-30 GPa). One of the approaches suggested to achieve the desired properties is by alloying Ti with biocompatible alloying elements, such as Niobium (Nb), at bespoke quantities. These alloys can then be used in Selective Laser Melting (SLM) and other AM processes, provided they have suitable particle size distributions, chemical homogeneity, and flowability. Commercial powders for AM are typically produced by atomisation routes, but this process is not financially viable unless large quantities of powdered material are produced, and therefore not suitable for small scale production such as a one-off patientspecific implant. This study assesses the feasibility of using low-volume, mechanically alloyed powders, of target Ti-Nb compositions for use in a SLM process.It investigates the particle distribution and flowability of the produced powders as well as the densification and microstructural properties of parts fabricated with them, using an array of physical and chemical tools and techniques.