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Abstract
In this study, comparative investigation of thermal oxidation treatment for Ti6Al4V was carried out to determine the optimum
oxidation conditions for further evaluation of corrosionwear performance. Characterization of modied surface layers was made
by means of microscopic examinations, hardness measurements and X-ray diffraction analysis. Optimum oxidation condition was
determined according to the results of accelerated corrosion tests made in 5 m HCl solution The examined Ti6Al4V alloy exhibited
excellent resistance to corrosion after oxidation at 600 C for 60 h. This oxidation condition achieved 25 times higher wear resistance
than the untreated alloy during reciprocating wear test conducted in a 0.9% NaCl solution.
r 2003 Elsevier Ltd. All rights reserved.
0142-9612/$ - see front matter r 2003 Elsevier Ltd. All rights reserved.
doi:10.1016/j.biomaterials.2003.10.009
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dried in hot air. Thermal oxidation treatments were containing 5 m HCl for 60 h. The minimum amount of
conducted at 600 C and 650 C for between 12 and 60 h the solution reacting in the corrosion tests was
at normal atmospheric condition. After characterization determined, taking into account the surface area of the
studies, corrosion and corrosionwear tests were samples as 0.3 ml/mm2 [15]. During the corrosion tests
performed on untreated and oxidized samples. the temperature of the solution was 2474 C. The
results of the corrosion tests were evaluated by measur-
2.1. Characterization tests ing the weight loss of the samples at certain intervals,
with an accuracy of 0.1 mg. After the test period of 60 h
Characterization of the surfaces was made by surface the surface appearances of the samples were examined
roughness and hardness measurements, X-ray diffrac- with a microscope at 10 magnication.
tion (XRD) analysis and optical microscopic examina-
tions. Three samples were averaged at each 2.3. Corrosionwear tests
characterization test to accurately determine relevant
properties. Corrosionwear tests were conducted on a reciprocat-
ing wear tester described in ASTM G133 standard. The
2.1.1. Surface roughness measurements length and the width of the wear test samples, which
A Mahr Perthen Perthometer S8P optical prol- were sliced from the transverse section of the 8 mm
ometer was used to examine the surface roughness of the diameter rod, were 20 and 8 mm, respectively. Two
samples. The effect of oxidation conditions on surface samples were tested to examine the wear performance of
roughness was determined according to average rough- each surface condition. During wear testing 150 g
ness (Ra) values, which dene the arithmetic mean of normal load was applied on the surfaces of the samples
departure of a surface prole from a mean line. with a 10 mm diameter Al2O3 ball. A commercially
available isotonic serum containing 0.9% NaCl was
2.1.2. Hardness measurements used as corrosive environment to simulate the corrosive
Hardness tests were carried out with a Vickers effect of the human body. Sliding speed of the ball was
pyramid indenter, using a Fischer HP 100 XY-PROG 20 mm/s and the stroke of the reciprocating motion was
ultramicrohardness tester. Hardness measurements were 9 mm. Wear tests were interrupted at certain intervals to
performed on the surfaces of the samples under four determine the progress of wear. At each interval samples
different indentation loads, ranging from 250 to were cleaned with alcohol and wear tracks were
1000 mN. At each load level, at least 10 successive examined by a surface prolometer. After examining
measurements were made. the wear tracks developed on the surfaces, the samples
were returned to the wear tester in their original
2.1.3. XRD analysis arrangement. Wear tests were performed for 300 min.
A Philips RV 3710 X-ray diffractometer was used for After the wear tests, wear tracks that developed on the
the XRD analysis. The glancing incidence X-ray untreated and oxidized surfaces were investigated by a
diffraction technique was used for surface phase JEOL JSM 6335 F scanning electron microscope (SEM).
identication of oxidized samples. CuKa radiation The wear of the Al2O3 balls was also examined with an
source was used and the incidence beam angle was 2 . optical microscope at the end of the wear tests.
Diffraction angle range was between 10 and 90 , with a
step increment of 0.02 and a count time of 1 s.
3. Results
2.1.4. Microscopic examinations
Microstructural examinations were conducted on the 3.1. Characterization tests
cross-sections of the oxidized samples with a Zeiss light
optical microscope. Cross-sections of the oxidized After thermal oxidation the surface of the Ti6Al4V
samples were prepared by standard metallographic alloy was covered with a dark colored oxide layer.
technique. After grinding and polishing metallographic Roughness of oxidized surfaces increased drastically
samples were etched with 2% HF solution. with increasing oxidation time and temperature as
presented in Fig. 1. Average roughness of untreated
2.2. Corrosion tests sample was 0.17 mm before oxidation.
XRD patterns of the untreated and oxidized samples
Accelerated corrosion tests were conducted to evalu- are given in Fig. 2. a-Ti and b-Ti peaks were obtained at
ate the relative corrosion resistance of untreated and different diffraction angles corresponding to different
oxidized samples. Two samples were used for each crystallographic planes of untreated alloy (Fig. 2a).
surface condition. Samples having 8 mm diameter and They were also observed after oxidation at 600 C
8 mm height were suspended in an acidic solution (Fig. 2b). This was basically, due to penetration of
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Fig. 3. The effect of oxidation temperature on the Vickers hardness (HV) values of oxidized surfaces for oxidation times of: (a) 12, (b) 24, (c) 36,
(d) 48 and (e) 60 h.
Fig. 4. Cross-sectional optical micrographs of the samples oxidized (a) at 600 C for 60 h and (b) at 650 C for 60 h (OL: Oxide layer, ODZ: Oxygen
diffusion zone).
samples, was sustained throughout the testing period. time. Longer oxidation times at 600 C formed a thicker
No measurable weight loss was obtained on the samples protective surface layer, which did not show any weight
that were oxidized at 650 C for duration times of 12 and loss in 36 h. Among the investigated materials, the
36 h. Prolonged corrosion tests resulted in abrupt sample oxidized at 600 C for 60 h exhibited the
increase in weight loss due to aking and removal of maximum corrosion resistance.
the oxide scales. For the samples oxidized at 600 C, Fig. 7 shows the optical micrographs of the cylindrical
weight loss gradually increased with increasing duration surfaces of the samples after corrosion testing time of
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Fig. 8. 3-D surface proles of untreated and oxidized surfaces at certain intervals of corrosion wear tests.
oxidized at 600 C for 60 h in a mild corrosive media. testing time of 300 min are presented. The wear tracks
Fig. 8 displays the 3-D proles of the wear tracks produced on these samples exhibited different topogra-
developed on the untreated and oxidized surfaces at phy. A typical feature of rough wear track produced on
certain intervals of corrosionwear tests. It is clearly untreated surface was extensive shear deformation due
seen that shallower and narrower wear track was formed to ploughing action of the Al2O3 ball (Fig. 10a). The
on oxidized surfaces than untreated ones. The results of wear tracks on oxidized surface were smooth (Fig. 10b)
corrosionwear tests were quantied by measuring the and contained microcracks with traces of local material
cross-sectional areas of the wear tracks from their 2-D removal (Fig. 10c). Thus, on oxidized surface wear was
proles. Fig. 9 graphically shows the progress of wear initiated by disruption of oxide layer and followed by
track area with respect to testing time. Steady wear of the wear of oxygen diffusion zone, which was locally
untreated surface was restrained by thermal oxidation. removed by cracking at extended testing times.
Accordingly, oxidized surface exhibited approximately The Al2O3 balls were also subjected to wear during
25 times higher corrosionwear resistance than the testing. The wear scars formed on the balls are depicted
untreated alloy, after testing time of 300 min. in Fig. 11. Optical microscopic examinations revealed
In Fig. 10 SEM micrographs of the wear tracks that, heavy wear of the ball on untreated surface
developed on the untreated and oxidized surfaces after a progressed by grain pull out mechanism. The topogra-
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phy of wear scar developed on the ball that slid on the 4. Discussion
oxidized surface was almost similar with that of
untreated surface but smaller by a factor of 16. Thus, Thermal oxidation at 600 C and 650 C modied the
the size of wear scar was proportional to the size of the surface of the examined Ti6Al4V alloy by introducing
wear track formed on the surface of the material being an oxide layer (anatase and/or rutile) with an oxygen
tested. diffusion zone beneath it. Increase of surface hardness
after thermal oxidation can be attributed to the hard
oxide layer covering the surface and contribution of
strains in the matrix due to dissolution of oxygen
[16,17].
The thickness of the oxide layer and oxygen diffusion
zone increased with increasing oxidation time. However,
growth of the oxide layer during thermal oxidation was
accompanied by surface roughening. The thickness and
the roughness of the oxide layer increased in an
accelerated manner, when oxidation was conducted at
650 C. This situation afrms the role of temperature on
oxidation rate by activating diffusing species. On the
other hand, accelerated oxidation rate due to increasing
temperature may put the whole oxide layer in a more
stressed condition as a result of intrinsic and thermal
effects [18,19]. The formation of defective oxide
structure provides easy diffusion paths for oxygen and
metal ions allowing oxidation progress in an uncontrol-
lable way. Since the corrosion resistance of thermally
oxidized surface layers relies on their chemical stability
Fig. 9. Progress of wear track areas during corrosionwear tests. and defect free structure, this observation may also be
Fig. 10. SEM micrographs of the wear tracks developed on (a) untreated and (b) oxidized surfaces. High magnication of the framed region is shown
in the in micrograph (c).
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Fig. 11. The wear scars that formed on Al2O3 balls during corrosionwear testing of: (a) untreated, and (b) oxidized surfaces.
valid for explaining the corrosion behavior of oxidized defective structure, it was subjected to mechanical
samples because strong reducing acids would not stresses during corrosionwear test. This situation
dissolve heavy oxide layer on titanium [20]. Small caused the local breakdown of the oxide layer and
structural defects (microcracks and micropores) may allowed the corrosive solution to enter the oxideoxygen
be responsible for the failure of oxidized surfaces [21]. diffusion zone interface. The oxide layer was gradually
During incubation period, aggressive ions penetrate removed by the combined action of corrosion and wear
towards the oxidemetal interface and steadily extend, together. Eventually, corrosionwear continued on the
undermining the oxide because of the galvanic oxygen diffusion zone by producing a smaller amount of
coupling of the oxide and substrate metal. Oxide layers wear debris. After extended testing times, cracking of
gradually detached from the surface as fragments. oxygen diffusion zone caused local material removal,
This observation points out the fact that corrosive and thereafter the depth of the wear track reached to the
solution has entered the interface through individual substrate. When the Al2O3 ball contacted with the
defects. As soon as the oxide fragments lost their contact substrate, it was subjected to wear with the mechanism
with the substrate, they detached. The corrosion (grain pull out) which was observed during testing of
behavior of the samples that were oxidized for short untreated surface Apparently, the wear mechanism of
times at 600 C differed to that of the other samples. The Al2O3 ball on untreated surface was maintained on
relatively thin oxide layer that covered these samples oxidized surface when the depth of the wear track
was a mixture of anatase and rutile. Anatase was readily reached to substrate. Grain pull out wear mechanism is
attacked and dissolved in reducing acids whereas rutile inevitable when the adhesion stresses between the sliding
was inert and resistant to attack [2,21]. Dissolution of surfaces tend to be greater than the cohesive strength of
anatase at the beginning of the corrosion test left some the materials [22]. It should be emphasized that, the
sites of oxidized samples unprotected and further extent of wear developed on the Al2O3 ball is controlled
corrosion continued with total removal of the oxide by the size of the contact area between the ball and the
layer. Increasing oxidation time yielded higher amount surface being tested.
of rutile in the oxidized surface, which increased
protective nature of oxide layer against the corrosive
environment. Less defective structures of oxide 5. Conclusion
containing more rutile formed at 600 C after longer
oxidation times. And this combination presented the The Ti6Al4V alloy was thermally oxidized at 600 C
most corrosion resistant oxide layer that formed on and 650 C to produce corrosion and wear resistant
Ti6Al4V alloy. surface layers. Oxide thickness and oxygen diffusion
Corrosionwear test results conrmed the superiority zone depth steadily increased with increasing oxidation
of the thermally oxidized surface over untreated alloy. temperature and time. Oxide layers were composed
Surface degradation of untreated alloy commenced with of anatase and rutile structures of TiO2. Roughening
the onset of sliding action and large amount of wear of oxidized surfaces was more severe after oxidation
debris was produced through the entire test duration. at 650 C. A signicant increment in surface hardness
The oxide layer prevented the wear of Ti6Al4V (3500 to 9000 HV) was achieved due to formation of a
alloy over a certain period of testing time. The removal hard oxide layer and an oxygen diffusion zone beneath
of oxide layer and diffusion hardened zone occurred it. According to results of corrosion tests carried out in
due to mechanical and chemical effects. Even though the an aggressive acidic solution (5 m HCl), oxidation at
oxidized (at 600 C for 60 h) surface exhibited the best 600 C for 60 h produced the most corrosion resistant
corrosion resistance in HCl solution with its less surface on Ti6Al4V alloy. Wear tests that were
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conducted in a mild corrosive solution (0.9% NaCl), alloys: the material and biological issues, ASTM STP 1272.
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Acknowledgements [11] Mishra AK, Davidson JA, Poggie RA, Kovacs P, FitzGerald TJ.
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