Microporous Titanium through Metal Injection Moulding of Coarse Powder and Surface Modification by Plasma Oxidation

Titanium is one of the most attractive materials for biomedical applications due to having excellent biocompatibility accompanied by good corrosion resistance. One popular processing technique for Ti is Metal Injection Moulding (MIM). However, there are several issues associated with the use of this technique, such as the high cost of the fine powder used, the high level of contamination and consequent alteration to material properties, as well as the large volume shrinkage that occurs during sintering. In this study, the use of a relatively coarse Ti powder with a mean particle size of 75 μm to process Ti parts with the potential for biomedical applications by MIM will be examined, compared to a commercial Ti feedstock, and subsequently coated using Plasma Electrolytic Oxidation (PEO). The results show that samples produced with the coarse powder shrink 35% less and have a relative density 14% less with an average pore size three-times larger than that of the commercial feedstock. This helps increase the potential competitiveness of MIM in the production of biomedical parts, as it reduces cost, shrinkage and results in more intentionally-induced micropores, such as are desired for biomedical implants. PEO treatment of the samples yields a thick rough coating comprised of a mixture of rutile and anatase with interconnected microporous channels and openings resembling the mouth of a volcanic crater.