Processing and properties of highly porous Ti6Al4V mimicking human bones

Ti6Al4V alloy samples with large pores suitable for bone implants are fabricated by pressing and sintering. Ti6Al4V powder is mixed with different volume fractions of salt particles. The sintering behavior up to 1260 degrees C is studied by dilatometry and pore features are observed by scanning electron microscopy and X-ray microtomography. Sintered materials with a relative density between 0.26 and 0.97 are obtained. 3D image analysis proves that large pores form a connected network when the amount of salt is 20% and above. The Young's modulus and the yield stress of sintered materials deduced from compression tests span over wide ranges of values, which are consistent with real bone data. A simple analytical model is proposed to estimate the relative density as a function of the fraction of salt. This model combined with classical Gibson and Ashby's power equations for mechanical properties can predict the fraction of salt required to obtain prescribed properties.