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Research Papers

Formability of Porous Tantalum Sheet-Metal

[+] Author and Article Information
Paul S. Nebosky

Department of Aerospace and Mechanical Engineering,  University of Notre Dame, Notre Dame, IN 46556pnebosky@sitesmedical.com

Steven R. Schmid1

Department of Aerospace and Mechanical Engineering,  University of Notre Dame, Notre Dame, IN 46556schmid.2@nd.edu

1

Corresponding author.

J. Manuf. Sci. Eng 133(6), 061006 (Dec 01, 2011) (5 pages) doi:10.1115/1.4005353 History: Received October 28, 2010; Revised October 21, 2011; Published December 01, 2011; Online December 01, 2011

Over the past 10 years, a novel cellular solid, Trabecular MetalTM (TM), has been developed for use in the orthopedics industry as an ingrowth scaffold. Manufactured using chemical vapor deposition (CVD) on top of a graphite foam substrate, this material has a regular matrix of interconnecting pores, high strength, and high porosity. Manufacturing difficulties encourage the application of stamping and forming technologies to increase CVD reactor throughput and reduce materials wastes. In this study, the formability of TM was evaluated using a novel camera-based system for measuring surface strains, since the conventional approach of printing or etching gridded patterns was not feasible. A forming limit diagram was then obtained using specially fabricated 1.65 mm thick sheets. No lubricant was used due to the cleanliness requirements for orthopedic implants.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

The EPOCHTM hip implant. This hip replacement consists of a cobalt-chrome core surrounded by a PEAK layer so that its stiffness matches that of bone. The PEAK layer partially penetrates the ingrowth pads during molding. The ingrowth pads are a shape that requires more complicated strains than simple bending in order to produce them.

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Figure 2

The optical arrangement of the ARAMIS system. If the camera position and angle between the cameras are known, the spatial object point P(X,Y,Z) can be determined from the corresponding two-dimensional image points p1 (x1 ,y1 ) and p2 (x2 ,y2 ) [10].

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Figure 3

The experimental setup for the hemispherical punch tests

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Figure 4

Trabecular MetalTM specimens. (a) A specimen that showed little formability. Note the visibly striated surface. (b) A sample that showed good formability.

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Figure 5

Forming-limit curves for Trabecular MetalTM

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Figure 6

The major strain field for specimen 18 at stage 64, just prior to cracking

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Figure 7

The minor strain field for specimen 18 at stage 64

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