Human tissue is structured mainly of self-assembled polymers (proteins) and ceramics (bone minerals), with metals present as trace elements with molecular scale functions. However, metals and their alloys have played a predominant role as structural biomaterials in reconstructive surgery, especially orthopedics, with more recent uses in non-osseous tissues, such as blood vessels. With the successful routine use of a large variety of metal implants clinically, issues associated with long-term maintenance of implant integrity have also emerged. This review focuses on metallic implant biomaterials, identifying and discussing critical issues in their clinical applications, including the systemic toxicity of released metal ions due to corrosion, fatigue failure of structural components due to repeated loading, and wearing of joint replacements due to movement. This is followed by detailed reviews on specific metallic biomaterials made from stainless steels, alloys of cobalt, titanium and magnesium, as well as shape memory alloys of nickel–titanium, silver, tantalum and zirconium. For each, the properties that affect biocompatibility and mechanical integrity (especially corrosion fatigue) are discussed in detail. Finally, the most critical challenges for metallic implant biomaterials are summarized, with emphasis on the most promising approaches and strategies.

Metallic implant biomaterials

Titanium and nickel alloys represent a significant metal portion of the aircraft structural and engine components. When these critical structural components in aerospace industry are manufactured with the objective to reach high reliability levels, surface integrity is one of the most relevant parameters used for evaluating the quality of finish machined surfaces. The residual stresses and surface alteration (white etch layer and depth of work hardening) induced by machining of titanium alloys and nickel-based alloys are very critical due to safety and sustainability concerns. This review paper provides an overview of machining induced surface integrity in titanium and nickel alloys. There are many different types of surface integrity problems reported in literature, and among these, residual stresses, white layer and work hardening layers, as well as microstructural alterations can be studied in order to improve surface qualities of end products. Many parameters affect the surface quality of workpieces, and cutting speed, feed rate, depth of cut, tool geometry and preparation, tool wear, and workpiece properties are among the most important ones worth to investigate. Experimental and empirical studies as well as analytical and Finite Element modeling based approaches are offered in order to better understand machining induced surface integrity. In the current state-of-the-art however, a comprehensive and systematic modeling approach based on the process physics and applicable to the industrial processes is still missing. It is concluded that further modeling studies are needed to create predictive physics-based models that is in good agreement with reliable experiments, while explaining the effects of many parameters, for machining of titanium alloys and nickel-based alloys.

Machining induced surface integrity in titanium and nickel alloys: A review

For measuring machines and machine tools, geometrical accuracy is a key performance criterion. While numerical compensation is well established for CMMs, it is increasingly used on machine tools in addition to mechanical accuracy. This paper is an update on the CIRP keynote paper by Sartori and Zhang from 1995 [Sartori S, Zhang GX (1995) Geometric error measurement and compensation of machines, Annals of the CIRP 44(2):599–609]. Since then, numerical error compensation has gained immense importance for precision machining. This paper reviews the fundamentals of numerical error compensation and the available methods for measuring the geometrical errors of a machine. It discusses the uncertainties involved in different mapping methods and their application characteristics. Furthermore, the challenges for the use of numerical compensation for manufacturing machines are specified. Based on technology and market development, this work aims at giving a perspective for the role of numerical compensation in the future.

Geometric error measurement and compensation of machines : an update

The ability to determine absolute distance to an object is one of the most basic measurements of remote sensing. High-precision ranging has important applications in both large-scale manufacturing and in future tight formation-flying satellite missions, where rapid and precise measurements of absolute distance are critical for maintaining the relative pointing and position of the individual satellites. Using two coherent broadband fibre-laser frequency comb sources, we demonstrate a coherent laser ranging system that combines the advantages of time-of-flight and interferometric approaches to provide absolute distance measurements, simultaneously from multiple reflectors, and at low power. The pulse time-of-flight yields a precision of 3 µm with an ambiguity range of 1.5 m in 200 µs. Through the optical carrier phase, the precision is improved to better than 5 nm at 60 ms, and through the radio-frequency phase the ambiguity range is extended to 30 km, potentially providing 2 parts in 1013 ranging at long distances. Using two coherent broadband fibre-laser frequency comb sources, a coherent laser ranging system for absolute distance measurements is demonstrated. Its combination of precision, speed and long range may prove particularly useful for space-based sciences.

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Rapid and precise absolute distance measurements at long range

The miniaturization of machine components is perceived by many as a requirement for the future technological development of a broad spectrum of products. Miniature components can provide smaller footprints, lower power consumption and higher heat transfer, since their surface-to-volume ratio is very high. To create these components, micro-meso-scale fabrication using miniaturized mechanical material removal processes has a unique advantage in creating 3D components using a variety of engineering materials. The motivation for micro-mechanical cutting stems from the translation of the knowledge obtained from the macro-machining domain to the micro-domain. However, there are challenges and limitations to micro-machining, and simple scaling cannot be used to model the phenomena of micro-machining operations. This paper surveys the current efforts in mechanical micro-machining research and applications, especially for micro-milling operations, and suggests areas from macro-machining that should be examined and researched for application to the improvement of micro-machining processes.

G.N. Peggs

Papers

Probing Systems in Dimensional Metrology

Large-Scale Metrology – An Update

Surfaces in Precision Engineering, Microengineering and Nanotechnology

The Design and Manufacture of Biomedical Surfaces

Nanotechnology: International Developments and Emerging Products