Porous Ti alloys are promising as medical prosthesis materials due to their superior body-compatible, corrosion-resistant and bone-matching mechanical properties . A particularly facile and scalable method of preparing porous metals and alloys is the ‘FFC-Cambridge process’, that allows the direct electro-deoxidation of oxides through cathodic polarisation in molten CaCl2 .
Using this process, we have synthesised various Ti alloys, i.e., Ti-xNb (x=24, 35, 42), Ti-xNb-ySn (x=24, 35, 42; y=4, 7.9), Ti-xNb-13Zr (x=13, 24, 35) and Ti-35Nb-7Zr-5Ta, directly from their oxides. The alloys were porous, had compositions close to the target values, and consisted of either dual-phase α,β or single-phase β structures with homogeneous distribution of the elements. The alloys exhibited bone-matching mechanical properties, and their corrosion performances in Hanks’ simulated body fluids were better than those of stainless steels and brass. The process and the materials made thus have a huge potential for future application in implant technology.