Comparative study of vacuum arc-remelting and spark plasma sintering processes on microstructure and corrosion behavior of Cp-Ti for biomedical implant applications

Titanium (Ti) and its alloys are widely used for biomedical applications due to their excellent mechanical properties and biocompatibility. However, the selection of an appropriate manufacturing process is critical to ensuring the optimal performance of Ti-based implants. This study investigates the effects of two fabrication methods –vacuum arc remelting (VAR) and spark plasma sintering (SPS) – on the microstructure and corrosion behavior of commercially pure titanium (Cp-Ti). VAR-Ti ingots were fabricated using arc-melting with multiple remelting cycles, whereas SPS-Ti specimens were sintered from Ti powders under pressure and pulsed current in a high-vacuum environment. Both specimens were subsequently heat-treated at 800 °C and furnace cooled. Microstructural characterization revealed coarser grains and porosity in VAR-Ti, while SPS-Ti showed refined, uniform α-phase structures. Electrochemical tests, including OCP, polarization, EIS, and ICP-MS, indicated slightly enhanced corrosion resistance in SPS-Ti, attributed to its defect-free microstructure. XPS analysis confirmed TiO2 surface formation on both samples. Additionally, both materials exhibited high ductility and excellent biocompatibility, with cell viability exceeding ISO 10993-5 thresholds. These findings highlight the advantage of SPS in producing defect-minimized Cp-Ti with improved corrosion behavior for biomedical applications.