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Hip implants face a significant challenge due to their limited lifespan, a concern amplified by the rising human life expectancy. Lattice structures have demonstrated the ability to provide precise control over geometry, thereby significantly enhancing implant performance. This paper introduces the development of graded additively manufactured Ti6Al4V lattice structures for orthopaedic implants. The objective focuses on developing a graded lattice unit cell design mirroring human bone properties, emphasising high surface curvature and design versatility to improve mechanical and biomedical properties, specifically osseointegration and stress shielding. The study involves modelling and grading simple cubic (SC) and body-centred cubic (BCC) lattice structures with various geometries and graded conditions and conducting compressive tests to identify the optimal configuration. The results showed that filleting was found to be the mechanical strength. On the other hand, BCC lattice structures demonstrated superior performance compared to SC structures. The optimised structure with a pore size of 400 µm provided an elastic modulus of 15.7 GPa, yield strength of 296 MPa and compressive strength of 530 MPa. This graded lattice design approach provides a promising technique for enhancing hip implant performance, offering potential improvements. [ABSTRACT FROM AUTHOR]

A two-stage simulation strategy is proposed to predict the as-cast structure. During the first stage, a 3-phase model is used to simulate the mold-filling process by considering the nucleation, the initial growth of globular equiaxed crystals and the transport of the crystals. The three considered phases are the melt, air and globular equiaxed crystals. In the second stage, a 5-phase mixed columnar-equiaxed solidification model is used to simulate the formation of the as-cast structure including the distinct columnar and equiaxed zones, columnar-to-equiaxed transition, grain size distribution, macrosegregation, etc. The five considered phases are the extradendritic melt, the solid dendrite, the interdendritic melt inside the equiaxed grains, the solid dendrite, and the interdendritic melt inside the columnar grains. The extra- and interdendritic melts are treated as separate phases. In order to validate the above strategy, laboratory ingots (Al-4.0 wt pct Cu) are poured and analyzed, and a good agreement with the numerical predictions is achieved. The origin of the equiaxed crystals by the 'big-bang' theory is verified to play a key role in the formation of the as-cast structure, especially for the castings poured at a low pouring temperature. A single-stage approach that only uses the 5-phase mixed columnar-equiaxed solidification model and ignores the mold filling can predict satisfactory results for a casting poured at high temperature, but it delivers false results for the casting poured at low temperature. [ABSTRACT FROM AUTHOR]