Annexure-V

PROGRESS REPORT

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project implementation. Subsequent reports should cover the next 12 Months and so
on.
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to DST.

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 PROGRESS REPORT

Project Title: Investigating the feasibility of wire arc additive No:

manufacturing process for bioimplants application

PI(Name &Address): [Link] of Birth : 11-06-1981

Professor
Department of Mechanical Engineering
[Link] College of Technology
Samayapuram, Trichy, Tamilnadu.
Co-PI(Name & Address):[Link] of Birth :

4. Broad area of Research : Wire arc Additive Manufacturing Process

4.1 Sub Area : Bioimplants Application

5. Approved Objectives of the Proposal:

1. To assess the feasibility of employing Wire Arc Additive Manufacturing (WAAM) for
fabricating bio-implants with superior mechanical integrity and improved biological
compatibility.
2. To systematically refine and optimize key WAAM process parameters—such as heat
input, wire feed rate, and travel speed—for manufacturing bio-implants from titanium and
its alloys.
3. To perform a comprehensive analysis of the micro structural characteristics and
mechanical performance of bio-implants fabricated using the WAAM technique.
4. To investigate the in-vitro and in-vivo biocompatibility of WAAM-fabricated bio-
implants, focusing on cell viability, tissue integration, and immune response

of Start: cost of Project:

of completion: Expenditure as on :
Capital -
General -
 6. Methodology: 1500 char (Half page)

Process Selection

Literature Review

Material Selection

Process Parameters Optimization

Prototype Model Preparation

Evaluate Micro-structural Analysis

Determination of Mechanical Properties

Evaluate Biocompatibility

This study will follow a systematic and multi-phase methodology to evaluate the potential of Wire
Arc Additive Manufacturing (WAAM) for the production of high-performance bio-implants. Initially,
a comprehensive literature review will be conducted to establish the current state of research in the
field, identifying existing gaps, material trends, and challenges related to the use of WAAM in
biomedical applications. Based on this, suitable materials such as commercially pure titanium and Ti-
6Al-4V will be selected due to their proven mechanical strength and biocompatibility.

Subsequently, an experimental plan will be developed to determine and optimize critical WAAM
process parameters—including wire feed rate, voltage, travel speed, and interlayer cooling time—
through a design of experiments (DOE) approach. Using the optimized parameters, bio-implant
prototypes will be fabricated under controlled environmental conditions.

The characterization phase will include detailed analysis of the microstructure using scanning
electron microscopy (SEM) and X-ray diffraction (XRD) to identify phase compositions and grain
morphology. Mechanical behavior will be evaluated via tensile testing, hardness measurements, and
impact resistance analysis to determine the functional reliability of the produced implants.

Finally, the biocompatibility evaluation will involve both in-vitro tests (such as cell viability assays,
adhesion, and proliferation studies) and in-vivo testing using suitable animal models to assess
biological response, osseointegration, and inflammation markers. The collected data will be analyzed
statistically to validate the feasibility of WAAM for biomedical applications.
 7. Salient Research Achievements:

7.1 Summary of Progress

Wire arc additive manufacturing (WAAM) has come a long way, both in terms of the process itself
and the mechanical features of the metal components it produces, due to the capacity to mass
production with fast deposition rates. Due to its expansion, a more diverse range of materials is now
utilized in WAAM’s operations. The analysis highlights the increasing interest in WAAM around
the world, highlighting recent advancements in robotics, sensors, welding processes, and CAX
technology. Contrarily, WAAM’s shortcomings in component manufacturing include less-than-ideal
surface quality, inadequate dimension accurateness and, in extremely rare instances, poor densities
due to aggressive melt pool contact. Titanium, aluminum, Ni-based alloys, and magnesium materials
made using different WAAM techniques are reviewed in this work along with their mechanical
properties. Additionally, the most common flaws observed in various materials are compiled here.
The present approaches of enhancing quality and reducing defects before and after processing are
detailed. In addition, medical properties of Bio-compatibility and anti-bacterial properties were
reviewed. Finally, we go over post-process, process monitoring and control, feedstock optimization,
process selection, and optimization to boost the quality of WAAM-fabricated components.

Aluminum alloys are utilized in the process of wire arc additive manufacturing (WAAM) because of
their exceptional strength-to-weight ratio and resistance to corrosion. The present state of WAAM
for stainless steels is examined with a focus on the materials’ microstructure, mechanical
characteristics, flaws, residual stress, and distortion. Because of their superior mechanical qualities
and ability to withstand corrosion, stainless steels are highly valued in a variety of industries,
including architecture, maritime engineering, and aerospace. Super alloys based on nickel have been
the primary focus of additive manufacturing research because of their high strengths at high
temperatures and the high expense of producing them using traditional methods. Titanium alloys
have also been the subject of much study. The chemical, aerospace, petrochemical, and aeronautical
sectors make extensive use of nickel-based super alloys because of their resistance to oxidation at
temperatures higher than 550 °C and their great strength. Inconel 718 and Inconel 625 alloy are
among the nickel-based super alloys that have been studied so far in relation to WAAM processing.
The hardness values of FeNi36 specimens constructed with PAW and GMAW were measured at
three distinct wall heights. The ATZM31 Magnesium alloy thin-wall component that was
manufactured via CMTWAAM has remarkable build-and deposition-directional ductility and
strength. Investigation on the thin wall composites shows impressively stronger strength and
superior ductility compared to the regular Cold Metal Transfer-Wire arc additive manufactured
AZ31 Mg alloy components. Several factors can lead to WAAM errors, including sloppy
programming, unsteady weld pool dynamics caused by incorrect factor settings, thermal distortion
caused by heat buildup, external influences (such gas contamination), and machine failures.

Product warping, layer delamination during deposition, loss of geometric accuracy, distortion, and
fatigue performance degradation are all consequences of plastic deformation in WAAM-
manufactured components caused by residual stress. A number of variables, such as the wire batch,
metal transfer mode, feed and transit speeds, and porosity, might influence the result. The fabricated
WAAM sample’s hardness and tensile strength are reduced due in large part to the humping defect.
Another typical flaw in fusion welds made of aluminum alloy is cracking, which occurs as a result of
the alloy’s solidification process. The crack can be seen in many beads, and it is most prevalent in
the reheated region with equiaxed grains, where the temperature is high.

WAAM makes extensive use of post-process heat treatment to manage hardness, increase material
strength, and decrease residual stress. Considerations such as operating temperature, desired material
properties. Improving material homogeneity and reducing residual tension are two benefits of inter-
pass cold rolling. The mechanical characteristics and micro structural evolution of the targeted
components become anisotropic during the WAAM process due to the depositional layers, alternate
re-heating and temperature gradient, and re-cooling. Welding applications have made use of UIT to
improved weld mechanical characteristics and reduce local residual stress. During mechanical
peening in carbon steels, compressive stresses are typically generated about 1–2.5 mm below the
component’s surface.
The study on Wire Arc Additive Manufacturing (WAAM) showcases notable progress in the
fabrication of bimetallic structures, namely the fusion of austenitic stainless steel (ASS) and low
carbon steel (LCS). These structures utilize the qualities of various materials to provide improved
mechanical performance and resistance to corrosion. The study of the microstructure of bimetallic
formations shows distinct anisotropic characteristics, such as the existence of vermicular delta-ferrite
in ASS and acicular ferrite in LCS. The presence of these microstructures results in mechanical
properties that are anisotropic, meaning they vary in different directions. The feasibility of using
graded materials is examined within the realm of additive manufacturing, specifically in the context
of Wire Arc Additive Manufacturing (WAAM).

The relationship between the implanted substance and the host tissue is referred to as
biocompatibility. The effectiveness of the implant will be determined in large part by this
interaction. Immune responses, tissue integration, and healing processes are examples of the host
response. Antibacterial materials, in contrast to most everyday materials, can effectively inhibit
bacterial adhesion, growth, and multiplication by means of surface treatment, appropriate material
shape, and the alloying of appropriate components. It has been asserted that metallic alloys that are
already antibacterial, such as Ti, Mg, SS, and Co alloys, can be even more effective against some
germs by adding Cu and Ag components.

Bone tissue in humans is composed of two main types: cancellous bone tissue, which is lighter and
located inside, and cortical bone tissue, which forms the dense outer layer. The porosity network of
cancelous bone is open, with pore sizes spanning from 200 to 1000 μm and porosity levels varying
from 30 to 95%. This structure can be mimicked by porous scaffolds, which promote fluid flow and
tissue formation.

As an outcome of the wide range of engineering materials and fabrication scales, it is anticipated that
numerous application specific WAAM system designs will be developed, rather than a universal
system that can solve all potential issues. In conclusion, our study showed that WAAM are a great
material to use when making bio implants since they prevent bacterial infections that might happen
after an implant has been placed.

7.2 New Observations: 1500 Char (Half page)

A recent study shows that WAAM-fabricated Ti-6Al-4V alloy, when subjected to solution
treatment (950 °C for 1 h) followed by aging at 580 °C, significantly reduces α′-Ti content and
optimizes oxygen and phase distribution. This leads to:

 Lowest corrosion rate (~7.9 μm/year)

 Highest coefficient of friction (~0.58) under simulated body fluid conditions
 Improved cell proliferation on days 7, especially at higher aging temperatures

Carefully controlled post-build heat treatments can markedly enhance both mechanical integrity
and biocompatibility of WAAM parts.

WAAM has been used to join NiTi (Nitinol) and Ti to create bimetallic structures with built-in
shape memory and actuation behaviors. These joints show:

 High microhardness (~600 HV) at the interface

 Improved actuation recovery and transformation temperatures compared to pure NiTi

Hybrid WAAM constructs can provide multi-functional implants, combining rigidity and
actuation potential.

Studies on non-titanium WAAM alloys (e.g. NiTi) show that optimal combinations of wire feed
speed, travel speed, and voltage can produce defect-free layers with controlled microstructure
and higher mechanical strength at the top layers. Though on NiTi, the principle applies to
titanium WAAM: fine-tuning parameters layer-by-layer influences porosity, grain morphology,
and mechanical robustness.

A Design of Experiments (DOE) tailored to WAAM builds—especially in relation to thermal

gradients and layer sequencing—can optimize structural quality.

Surface modifications have dramatic effects on tissue integration:

 Picosecond laser texturing on Ti-6Al-4V yields groove structures that accelerate

hydroxyapatite deposition (3×), protein adsorption (2.5×), and cell adhesion (2×)
compared to untreated surfaces.
 Apatite–wollastonite–chitosan coatings significantly enhance osteoblast adhesion,
proliferation, and early mineralization in vitro.

Including surface treatments—either laser patterning or bioactive coatings—after WAAM

significantly elevates early-stage osseointegration.

7.3 Innovations: 5 lines 250 char

Through techniques like micro-arc oxidation (MAO), titanium implant surfaces are doped with
ions such as Zn, Cu, Mg, or Ag to dramatically improve implant performance.

Cu-doped coatings deliver impressive antibacterial activity and promote bone angiogenesis and
regeneration .

Ag-sputtered surfaces completely inhibit peri-implant pathogens while maintaining osteoblast

viability .

Micro-arc oxidation with ion incorporation enhances osseointegration, angiogenesis, and

corrosion resistance .

Increase hydroxyapatite formation rate by up to 3×

Boost protein adsorption by approximately 2.5×

7.4 Application Potential:

7.4.1 Long Term
Development of Ti–NiTi bimetallic WAAM structures enabling shape-memory or actuation features—
ideal for adaptive bone anchors or self-adjusting implants. Integration with nano-ion-doped coatings (e.g.
Cu, Ag, Zn), microarc oxidation (MAO), or bioactive glass coatings to impart antibacterial, osteogenic,
and corrosion-resistant functions. Ti-Ta or Ti–TiTa lattice scaffolds add elastic modulus matching to bone
and enhanced bone ingrowth—amenable to WAAM evolution
7.4.2 Immediate
Patient-Specific Orthopedic and Dental Implants
Porous Titanium Foam and Lattice Implants
Prototype & Research-Grade Devices

7.5 Any other

NIL

Research work which remains to be done under the project(for on-going projects)

NIL

PhDs Produced no: Technical Personnel trained: Research Publications arising

out of the present project:
 List of Publications from this Project(including title, author(s),journals & year(s)
(A) Papers published only in cited Journals(SCI)

(B) Papers published in Conference Proceedings, Popular Journals etc.

Patents filed/to be filed:

Major Equipment(Model and Make)

S Sanctioned List Procured Cost Working Utilization
No (Yes/No) (Rs in (Yes/No) Rate(%)
Model & make lakhs)

Upload Images of equipment’s.