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Additive manufacturing of Ni-rich nitinol for superelastic properties for stent application

Agarwal, Neha orcid logoORCID: 0000-0002-1296-2560 (2025) Additive manufacturing of Ni-rich nitinol for superelastic properties for stent application. PhD thesis, Dublin City University.

Abstract
Nitinol, an alloy of nickel and titanium, has emerged as a promising material for biomedical applications, due to its exceptional superelasticity and shape memory effect. These unique properties allow stents to expand and contract in response to physiological conditions, providing superior performance compared to conventional metallic stents. However, traditional manufacturing techniques, such as machining and laser cutting, present significant challenges in processing nitinol due to its high work hardening rate, poor machinability, and complex phase transformation behavior. These limitations have driven the adoption of Laser Powder Bed Fusion (L-PBF) that enables the fabrication of intricate and patient-specific stent designs with greater precision and structural complexity. Nitinol parts produced using this method often suffer from inherent defects such as high residual stresses, microstructural inhomogeneities, porosity, and poor surface finish due to the rapid solidification and localized heat accumulation during the printing process. These factors can significantly degrade mechanical performance, reducing the fatigue resistance, superelastic behavior, and functional longevity of the stent. Therefore, post-processing treatments are essential to achieve optimal functional properties. Heat treatments, including solution annealing and ageing, play a critical role in reducing residual stresses, refining the microstructure, and tuning the phase transformation temperatures which enable setting the superelastic response required for stent applications. Similarly, surface modification techniques such as electropolishing are necessary to reduce surface roughness and improve corrosion resistance, minimizing the risk of nickel ion leaching in the human body and ultimately enhancing the biocompatibility of the stent. Optimizing process parameters in L-PBF, with effective post-processing strategies, is important to tailor the mechanical performance, surface characteristics, and biocompatibility of Ni-rich nitinol for medical applications. This study investigates the effects of L-PBF process parameters, ageing heat treatment, and electropolishing on the functional properties of Ni-rich nitinol. The goal is to enable nitinol metal additive manufacturing for next-generation stent production.
Metadata
Item Type:Thesis (PhD)
Date of Award:13 August 2025
Refereed:No
Supervisor(s):Brabazon, Dermot and Obeidi, Muhannad
Subjects:Engineering > Materials
Engineering > Mechanical engineering
Engineering > Production engineering
Engineering > Biomedical engineering
Physical Sciences > Lasers
DCU Faculties and Centres:DCU Faculties and Schools > Faculty of Engineering and Computing > School of Mechanical and Manufacturing Engineering
Research Institutes and Centres > Advanced Processing Technology Research Centre (APT)
Research Institutes and Centres > I-Form
Use License:This item is licensed under a Creative Commons Attribution-NonCommercial-No Derivative Works 4.0 License. View License
Funders:Research Ireland
ID Code:31409
Deposited On:24 Nov 2025 11:02 by Dermot Brabazon . Last Modified 24 Nov 2025 11:02
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