Comparative Study of the Microstructure and Properties of Cast-Fabricated and 3D-Printed Laser-Sintered Co–Cr Alloys for Removable Partial Denture Frameworks

Since additive technologies in dentistry are gradually replacing metal casting technology, it is necessary to evaluate new dental constructions intended for the development of removable partial denture frameworks. The aim of this research was to evaluate the microstructure and mechanical properties of 3D-printed, laser-melted and -sintered Co–Cr alloys, and perform a comparative study with Co–Cr castings for the same dental purposes. The experiments were divided into two groups. The first group consisted of samples produced by conventional casting of the Co–Cr alloy. The second group consisted of 3D-printed, laser-melted and -sintered specimens produced from a Co–Cr alloy powder divided into three subgroups, depending on the technological parameters chosen for manufacturing (angle, location and heat treatment). Examination of the microstructure was carried out by classical metallographic sample preparation, using optical microscopy and scanning electron microscopy with energy dispersive X-ray spectroscopy (EDX) analysis. A structural phase analysis was also performed by XRD. The mechanical properties were determined using a standard tensile test. The microstructure observation showed a dendritic character in the case of castings, while in the case of 3D-printed, laser-melted and -sintered Co–Cr alloys, the microstructure was typical for additive technologies. The XRD phase analysis confirmed the presence of Co–Cr phases (ε and γ). The results of the tensile test showed remarkably higher yield and tensile strength values and slightly lower elongation of the 3D-printed, laser-melted and -sintered samples than those produced by conventional casting.