Chemical, Physical, and Mechanical Properties and Microstructures of Laser-Sintered Co–25Cr–5Mo–5W (SP2) and W–Free Co–28Cr–6Mo Alloys for Dental Applications

We examined the chemical, physical, and mechanical properties and microstructures of laser-sintered Co–25Cr–5Mo–5W (SP2) and W–free Co–28Cr–6Mo alloys. The tensile and fatigue properties of the laser-sintered Co–Cr–Mo alloys were extremely superior to those of dental-cast alloys. The ultimate tensile strength (σ(UTS)) and total elongation (T.E.) were close to those of hot-forged Co–28Cr–6Mo alloys. The fatigue strengths (σ(FS)) at 10(7) cycles of the 90°-, 45°-, and 0°-direction-built Co–28Cr–6Mo alloys were ~500, ~560, and ~600 MPa, respectively. The ratio σ(FS) /σ(UTS) was ~0.4. These superior mechanical properties were attributed to the fine π-phase particles in the grains and grain boundaries of the fine face–centered cubic (fcc) matrix formed owing to the rapid solidification. The chemical composition of 20-times-laser-sintered Co–Cr–Mo alloy without the virgin powder added was approximately the same as that of the alloy laser-sintered with the virgin powder. σ(FS) of the 90°-direction-built alloys after laser sintering 20 times was also ~500 MPa. σ(UTS) of hot-forged Co–28Cr–6Mo alloys decreased with increasing annealing temperature, whereas T.E. increased. For the Co–Cr–Mo alloys annealed at 1000 to 1150 °C for 30 min after laser sintering, the rates of decrease in σ(UTS) were small. σ(FS)/σ(UTS) increased to near those of annealed Co–28Cr–6Mo alloys after hot forging. The durability of clasps fabricated by laser sintering was superior to that of dental-cast clasps.