Traditional Ti–6Al–4V implants pose challenges due to their high stiffness and potential toxicity, prompting the development of β-type titanium (Ti) alloys with non-toxic alloying elements like niobium (Nb). Titanium hydride (TiH₂) was selected as a precursor due to its improved sinterability, oxidation resistance, and affordability. The TiH₂–Nb alloy was produced through mechanical alloying and powder metallurgy, with optimisation using the Box-Behnken Design (BBD) method. Elemental TiH₂ (60 wt%) and Nb (40 wt%) powders were milled at various speeds (100 to 300 rpm), compacted at 500 MPa, and sintered under an argon atmosphere at temperatures between 800 °C and 1200 °C for 1 to 3 h. Response surface methodology (RSM) identified sintering temperature as the most influential factor on compressive strength and elastic modulus. Optimal conditions, milling at 200 rpm and sintering at 1200 °C for 3 h, yielded in a compressive strength of 1768 MPa and an elastic modulus of 8.7 GPa, closely matching human cortical bone properties. TiH₂–Nb alloy outperformed Ti–Nb alloy in terms of densification (98.56 % relative density), reduced porosity (1.44 %), and desirability score (0.9). Thermogravimetric (TG) analysis confirmed effective dehydrogenation at higher milling speeds due to enhanced Nb diffusion and defect density. X-ray diffraction (XRD) confirmed formation of a dual-phase α+β Ti structure. Optimised TiH₂–Nb alloys offer a promising alternative to Ti–6Al–4V implants, with reduced stress shielding and improved mechanical compatibility for future orthopaedic implants.
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