Original article

Fatigue strength: effect of welding type and joint design

executed in Ti-6Al-4V structures

Juliana M.C. Nuñez Pantoja1, Ana P. Farina1, Luis G. Vaz2, Rafael L.X. Consani1, Mauro A. de
Arruda Nóbilo1 and Marcelo F. Mesquita1
1
Department of Prosthodontics and Periodontology, Piracicaba Dental School, University of Campinas, Piracicaba, São Paulo, Brazil;
2
Department of Dentistry Materials and Prosthodontics, Araraquara Dental School, State University of São Paulo Julio de Mesquita Filho,
Araraquara, São Paulo, Brazil

doi: 10.1111/j.1741-2358.2011.00598.x
Fatigue strength: effect of welding type and joint design executed in Ti-6Al-4V structures
Background: This study evaluated the fatigue strength of Ti-6Al-4V-machined structures submitted to
laser (L)-welding and TIG (TIG)-welding procedures, varying the joint designs.
Materials and methods: Seventy dumbbell rods were machined in Ti-6Al-4V alloy with central diam-
eters of 3.5 mm. The specimens were sectioned and welded using TIG or L and three joint designs {‘I’
design, varying welding distances [0.0 mm (I00) or 0.6 mm (I06)], or ‘X’ [X] design}. The combinations of
variables created six groups, which, when added to the intact group, made a total of seven groups (n = 10).
L was executed as follows: 360 V/8 ms (X) and 390 V/9 ms (I00 and I06), with focus and frequency
regulated to zero. TIG was executed using 2:2 (X) and 3:2 (I00 and I06) as welding parameters. Joints were
finished, polished and submitted to radiographic examination to be analysed visually for the presence of
porosity. The specimens were then subjected to mechanical cyclic tests, and the number of cycles com-
pleted until failure was recorded. The fracture surface was examined using a scanning electron microscope.
Results: The Kruskal–Wallis and Dunn test (a = 0.05) indicated that the number of cycles resisted for
fracture was higher to X for both welding procedures. To L, I06 was as resistant as X. The Mann–Whitney
U-test (a = 0.05) indicated that L joints were more resistant than TIG to I00 and I06. Spearman’s corre-
lation coefficient (a = 0.05) indicated a negative correlation between the number of cycles and presence of
porosity.
Conclusion: Thus, to weld Ti-6Al-4V structures, the best condition is X, independent of the welding
method employed.

Keywords: titanium alloys, fatigue Performance, laser-weld Joint, TIG Welding, dental implant prostheses.

Accepted 4 August 2011

reason. The Ti-6Al-4V alloy is the most common

Introduction
For many years, conventional removable dentures
were the only treatment available for edentulous
elderly people, although these people, in most cases,
suffered owing to the instability of mandibular
dentures1,2. With the implantology approach, an
alternative for these people’s treatment appeared2,3.
The implant prostheses frameworks are usually
made from titanium because of its biocompatibility,
excellent fatigue and corrosion resistance, low
density, low thermal conductibility and low rela-
tivity cost, when compared with gold dental al-
loys2,4–6. Several titanium alloys are used for this
alloy used because of its resistance and high-per-
formance5–7.
Implant prostheses require more accurate fabri-
cation criteria than conventional ones because
of the lack of periodontal tissues. Marginal misfit
of implant-supported frameworks may cause
biologic complications of the surrounding tissues or
mechanical failure of the prostheses8. However,
potential distortions can be created at any step of the
framework-fabrication process9,10 and can be cor-
rected by employing welding procedures6,9,11–13.
Titanium alloys are characteristically difficult to
cast and weld because of the high melting point

Ó 2011 The Gerodontology Society and John Wiley & Sons A/S, Gerodontology 2012; 29: e1005–e1010 e1005
e1006 J. M. C. Nuñez Pantoja et al.
and strong affinity to gases, such as oxygen,
hydrogen and nitrogen12,14,15. For this reason, it is
necessary to use a special machine that employs
argon shielding in the welding chamber to solder
titanium frameworks12,15,16. The laser-welding
technique and TIG-welding procedure are the most
commonly used when it comes to titanium2,6,15–17.
These processes create reduced joining distor-
tions, less damage to veneering coverage and close
yield strength to the base metal under static con-
ditions11,12,15,18. However, some reports on laser
welding of titanium and titanium alloys have
shown the presence of large pores in the laser-
repaired joints6,13.
Despite the better fit, welded frameworks must
not present the same fatigue strength as compared
to intact structures6,13. It is common to find voids,
inclusions and notches inside the joints that act as
stress raisers in the fatigue process, which occurs
when these joints are submitted to cyclic load-
ings6,15.
Welding protocols are not entirely established in
scientific literature, although it is known that the
joint’s design directly affects its mechanical resis-
tance6,15. In structures with diameters larger than
3.0 mm, the laser beam cannot penetrate the cen-
tre of the cross section if there is an ‘I’ design with
juxtaposition of the parts6,15,18,19. In thin diame-
ters, the resistance is lower when there is space
between the joint parts, when compared with
juxtaposition of parts, owing to gas arrestment
during the addition of metal used to fill the gap6,19.
Thus, aiming to establish the best joint design for
structures that are 3.5 mm in diameter, depending
on the type of welding used, this study evaluated
the fatigue strength of Ti-6Al-4V-welded struc-
tures, using several joint designs and two welding
methods.
Materials and Methods
Specimen fabrication
Seventy dumbbell-shaped rods, with 3.5 mm in
the central segment, were machined, based on
norm ASTM E8M-0420 The specimens were ma-
chined to isolate the variables of internal porosity
and external irregularities inherent to the casting
process and to the manual finishing process6,7,13,
and this diameter (3.5 mm) was used to
simulate a welded point of a 10-elements fixed
prosthesis2,6.
Forty of these rods were sectioned in half, per-
pendicularly to the long axis, and 20 of them were
sectioned and bevelled to form an ‘X’ (chamfer of
Ó 2011 The Gerodontology Society and John Wiley & Sons A/S, Gerodontology 2012; 29: e1005–e1010
1 mm/30°) when the lined-up of parts were ob-
served from a side view (Fig. 1a). The metal adja-
cent to the gap was blasted with abrasive particles
of aluminium oxide of 100 lm at a pressure of
0.55 MPa13. The parts were lined up in a metal
matrix to maintain distances of 0.0 and 0.6 mm
between them (Fig. 1b,c) for the ‘I’ design and just
with juxtaposition of parts to the ‘X’ design
(Fig. 1a). For the laser-welding procedure (L),
the welding was carried out using energy of
360 V/8 ms (X)6 and 390 V/9 ms (I00 and I06),
with the focus and frequency calibrated at zero,
with a Desktop–F (Dentaurum, Pforzheim, Ger-
many) laser machine. For the TIG procedure (TIG),
3:2 (I00 and I06) and 2:2 (X) were used as welding
parameters with the ratio numerator representing
the power used and the denominator representing
the programmed time. These procedures were
conducted in the NTY 60C machine (Kernit,
Indústria Mecatrônica Ltda., Indaiatuba, Brazil).
Initially, two welding points were made on oppo-
site sides of the cross section to be welded to sta-
bilise parts of the specimen aligned, and then the
welding was completed by a trained and competent
professional6. The ‘X’ designs were welded, starting
the procedure in the centre of the specimens to
mark full contact in the centre of each half piece;
the welding was then completed using commer-
cially pure titanium grade 2 metal filler (Dentau-
rum) to provide a complete joint between the two
parts.
The combination between the variables (welding
design and type of welding) created a total of six
groups (n = 10), which, together with the control
group (intact), made a total of seven groups: G1 –
(a) (b) (c)
Figure 1 Alignment of the specimens: (a) X (b) I00 and
(c) I06.
 Fatigue strength of Ti-6Al-4V joints e1007

L/X, G2 – L/I06, G3 – L/I00, G4 – TIG/X, G5 – TIG/
I06, G6 – TIG/I00 and G7 – Intact.
After the welding processes were completed, the
joints were finished and polished with a rubber no.
5001 polisher (Dedeco Dental, New York, NY, USA)
and titanium polishing paste (Tiger Brilliant Polier
Paste, Dentaurum, Pforzheim, Alemanha). During
the finishing process, the specimens’ diameters
were constantly verified with an electronic calliper
(Starret Tools Co. Ltd., Shanghai, China), assuring
accuracy of within 0.01 mm6.
Radiographs of the joints were taken with
radiographic film (Ektaspeed Plus; Eastman Kodak,
Rochester, NY, USA) to identify internal defects.
The radiographic examination consisted of expo-
sure of the specimens to radiation (90 kV, 15 mA,
0.6 s and 12 mm of distance), using a periapical
film2,6,13. The radiographies (Fig. 2) were visually
analysed for the presence of porosity in the joints.
Mechanical cycling test
Before the mechanical cycling test, three extra
randomly intact specimens were submitted to ten-
sile tests to establish the mean yield strength at
0.2% permanent strain. The stress established for
the fatigue test (291 MPa) was calculated as 30% of
the mean yield strength (970 MPa)6. The loading
frequency in the fatigue test was 15 Hz6, and the
loading used was 2800 N. The specimens were then
submitted to fatigue strength tests using a testing
Figure 2 Radiograph of TIG/I00 specimen (Arrows indi-
cate void).
machine (Test Star II, Material Testing System;
Systems Corp, Minneapolis, MN, USA), and the
number of cycles required to cause the fatigue
fracture was registered. The specimens were tested
submerged in synthetic saliva (1.5 mM Ca, 3.0 mM
P, 20.0 mM NaHCO3, pH 7.0)21 at room tempera-
ture to 100 000 cycles6.
Fatigue fracture surfaces of representative speci-
mens were examined using a scanning electron
microscope (Electron Probe Microanalyser, Jeol
model JXA 840 A; Jeol Ltd, Tokyo, Japan).
Statistical Analysis
An exploratory analysis of the number of cycles
was completed, and the non-parametric test
was requested. Kruskal–Wallis and Dunn tests (a =
0.05) were applied to compare designs (3–3) inside
the level of type of welding. The Mann–Whitney
U-test (a = 0.05) was applied to compare the type
of welding (2–2) inside the level of design and to
also compare (2–2) the control group with all of the
groups. The data from the radiographic analyses
were correlated with the number of cycles by the
Spearman’s correlation coefficient (a = 0.05) to
each type of welding/joint design and to all
grouped data.
Results
Table 1 shows the median values of the number of
cycles until fracture in the experimental groups.
The number of cycles required until fracture was
seen to be higher to the ‘X’ design for both welding
procedures and to the ‘I’ design without the jux-
taposition of parts for laser welding (p < 0.05). The
lower number of cycles data was found with ‘I’
designs with juxtaposition of parts (p < 0.05).
When the welding methods were compared, the
Mann–Whitney U-test (a = 0.05) indicated the

Table 1 Median (standard devia-

tion) values of number of cycles res- Type of welding
isted in the experimental groups.
Designs Laser TIG
a
‘‘X’’ 32 376.5 (8009.8) Aa 40 573.3 (10 512.35) Aaa
‘‘I’’/distance 0.6 mm 31 422 (8121.557) Aaa 8866 (2439.08) Bba
‘‘I’’/distance 0.0 mm 2720 (1173.58) Baa 1082.5 (635.08) Cba
Intact group = 100 000 (0,0). aDiffers from intact group (Mann–Whitney U-
test, a = 0.05).
Median values followed by the same letter are not significantly different
(Kruskal–Wallis/Dunn, a = 0.05). Capital letters compare designs inside the
level of the factor type of welding, and small letters compare type of welding
inside the level of design factor.

Ó 2011 The Gerodontology Society and John Wiley & Sons A/S, Gerodontology 2012; 29: e1005–e1010
e1008 J. M. C. Nuñez Pantoja et al.

differences between G3 and G6 (p = 0.0032) and pores or voids caused by insufficient weld penetra-
between G2 and G5 (p = 0.0002), with the laser- tion (arrows) was higher when the joint opening
weld joints being the most resistant. All specimens was 0.0 mm for ‘I’ design specimens, for both types
included in the control groups achieved over of welding. For the ‘I’ design with 0.6 mm of joint
100 000 cycles, and this group was the most resis- opening, the TIG procedure showed less welding
tant of all the groups. penetration than laser welding, and the internal
The Spearman’s correlation coefficient (a = 0.05) void was smaller in ‘X’ designs.
revealed a negative correlation (p = 0.0141,
rs = )0.3152) between the number of cycles and
Discussion
the presence of porosity (Table 2). In these cases,
specimens that had pores in the joint, as observed Structural defects within the joints assume greater
by radiographies (Fig. 2), were less resistant to significance under cyclic loading than under static
mechanical cycling. tensile loading22. Porosities and voids can occur as a
Figures 3 and 4 show SEM photomicrography of result of gas arrestment, insufficient deep welding
the fractured surfaces of laser-weld joints and TIG- penetration or by the capture of inclusions such as
weld joints, respectively. Figures 3(a) and 4(a) acrylic resin used to join parts in the mouth to be
show the surface of ‘X’ designs. Figures 3(b) and welded15. Gas-arrestment formation can be related
4(b) show the 0.6-mm joint opening of ‘I’ design. to the rapid solidification process, to energy excess
Figures 3(c) and 4(c) show the 0.0-mm joint released during the welding process or simply to
opening with the ‘I’ design. The presence of internal vaporisation of volatile alloying elements6,15.
According to some authors, full contact of base
Table 2 Association between number of cycles survived metals is associated with successful laser joints13,18,
and presence of internal voids in radiography examina- although this is not an absolute truth because the
tion degree of weld penetration depth is dependent on
the diameter of the region to be welded. Some
Spearman’s studies show that the laser beam penetration is
coefficient p limited to 1.5 mm in depth3,18,19,23. In a previous
study, the weld penetration depth was insufficient
Laser
‘‘X’’ )0.7817 0.0075
for specimens with 3.5 mm diameters6, a finding
‘‘I’’ distance 0.6 mm )0.6963 0.0252 that corroborates the results of this study (Table 1).
‘‘I’’ distance 0.0 mm )0.6963 0.0252 Figures 2(b), 3(c) and 4(c) show the insufficient
welding penetration in the centre of the specimens.
TIG When more than 2 mm in depth is required, an
‘‘X’’ )0.6963 0.0252 ‘X’-shaped preparation should be used, and weld-
‘‘I’’ distance 0.6 mm * * ing always requires the use of a metal filler,
‘‘I’’ distance 0.0 mm )0.6963 0.0252 essential to optimise laser welding, minimise
All type of welding/all )0.3152 0.0141 tensions occurring in the work piece and support
designs the joint6,15. In this study, this was true for the two
*All specimens present pores in radiographies; thus, welding procedures studied (Table 1, Figs 3a and
correlation was impossible. Spearman’s coefficient ranges 4a); however, greater emphasis should be given to
between )1 and 1. the TIG-welding procedure because of the fact that,

(a) (b) (c)

Figure 3 SEM photomicrograph of fracture of laser-weld specimens: (a) X (b) I06 and (c) I00 (Arrows indicate voids).

Ó 2011 The Gerodontology Society and John Wiley & Sons A/S, Gerodontology 2012; 29: e1005–e1010

(a) (b)
Figure 4 SEM photomicrograph of fracture of TIG-weld specimens: (a) X (b) I06 and (c) I00 (Arrows indicate voids).
for laser welding, the ‘I’ design with 0.6 mm of
joint opening is a favourable design (Table 1,
Fig. 3b).
The TIG welding is a punctual welding procedure
because the energy supplied to the joint is given
through the contact of the tungsten electrode with
the metal part to be welded, which generates an
electric arc16. Thus, the welding penetration deep
inside the cross section of thick specimens is ham-
pered, even when there is a gap between parts,
because of the fact that the electrode does not reach
the central portion of the cross section, especially in
delicate gaps (0.6 mm). On the contrary, the laser
beam can reach this region and melt the metal filler
interposed between the two parts. The laser beam
can be considered a monochromatic and directional
light beam, high energy and able to be focused on
very small areas15,18. This may explain the higher
results with laser-weld joints in ‘I’ without juxta-
position of parts (Table 1), when compared with
TIG-welding joints (p = 0.0002).
In a previous study6 that used similar methods,
the ‘I’ design with a gap between parts did not create
dumbbells as tough as those obtained in this study.
A methodology improvement was likely responsible
for these differences. This study used a metallic de-
vice to align the parts to be welded, avoiding the
union of the parts with acrylic resin. In this way, it
was possible to perform the cleaning and oxide
blasting of the parts with less probability of causing
inclusions originating from microscopic remnants of
acrylic resin, solid vaseline or oxide particles.
It is important to note that none of the treated
groups had equivalent results with the control
groups, which shows that Ti-6Al-4V-welded speci-
mens of 3.5 mm in diameter are less resistant to
mechanical cycling than are intact specimens
(Table 1). This is probably due to the fact that the
intact specimens were free from any internal or
external irregularities, being very resistant speci-
mens. They were machined from pre-fabricated
bars of Ti-6Al-4V grade 5, the same used in pros-
Ó 2011 The Gerodontology Society and John Wiley & Sons A/S, Gerodontology 2012; 29: e1005–e1010
Fatigue strength of Ti-6Al-4V joints e1009
(c)
thetic components and in CAD-CAM frameworks.
This, along with the reduced weld ability of Ti-6AL-
4V, can explain these results24,25. Titanium weld
ability decreases with increased levels of b stabilis-
ers24. Because vanadium is a b stabiliser, the a-b
alloy, Ti-6Al-4V, presents weld ability inferior to
that of cp Ti24,25.
Nuñez-Pantoja et al.6 obtained results regarding
some welded specimens similar to those of intact
specimens. These different results may be due to
the difference in dumbbell cross section diameters
or due to the different lots used to machine the
specimens in both studies. The difference in lots
can lead to different mean yield strengths.
The radiographic analyses of the joints demon-
strated a negative correlation, as revealed by the
Spearman’s correlation coefficient (rs = )0.3152,
p = 0.0141), when the groups were analysed to-
gether. It was observed that when there was
porosity inside the joints in radiographic analyses
(Fig. 2), the number of cycles decreased, which
corroborates with Nuñez-Pantoja et al 6. This cor-
relation confirms that internal porosity in fact acts
as a stress raiser6,13,19,22, decreasing the fatigue life
of the prostheses. Thus, radiographs of welded
joints can be considered a way to perform quality
control of TIG and laser-welded joints in clinical
practice.
An important detail to be discussed is that this
study did not aim to quantify welded framework
survival. Instead, this study aimed to evaluate the
best design to be used to weld 3.5 mm in diameter,
depending on the type of welding used. This trial
of materials resistance aimed to compare the wel-
ded joints. As such, no conclusions can be drawn
with regard to the number of years that welded
frameworks will survive in the buccal cavity. It is
suggested that in this manner, for future studies, a
well-designed clinical study or a study that
simulates clinical conditions, using a simulated
masticatory load, can verify the longevity of these
joints.
e1010 J. M. C. Nuñez Pantoja et al.
Conclusion
Within the limitations of this study, it may be con-
cluded that the best design for TIG-weld structures
that are 3.5 mm in diameter is the ‘X’. To laser-weld
these cross sections, the ‘X’ design or the ‘I’ design
can be used, without juxtaposition of the parts.
Acknowledgements
This study was supported by FAPESP (Grant no. 09/
50567-1) and NEODENT Indústria e Comércio de
Materiais Dentários – Ltda.
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Correspondence to:
Juliana Maria Costa Nuñez Pantoja, Travessa Dona
Eugênia, 135 ap. 71, Piracicaba, Sao Paulo,
13416-218, Brazil.
Tel.: +55 19 8203 8158
Fax: +55 19 2106 5218
E-mail: julynunez@terra.com.br
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