Plasma Arc Assisted Additive Manufacturing Using Magnesium Alloys: A Review

Abstract

Magnesium alloys have emerged as essential materials in biomedical applications due to their biocompatibility and biodegradability. However, the complex geometries and specialized qualities required for sophisticated implants are beyond the reach of traditional manufacturing methods. To overcome these issues, this work explores a novel additive manufacturing (AM) technique called plasma arc-based hybrid heating (arc fusion and laser-based). By leveraging the synergistic effects of plasma and hybrid energy, it enables precise control over extreme processing temperatures, facilitating the fabrication of magnesium alloys with optimized microstructures and enhanced mechanical performance. This research systematically examines the relationship between plasma-driven thermal dynamics, grain refinement mechanisms, and resultant mechanical properties, including tensile strength and fatigue resistance. Furthermore, the study highlights the role of rapid solidification in minimizing defects such as porosity and residual stresses, which are critical factors for implant longevity. These findings underscore the transformative potential of plasma technology in advancing the production of patient-specific biomedical devices, offering a pathway to high-performance, custom-designed magnesium implants. This work not only bridges existing gaps in the additive manufacturing of bio-compatible metals but also establishes a foundation for future innovations in sustainable medical solutions.