Surface characteristics of additively manufactured CoCr and Ti6Al4V dental alloys: The effects of carbon and gold thin film coatings, and alkali‐heat treatment

Abstract This study investigates the impact of surface modifications on additively manufactured CoCr and Ti6Al4V dental alloys, focusing on surface properties. Thin film carbon (C) and gold (Au) coatings, as well as alkali‐heat treatment, were applied to the high‐ and low‐polished specimens. Scanning electron microscopy (SEM) showed that thin film coatings retained the underlying surface topography, while the alkali‐heat treatment induced distinct morphological changes. Energy‐dispersive x‐ray spectroscopy (EDS) analysis revealed that C‐coating enriched surfaces with C, and Au‐coating introduced detectable amounts of Au. Nevertheless, signs of coating delamination were observed in the high‐polished specimens. Alkali‐heat treatment led to the formation of a sodium titanate layer on Ti6Al4V surfaces, confirmed by sodium presence and Fourier transform infrared spectroscopy (FTIR) results showing carbonate bands. Surface roughness measurements with atomic force microscopy (AFM) showed that C‐coating increased surface roughness in both high‐ and low‐polished alloys. Au‐coating slightly increased roughness, except for low‐polished Au‐coated Ti6Al4V, where a decrease in roughness was observed compared to low‐polished bare Ti6Al4V, likely due to surface defects present in the latter resulting from the additive manufacturing process. Alkali‐heat treatment led to a pronounced increase in roughness for both alloys, particularly for Ti6Al4V. Both thin film coatings decreased the water contact angles in all specimens in varying magnitudes, indicating an increase in wettability. However, the alkali‐heat treatment caused a substantial decrease in contact angles, resulting in a highly hydrophilic state for Ti6Al4V. These findings underscore the substantial impact of surface modifications on additively manufactured dental alloys, potentially influencing their clinical performance. Research Highlights Thin film coatings and chemical/heat treatment modify the surface properties of additively manufactured dental alloys. The surfaces of the alloys get rougher and more hydrophilic after alkali‐heat treatment. Thin gold coatings exhibit potential adhesion challenges.