Microstructural and Mechanical Properties of Cobalt–Chromium Alloy Obtained by Laser Powder Bed Fusion for Biomedical Applications

Cobalt–chromium (CoCr) alloys have gained significant importance in the field of medical implants due to their outstanding combination of mechanical strength and excellent wear and corrosion resistance. Compared with other state-of-the-art materials, such as stainless steel or titanium, CoCr alloys typically exhibit superior fatigue strength, which is particularly advantageous for implants and components exposed to long-term repetitive loading. The present study investigates the feasibility of using commercially available CoCr alloy powders in the Laser Powder Bed Fusion (PBF-LB/M) process for the fabrication of biomedical implants. Microstructural characterization of the PBF-LB/M-manufactured CoCr samples revealed a dense, refined cellular–dendritic microstructure with a high degree of densification, characteristic of the rapid solidification associated with the PBF-LB/M process. The evaluation of mechanical performance, wear behavior, and corrosion resistance provides valuable insights into the suitability of these alloys for biomedical applications, especially in the design of complex implants requiring enhanced durability and long-term reliability. Furthermore, compression testing highlighted the influence of layer orientation on mechanical properties, emphasizing the importance of strategic prototyping and building orientation selection in the PBF-LB/M process. Tribological behavior assessed under dry sliding conditions demonstrated a significantly reduced coefficient of friction and lower wear rate compared to a conventional 316L stainless steel, which is frequently used in similar applications. Corrosion resistance was evaluated by potentiodynamic polarization measurements in Ringer electrolyte, showing that the PBF-LB/M-fabricated CoCr samples exhibit good corrosion resistance in environments resembling physiological fluids. Overall, the PBF-LB/M technique represents a promising manufacturing route for next-generation CoCr biomedical implants, particularly for orthopedic and dental applications. Beyond the biomedical field, the findings of this study also support the potential extension of PBF-LB/M-processed CoCr alloys to industrial sectors requiring high wear and corrosion resistance, including aerospace and automotive applications.