Abstract: Bone-mimicking gradient porous NiTi shape memory alloys (SMAs) are promising for orthopedic implants due to their distinctive superelastic functional properties. However, premature plastic deformation in weak areas such as thinner struts, nodes, and sharp corners severely deteriorates the superelasticity of gradient porous NiTi SMAs. In this work, we prepared gradient porous NiTi SMAs with a porosity of 50% by additive manufacturing (AM) and achieved a remarkable improvement of superelasticity by a simple solution treatment regime. After solution treatment, phase transformation temperatures dropped significantly, the dislocation density decreased, and partial intergranular Ti-rich precipitates were transferred into the grain. Compared to as-built samples, the strain recovery rate of solution-treated samples was nearly doubled at a pre-strain of 6% (up to 90%), and all obtained a stable recoverable strain of more than 4%. The remarkable superelasticity improvement was attributed to lower phase transformation temperatures, fewer dislocations, and the synergistic strengthening effect of intragranular multi-scale Ti-Ni precipitates. Notably, the gradient porous structure played a non-negligible role in both superelasticity deterioration and improvement. The microstructure evolution of the solution-treated central strut after constant 10 cycles and the origin of the stable superelastic response of gradient porous NiTi SMAs were revealed. This work provides an accessible strategy for improving the superelastic performance of gradient porous NiTi SMAs and proposes a key strategy for achieving such high-performance architectured materials.

Key words: Shape memory alloys, Superelasticity, Gradient porous structure, Solution treatment, Stable recoverable strain