On the machinability and properties of Ti-6Al-4V biomaterial with n-HAp powder-mixed ED machining

Nano-hydroxyapatite powder was used in electric discharge machining to modify the surface of Ti-6Al-4V medical alloy. Herein, electric discharge machining was performed, with and without powder-mixed flushing for evaluation of the material erosion rate and surface roughness. In addition to dielectric type, several process parameters including current, pulse-on duration, pulse-off duration, and electrode hole diameter were considered. The experiments were planned by Taguchi design technique and conducted to analyze the material erosion rate and surface roughness. After machining, scanning electron microscope, energy-dispersive X-ray spectrometry, and X-ray diffraction techniques were used to evaluate the surfaces of the samples. Furthermore, wear and corrosion tests were also carried out on the Ti alloy with modified surfaces. The influential factors were identified based on analysis of variance results. Current and dielectric type were the significant factors, both for the material erosion rate and surface roughness. The scanning electron microscope images of Ti-6Al-4V samples highlighted that the process parameters exhibited a vital influence on the topology and microstructure of machined surface. Furthermore, energy-dispersive X-ray spectrometry and X-ray diffraction analyses confirmed the presence of hydroxyapatite on Ti alloy surface after machining. Moreover, the results of wear and corrosion tests revealed lower wear and corrosion rates of the surface-treated workpiece with nano-hydroxyapatite.