In electrical discharge machining (EDM), the tool electrode is one of the substantial components of the system, and it ensures the success or failure of the EDM process. The electrode’s role is to conduct electrical charges and erode the workpiece to the desired shape. Different electrode materials have different impacts on machining. Certain electrode materials remove metal quickly but wear out rapidly, while others degrade slowly but the material removal is too slow. The choice of the electrode has an influence on both the mechanical properties, such as metal removal rate (MRR), wear rate, surface finish, surface modification and machinability, and the electrical properties, such as sparking initiation, time lag, gap contamination and process stability. There are factors to consider when fabricating an electrode, which include the type of workpiece materials, the metallurgical alloying of the materials, the choice of fabrication techniques, the intended use of the electrode, and material cost. Considerable challenges in EDM electrode fabrication have been reported, which include excessive tool wear for green compact electrodes, high toughness for sintered electrodes, and poor rigidity for additively manufactured electrodes. To address these issues, researchers have explored different manufacturing methods, such as casting, conventional machining, electrodeposition, powder metallurgy and additive manufacturing. In this paper, the various techniques attempted and adopted in EDM electrode manufacturing are analyzed and discussed. This paper also sought to give insight into EDM, its various forms, the dielectric fluid’s properties, EDM electrode’s size and shape, the effects of the electrode on the EDM process, material removal, electrode wear, present technologies for electrode fabrication, and the limitations of these technologies. Finally, directions for future research are highlighted.

The aim of this study is to synthesize Titania nanotubes (TNTs) on the 3D-printed Ti-6Al-4V surface and investigate the loading of antibacterial vancomycin drug dose of 200 ppm for local drug treatment application for 24 h. The antibacterial drug release from synthesized nanotubes evaluated via the chemical surface measurement and the linear fitting of Korsmeyer–Peppas model was also assessed. The TNTs were synthesized on the Ti-6Al-4V surface through the anodization process at different anodization time. The TNTs morphology was characterized using field emission scanning electron microscope (FESEM). The wettability and the chemical composition of the Ti-6Al-4V surface and the TNTs were assessed using the contact angle meter, Fourier transform infrared spectrophotometer (FTIR) and the X-ray photoelectron spectroscopy (XPS). The vancomycin of 200 ppm release behavior under controlled atmosphere was measured by the high-performance liquid chromatography (HPLC) and hence, the position for retention time at 2.5 min was ascertained. The FESEM analysis confirmed the formation of nanostructured TNTs with vertically oriented, closely packed, smooth and unperforated walls. The maximum cumulative vancomycin release of 34.7% (69.5 ppm) was recorded at 24 h. The wetting angle of both Ti-6Al-4V implant and the TNTs were found below 90 degrees. This confirmed their excellent wettability.

The aim of this study is to assess the stress distribution on the bone tissue and bone-implant interface of a customized anatomic root-analog dental implant (RAI) by means of finite element analysis (FEA) for different types of bone density. A mandibular right second premolar was selected from the CBCT database. A DICOM file was converted to an STL file to create a CAD model in FEA software. The bone boundary model was created, while bone density types I–IV were determined. Von Mises stress was measured at bone tissues and bone-implant interfaces. To validate the models, the RAI was 3D printed through a laser powder-bed fusion (L-PBF) approach. The results revealed that all RAI designs could not cause plastic deformation or fracture resulting in lower stress than the ultimate tensile stress of natural bone and implant. Compared to a conventional screw-type implant, RAIs possess a more favorable stress distribution pattern around the bone tissue and the bone-implant interface. The presence of a porous structure was found to reduce the stress at cancellous bone in type IV bone density.

Austenitic 316L stainless steel has been the most widely acceptable biomaterial for producing implants. The downside of this material includes the leaching of nickel ions from the matrix that limits its’ usage in implant manufacturing. In this research, production of stainless steel alloy modified with boron and titanium is investigated. The sintering of the alloy systems is carried out in nitrogen atmosphere for a dwell time of 8 h. The X-Ray diffraction (XRD) analysis reveals that dwell time and alloy composition leads to the formation of strong nitrides and borides. The X-Ray Photoelectron Spectroscopy (XPS) results show the presence of nitrogen on to the surface of sintered specimens. The nitride layer on the surface of the specimens is helpful in the retention of nickel ions in the stainless steel matrix, as indicated in the weight loss measurements. The cytotoxicity assessment indicates that the developed alloys are biocompatible and can be used as implant materials.

This research investigates the simultaneous sintering and surface nitriding of 316L stainless steel alloy using powder metallurgy method. The influence of sintering temperature and dwell time are investigated for maximum nitrogen absorption, densification and increased microhardness using response surface methodology (RSM). In this study, 316L stainless steel powder was compacted at 800 MPa and sintered at two different temperatures of 1150 and 1200 °C with varying dwell times of 1, 3, 5 and 8 h in nitrogen atmosphere. The sintered compacts were then characterized for their microstructure, densification, microhardness and nitrogen absorption. The results revealed that increased dwell time assisted nitrogen to diffuse into stainless steel matrix along with the creation of nitride layer onto the sample surface. The microhardness and density also increased with increasing dwell time. A densification of 7.575 g/cm³ and microhardness of 235 HV were obtained for the samples sintered at 1200 °C temperature with 8 h dwell time. The simultaneous sintering and surface nitriding technique developed in this research work can help in improving corrosion resistance of this material and controlling leaching of metal ions for its potential use in biomedical applications.

This study attempts to simultaneously machine and synthesize a biomimetic nanoporous hydroxyapatite coating on the Zr₆₇Cu₁₁Ni₁₀Ti₉Be₃ bulk metallic glass (BMG) surface. The aim is to investigate and optimize the hydroxyapatite deposition rate and the surface roughness during the electro-discharge coating of Zr₆₇Cu₁₁Ni₁₀Ti₉Be₃ BMG. Scanning Electron Microscopy (SEM), X-ray powder Diffraction (XRD) and Energy-dispersive X-ray Spectroscopy (EDS) were employed to characterize and analyze the results. Response Surface Methodology using D-optimum custom design approach was utilized to generate the models and optimize the input parameters. A globule nanostructured and nanoporous coating of about 25.2 µm thick, containing mainly Ca, O, and K were ascertained. Further XRD analysis confirmed the deposition of biocompatible oxides (HA, CaZrO₃, and ZrO₂) and hard ZrC coating on the Zr₆₇Cu₁₁Ni₁₀Ti₉Be₃ BMG surface. A significant improvement in cell viability was observed in the HA electro-discharge coated BMG specimens. The numerical models for the Hydroxyapatite Deposition Rate (HDR) and Surface Roughness (SR) were developed and experimentally validated using the optimized parameters setting suggested by the software. The achieved average predicted error of 4.94 and 5.09% for the HDR and SR respectively confirmed the excellent reproducibility of the developed models.