Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Experimental investigations in powder mixed

electric discharge machining of Ti35Nb7Ta5Zr-
titanium alloy

Chander Prakash, H. K. Kansal, B. S. Pabla & Sanjeev Puri

To cite this article: Chander Prakash, H. K. Kansal, B. S. Pabla & Sanjeev Puri
(2017) Experimental investigations in powder mixed electric discharge machining of
Ti35Nb7Ta5Zr-titanium alloy, Materials and Manufacturing Processes, 32:3, 274-285, DOI:
10.1080/10426914.2016.1198018

To link to this article: http://dx.doi.org/10.1080/10426914.2016.1198018

Accepted author version posted online: 21

Jun 2016.
Published online: 21 Jun 2016.

Submit your article to this journal

Article views: 198

View related articles

View Crossmark data

Citing articles: 2 View citing articles

Full Terms & Conditions of access and use can be found at

http://www.tandfonline.com/action/journalInformation?journalCode=lmmp20

Download by: [University of Nebraska, Lincoln] Date: 04 August 2017, At: 02:59
 MATERIALS AND MANUFACTURING PROCESSES
2017, VOL. 32, NO. 3, 274285
http://dx.doi.org/10.1080/10426914.2016.1198018

Experimental investigations in powder mixed electric discharge machining of

Ti35Nb7Ta5Zr-titanium alloy
Chander Prakasha , H. K. Kansala, B. S. Pablab, and Sanjeev Puric
a
Department of Mechanical Engineering, University Institute of Engineering and Technology, Panjab University, Chandigarh, India; bDepartment of
Mechanical Engineering, National Institute of Technical Teachers Training and Research, Chandigarh, India; cDepartment of Biotechnology, University
Institute of Engineering and Technology, Panjab University, Chandigarh, India

ABSTRACT ARTICLE HISTORY

The present research is the first type of study in which the application of powder mixed electrical Received 15 December 2015
discharge machining (PMEDM) for the machining of -phase titanium (-Ti) alloy has been proposed. -Ti Accepted 18 April 2016
alloys are new range of titanium alloys, which has a wide-spread application in dental, orthopedics, shape KEYWORDS
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017

memory, and stents. The aim of the present study is to fabricate submicro- and nanoscale topography by Alloy; -Ti; micro-cracks;
PMEDM process to enhance the biocompatibility without affecting machining efficiency. The effect of Si MRR; nano; porosity; RLT; SR;
powder concentration along with pulse current and duration on the surface and machining TWR
characteristics has been investigated. A significant decrease in surface crack density on the machined
surface with 4 g/l Si powder concentration was observed. When -Ti alloy was modified at 15 A pulse
current, longer pulse interval with 8 g/l concentration of Si powder particles, the interconnected surface
porosities with pore size 200500 nm was observed. Moreover, at Si powder concentrations of 2 g/l and
4 g/l, the recast layer thickness is 8 m and 23 m, respectively. Elemental mapping analysis confirmed
that PMEDM also generated carbides and oxides enriched surface, a favorable surface chemistry to
enhance the biocompatibility of -Ti alloy. Furthermore, PMEDM also enhances the machining
performance by improving material removal rate and reducing tool wear rate.

Introduction possessed the potential to modify the surface of Ti-6Al4 V

alloy-based implant and produce a biocompatible layer of
Titanium (Ti) and its alloys are the high strength-to-weight
nano-hydrides [9]. The nanoporous featured layer by EDM
ratio materials used in many engineering fields such as mech-
has favorable impact on cell attachment and provides a vehicle
anical, aerospace, military, and biomedical, because of their
for cell growth and proliferation [10]. EDM also alter the
unique mechanical properties [1]. Ti and its alloy are being
surface chemistry of Ti6Al4 V alloy into oxides and car-
extensively used in orthopedic applications owing to its excel-
bides, which is favorable for bone-implant anchorage [11].
lent biocompatibility, outstanding corrosion resistance, and
The capability of EDM to enhance the surface hardness, wear
high fatigue endurance [2]. Among Ti alloys, -Ti a new range
resistance, corrosion resistance, and bioactivity of Ti-6Al4V
of Ti alloy that has gained more attention due to its low elastic
alloy by surface alloying has been reported by bin et al. [12].
modulus (5055 GPa), light weight, excellent corrosion resist-
Janecek et al. reported in his research that EDMed surface
ance, and superior biocompatibility [3]. Ti and its alloy are
promotes cell adhesion on Ti6Al4V alloy, but high surface
laborious and hard to machine by conventional machining
roughness (SR) and crack density reduced the fatigue perfor-
process due to its high tendency to form oxides, and chemical
mance that results in clinical failure [13]. Further, his co-
reactivate with all types of tool material, which results in poor
author reported in their research that fatigue endurance of
surface characteristics [4]. For machining such type of materi-
Ti6Al4V alloy were severely affected by high SR and crack
als, non-conventional machining methods were best suitable
density [14]. It was also reported that the fatigue performance
with high accuracy [5]. Among non-conventional machining
of EDMed specimens can be improved by heat-treatment
methods, electric discharge machining (EDM) has been
methods followed by EDM process [15]. Due to the electro-
long-established to machine Ti and its alloy easily [6]. EDM
thermal nature of the EDM process, the action of generation
is an electrothermal machining process, which generates a
of thermal energy and quenching occurred rapidly in process
large number of electrical sparks in a fraction of seconds.
cycle [16]. As a result, the material gets thermally affected and
These electrical sparks produce intense heat that removes
a number of surface defects like high SR, high surface crack
material from the workpiece surface; consequence of this can
density, and macro size pit/dimples were formed on the
machine hard or tough material easily [7]. Recently, Prakash
machined surface that deteriorates the surface quality [17].
et al. critically reviewed the application of EDM to machine
The poor surface quality degraded the corrosion performance
the Ti and its alloy for biomedical applications [8]. EDM has

CONTACT H. K. Kansal shaarut@yahoo.com Department of Mechanical Engineering, University Institute of Engineering and Technology,
South Campus Panjab University, Sector-25, Chandigarh, India-160014.
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/lmmp.
2017 Taylor & Francis
 MATERIALS AND MANUFACTURING PROCESSES 275

[18] and fatigue performance [19] of implant, and as a result

bone-implant interface failure occurs.
In order to prevent the formation of surface cracks, high
roughness, and thick recast layer during EDM, a number of
advancements in EDM process have been employed by many
researchers such as ultrasonic vibration-assisted EDM [20],
rotary assisted EDM (RAEDM) [21], HyFlex EDM [22],
electrodischarge coating/surface modification by composite
or green tool electrode [2328], near dry EDM [29], and pow-
der mixed EDM (PMEDM) [3036]. Among them, PMEDM
has been considered the most promising approach to enhance
the surface quality by reducing surface crack density [37].
Chen et al. reported the application of PMEDM to modify
the surface of Ti6Al4V implant for biomedical application
and it was found that the surface cracks and recast layer thick-
ness can be controlled by the PMEDM process [38]. Prakash
et al. have been reported the potential of PMEDM to enhance Figure 1. (a) EDM machine, (b) and (c) experimental setups of powder mixed
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017

the surface microhardness, corrosion resistance, and bioactiv- EDM.

ity of -Ti implants used in orthopedic applications [39].
Recently, Ekmekci et al. proposed the application of PMEDM
to deposit the biocompatible layer of hydroxyapatite powder
on Ti6Al4V alloy for the medical applications [40].
However, to the best of our knowledge, machining of Ti
35Nb7Ta5Zr (-phase) alloy by PMEDM and is hardly
reported and there is no study available that shows the specu-
lative exploration of PMEDM parameters on surface and
machining characteristics of Ti35Nb7Ta5Zr Ti alloy such
as surface topography, surface crack density, elemental compo-
sition, recast layer thickness (RLT), SR, material removal rate
(MRR), and tool wear rate (TWR). So there is an urgent need
to investigate the surface and machining characteristics of -
Ti alloy and to contribute in the area of material and manufac-
turing process by machining of -Ti alloy a new range of
biomaterial using PMEDM process. Therefore, in the present
research work, an attempt has been made by dispersing silicon
powder particles in dielectric fluid of EDM to enhance the
biocompatibility by producing favorable surface characteristics
and machining characteristics (MRR and TWR).
Figure 2. Schematic diagram of powder mixed electric discharge machining.

Materials and methods by wire-cutting EDM. Before performing experiments, the

workpiece specimens were well polished using adequate
In the present study, a new class of titanium alloy (-phase Ti polishing methods in order to remove surface irregularities.
NbTaZr) was used as workpiece material and its chemical Then, experiments were performed on newly fabricated
composition is shown in Table 1. The -Ti alloy was cast using experimental setup of PMEDM. The PMEDM experimental
the facility available at DRDO-DMRL, India with mixture of setup has mainly a machining tank with liquid capacity of
titanium (Ti) along with niobium (Nb), tantalum (Ta), and 8 l, circulation system, and a stirrer to mix the powder parti-
zirconium (Zr) powder as raw materials. The Ti35Nb7Ta cles with hydrocarbon oil. Figure 1(a) and (b-c) shows the
5Zr (TNTZ) alloy was prepared using the vacuum arc melting
technique to obtain compact and homogenous ingots with
neither weight loss nor oxidation. Table 2. Processing parameters for powder mixed electric discharge machining
The workpiece specimens of 30 mm 30 mm 10 mm of -phase Ti alloy.
(l b t) were cut from the cast ingot of -phase Ti alloy Working parameters Description
Tool electrode Commercially pure Ti (CP-Ti)
Workpiece Ti-35Nb-7Ta-5Zr, -phase titanium alloy
Table 1. Chemical composition of -Ti implant alloy. Polarity Tool (), Workpiece ()
Pulse current (A) 5,10,15,20,25
Titanium Niobium Tantalum Zirconium Pulse duration (s) 5,10,20,40,80
Elements (Ti) (Nb) (Ta) (Zr) Duty cycle (%) 8
Weight percentage Balance 35 7 5 Powder type and size (m) Silicon (Si) and <35
(%) Concentration (g/l) 0 (EDM), 2, 4, 6 and 8
 276 C. PRAKASH ET AL.
photographs of Sparkonix die-sinking EDM machine (model
SZNC-35-5030) and experimental setup of PMEDM, respect-
ively. Figure 2 illustrates the schematic representation of newly
designed experimental setup of PMEDM. A cylindrical com-
mercially pure Ti rod with diameter of 10 mm was used as
the tool electrode. The hydrocarbon oil was used as dielectric
fluid and machining tank was filled with 8 l dielectric fluid.
The pure silicon (Si) powder of particle size <35 m has been
chosen as additive in dielectric fluid. The experimental con-
ditions are shown in Table 2. Then, a number of experiments
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
Figure 3. SEM Micrograph of modified -Ti alloy without powder addition (a-b) Ip 5A, Ton 10 s; (c-d) Ip 10 A, Ton 10 s; (c-d) Ip 5A, Ton 80 s.
were performed and performance output in terms of surface
and machining characteristics has been measured.
After machining, the surface and machining characteristics,
such as surface topography, surface crack, elemental compo-
sition, RLT, SR, MRR, and TWR, have been investigated by
field-emission scanning electron microscopy (FE-SEM; JEOL
7600 F), energy dispersive X-ray analysis (EDXA), Mitutoyo
SR tester, and precision weighing balance machine. The
average SR (Ra) was measured with a cutoff length of
0.08 mm and an evaluation length of 0.4 mm. To measure

the RLT, the cross section of each machined specimen was
prepared and examined by FE-SEM. The MRR and TWR are
calculated as reported elsewhere [4142]. The MRR and
TWR were calculated using Eqs. (1) and (2), respectively as
follow:
Wwb Wwa
MRR
tm
Wtb Wta
TWR
tm
where tm is the machining time and Wwb and Wwa are the
weight of workpiece before and after machining, respectively,
and Wtb and Wta are the weight of tool electrode before and
after machining, respectively.
Results and discussion
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
In the present study, the investigation of surface quality along
with machining characteristics has been addressed to ensure
the achievement of higher quality surface without deteriorat-
ing the machining efficiency. The surface characteristics, such
as SR, micro-cracks, RLT, and surface chemistry, determine
the biocompatibility of substrate and the prime importance
for the optimization of adhesion, spreading, and proliferation
of cells. In previous research findings, it was reported that the
Figure 4. SEM micrograph of modified -Ti alloy at Ip 15 A, Ton 10 s with Si powder of concentration (a, b) 2 g l; (c, d) 4 g l.
MATERIALS AND MANUFACTURING PROCESSES 277
submicron SR in combination with nano-scale topography is
favorable for osseointegration [39].
The surface characteristics, morphology, and composition
are directly proportional to the discharge energy produced
in EDM and the discharge energy is a function of pulse current
and duration. Figure 3 shows the SEM micrograph of -Ti
1 implant surface after EDM at different conditions. The
evidences of redeposited molten metal, globules, macroscale
craters, micro-cracks, and pock marks have been identified.
2
Under the conditions of pulse current 5 A and duration
10 s, the specific width and length of surface cracks, ridges
of redeposited molten metal, discharge craters were formed,
as can be seen in Fig. 3(a) and (b), respectively. As the pulse
current increases to 10 A, the ridges of redeposited molten
metal and surface crack density increases. The poor surface
quality was clearly evidenced from the EDMed surface. This
is because with increase in pulse current, the generated
discharge energy increases, which melt more material from
workpice surface in the form of debris. These debris cannot
flush out and deposited in the form of oxides and carbides
on the periphery of the craters, allowing spherical coarse
grains growth and hence responsible for high ridges of rede-
posited molten metal and results in poor surface quality.
Figure 3(c) and (d), respectively, shows SEM micrograph of
-Ti implant surface after EDM under the conditions of pulse
 278 C. PRAKASH ET AL.
current 10 A and duration 10 s. As the pulse duration
increases, the discharge crater become deeper and wider. This
is because, with the increase in pulse duration, the generated
discharge energy proliferates and penetrates deeply into the
workpiece. As a result, the material is removed from workpice
surface with deep and wider crater size. Figure 3(e) and (f),
respectively, shows SEM micrograph of -Ti implant surface
after EDM under the conditions of pulse current 5 A and
duration 80 s. Micron size (100150 m) pits/craters with
higher surface crack density was fabricated on the EDMed
surface, which exhibited rough surface and poor quality. The
findings of the present EDMed surface morphology is similar
to the results obtained after machining with EDM in distilled
water [13, 30]. The presence of surface defects and micro-
cracks significantly reduced the strength of implant, fatigue
performance, as reported previously by Mover et al. [18] and
Chen et al. [30]. Moreover, the micro-cracks facilitates
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
corrosion propagation and reduces the corrosion resistance
and results in clinical failure, as reported previously by Ntasi
et al. [19].
In the present study, to prevent the formation of large dis-
charge craters and cracks during EDM process, the silicon
powder particles with suitable concentration has been added
into EDM oil (called PMEDM). Figure 4 shows the SEM
micrograph of -Ti implant surface after PMEDM. As
compared to EDM, PMEDM provides smooth surface
Figure 5. Machining mechanism of material removal from workpece in (a) EDM and (b) PMEDM process.
morphology, and interconnected discharge craters with
reduced size. Figure 4(a) and (b), respectively, shows the
SEM micrograph of -Ti implant surface after PMEDM under
the conditions of pulse current 15 A and duration 10 s with Si
concentration of 2 g/l. It can be clearly seen that the ridges of
redeposited molten metal become flat and interconnected;
however, the surface micro-cracks still exit. When the Si con-
centration increased to 4 g/l, ridges of redeposited molten
metal reduced and crack-free, very smooth surface was
obtained. It can be seen that the microscopic crater/pit size
was in the 1520 m range on the surface of the PMEDM
machined samples as can be seen in Fig. 4(c and d). It can
be concluded that presence of silicon powder particles in
dielectric fluid compete against in formation of surface defects.
This is because with the addition of powder particles, the dis-
charge gap increases, which initiate more spark locations and
frequency. As a result, the generated thermal energy decreases
and material is removed in the form of microdebris with small
crater size from the workpiece surface. The eroded debris can
flush out easily due to large discharge gap, which enhances the
surface finish and MRR. The present findings are similar to the
findings of Marashia et al. [41]. Figure 5 presents the sche-
matic representation machining mechanism of EDM and
PMEDM, and surface characteristics obtained after machining.
Nanoporous structures and nano-featured surface was
observed on machined surface. Figure 6 shows the SEM
 MATERIALS AND MANUFACTURING PROCESSES 279
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017

Figure 6. SEM micrograph showing surface nanoporosities on modified surface of -Ti alloy at Ip 15A, Ton 50s and 8% with differenet concentartion of Si
powder particles (a) 0 g/l-EDM only; (b) 2 g/l; (c) 4 g/l; (d) 6 g/l and (e) 8 g/l.

micrographs of -Ti implant surface at pulse current (Ip) 15
A, pulse duration (Ton) 50s and duty cycle 8% (long pulse
interval) with different concentration of silicon powder
particles. Figure 6(a) shows presence of surface porosity on
the EDM modified surface. At high magnification (10000 ),
the surface nanoporosities were clearly observed but with the
presence micro-cracks. As the Si powder concentration
increased to 2 g/l, the density and size of surface nanoporos-
ities has been declined (Fig. 6b). As the silicon powder
concentration increased to 4 g/l, a very thin layer of surface
porosities was observed, because due to presence of Si powder,
good flushing occurred causing reduction in the material
migration on the machined surface. As a result, the surface
nanoporosities with lesser density can be observed in
Fig. 6(c) SEM micrograph. Figure 6(d) shows presence of
nanoporosity on the modified surface at 6 g/l silicon powder
concentration. The increased level of surface nanoporosities
was observed on the modified surface. When the Si powder
 280 C. PRAKASH ET AL.
concentration increased to 8 g/l, the size and density of surface
porosities at nano-scale level can be clear seen in Fig. 6(e). At
higher magnification level (12000 ), the surface porosities of
size 200500 nm were observed. During machining of
PMEDM, the eroded debris migrated toward the workpiece
surface due negative pressure by means of electrophoresis
and deposited on workpiece surface. Due to sudden
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
Figure 7. Cross-section SEM micrograph of -Phase Ti alloy at Ip 5A, Ton 10s at (a) 0 g/l- EDM; (b) 2 g/l; (c-d) 4 g/l of Si powder concentration.
quenching, the absorbed gases are released that leads to the
creation of porosity and foamy-like shapes on the top surface
[8, 39]. As reported in previous research studies, the nanopor-
ous surface provides a biological environment for the growth
of tissues around the implant and builds a strong biological
interface and improved the implant stability [11]. The charac-
teristics of surface morphology has greatly been influenced by

Si powder concentration. The fabrication of surface nanopor-
osities increases the hydrophilicity of the surface, which is
favorable for the osseiointegration or bone ingrowth [39].
It was reported in a number of findings that the RLT has
direct relation to pulse current, duration, and interval [38].
Figure 7 shows the cross section SEM micrograph of RLT of
machined surface at 0 g/l (EDM), 2 g/l, and 4 g/l Si
concentration. It can be observed that with 2 g/l Si concen-
tration, the RLT decreased from 12 m to 8 m and at 4 g/l Si
concentration a very thin (23 m thick) RLT was obtained.
The addition of Si powder particles have very significant effect
on recast layer (RLT). If the concentration increases further
upto 6 g/l, the thickness of recast layer increased to 10 m and
at 8 g/l the thickness of recast layer was measured about
1520 m under the same working conditions, similar to the
finding reported by Chen et al. [38]. The thickness of recast
layer depends on powder concentration along with peak
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
current, pulse duration, and pulse interval [23, 3841]. At
higher powder concentration, the powder particle along with
eroded debris entrapped between the discharge gaps cannot
flush out. As a result, they transferred toward the workpiece
surface and deposited on the machined surface causing increase
in ridges of redeposited material in the form of recast layer.
Along with surface morphology, surface composition and
chemistry of implant surface play a very vital role to enhance
Figure 8. EDAX elemental map shows the composition of -Phase Ti alloy after machining with (a, b) EDM and (c, d) PMEDM.
MATERIALS AND MANUFACTURING PROCESSES 281
biocompatibility and bone-implant anchorage [13, 15, 4345].
In previous research findings, TiO2 [9, 3839], SiO2, [39, 43]
ZrO2, [44], Nb2O5 [39, 45], and TiC [12], like promising bio-
ceramic oxides and carbide, have been used for surface coating
of implants to enhance its biocompatibility, hardness, wear,
and corrosion resistance. According to our previous results,
PMEDM is able to fabricate biomimetic nanoporous biocera-
mic layer on -Ti implant surface and shows excellent biocom-
patibility and corrosion resistance. Figure 8 shows the EDS
mapping analysis of EDMed and PMEDMed surface of -Ti
implant. It can be clearly seen from the map in Fig. 8(a)
and (b), respectively, oxygen (O) and carbon (C) exits on
the EDMed surface with bases material of -Ti alloy. The pres-
ence of C and O is a common finding in EDM process, mainly
attributed due to the decomposition of the hydrocarbon oil in
high temperatures of spark energy. The EDS mapping of
EDMed surface confirms that the presence of C and O, which
leads to the formation of carbides and oxides in higher pro-
portion. On the other hand, C, O, and Si also exit with the
bases material elements on the PMEDMed surface, as can be
seen in Fig. 8(c and d). As a result, the decomposed elements
formed oxides and carbides on the machined surface, which
may expected to enhance the surface properties. In compari-
son with previous research findings, the increased surface
hardness is associated with formation of TiC, TiO2, and
 282 C. PRAKASH ET AL.
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
Figure 9. Effect of pulse current and Duration on (a, b) SR; (c, d) MRR; and (e, f) TWR.
ZrO2 like hard phases in recast layer [12, 39]. The surface
microhardness has been increased up to 1080 HV as
previously reported in ref. [39].
Osseointegration is known to be influenced especially by
microscale roughness and nanoscale topological features
[39]. Figure 9(a) and (b) shows the combined effect of pulse
current and duration on the variation of SR, respectively. In
the case of EDM only, SR increases as pulse current and
duration increases. This is because with the increase in pulse
current and duration the enormous amount of heat energy
developed causing immense melting of the work piece surface
and damaged the surface as a result in larger and deep crater
are formed causes increase in SR value, as described previously
in Fig. 5(a). On the other hand, in the case of PMEDM the
observed value of SR with respect to pulse current and pulse
duration is low as compared to EDMed results. At 4 g/l
powder concentration the observed vale of SR is very low at
any setting of pulse current and pulsed duration. In earlier

findings, Kansal et al. [31] and Singh et al. [35] have reported
that 4 g/l powder concentration is optimum at which the dis-
charge gap is high and as a result the generated thermal energy
decreases, and the reduced amount of material in the form of
microdebris were removed from the workpiece surface. As a
results micro-size craters were formed that improved the sur-
face finish (decreased SR), as described previously in Fig. 5(b).
If the powder concentration increases further then it shows an
incline in SR value. At high concentration of powder particle,
distribution of sparks may be inconsistently.
Machining characteristics includes MRR and TWR were
also observed. Figure 9(c) and (d), respectively, shows the
combined effect of pulse current and duration with powder
concentration on the variation of MRR. It can be clearly seen
that the MRR increases as pulse current and duration increases
with powder concentration. It is well known fact that with
increase in pulse current and duration, the MRR is increase,
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
but with increase in powder concentration the MRR also
increased effectively. As discussed earlier, this is because with
addition of powder particles between electrodes the spark gap
increased. As a result number of charged powder particle
occupy the gap between tool electrode and workpiece; thus
the spark distributes between powder particle and both
electrodes and occurrence of spark frequency and location
increased, as explained previously in Fig. 5(b). The material
is removed in microdebris but at relatively high rate as
compared to EDM, which is responsible for high removal of
material in the case of PMEDM. Figure 9(e) and (f), respect-
ively, shows the combined effect of pulse current and duration
with powder concentration on the variation of TWR, respect-
ively. In the case of EDM, the TWR is increases with pulse cur-
rent and decreases with the increases in pulse duration [42].
But it can be seen that the TWR is decreased effectively as
machining is performed with powder particles, because of the
distribution of the thermal energy generated by electrical
sparks, as explained previously in Fig. 5(b). Similar results have
been reported earlier by researchers like Singh et al [42], Kansal
et al. [31, 33], and Marashia et al. [41], and it has been found
that the presence of powder particles in EDM significantly
improves the MRR, declines the TWR, improves the surface
finish (by reducing the SR value), and enhances the machining
performance by saving tool electrode cost.
Conclusions
In the present research work, the application and capability of
PMEDM to machine the -Ti implant alloy have been investi-
gated. After inclusive analysis of presented work on machining
of -Ti alloy using PM-EDM, the major conclusions can be
drawn as follows:.
1. The silicon, as powder additive in dielectric fluid of EDM
(PMEDM), significantly improved the surface quality by
reducing surface defects like micro-cracks, craters/pit size,
and RLT. At 4 g/l Si powder concentration, the powder
movement perform finishing or polishing action and as a
result very smooth crack-free surface.
2. The thickness of recast layer has significantly affected by
concentration of Si powder. At 4 g/l Si concentration, a thin
recast layer (3 m thick) was obtained. On the other hand,
MATERIALS AND MANUFACTURING PROCESSES 283
with increase in the concentration of Si to 8 g/l, the
thickness of recast layer increases to 15 m at the same
working conditions.
3. Furthermore, PMEDM was able to fabricate nanoporous
biocompatible surface favorable for osseointegration. In
addition, PMEDM proved a promising and potential tech-
nique to control the size and density of porosities on the
machined surface.
4. PMEDM facilitates the generation of surface porosities on
the machined surface and potentially control the size and
density of porosities on the machined surface. When -Ti
alloy machined with 15 A peak current, 50 s pulse dur-
ation, 8% duty cycle (>500 s longer pulse interval) and
8 g/l Si concentration, a nanoporous surface with pore size
200500 nm has been fabricated on the modified surface,
which increases the hydrophilicity of the -Ti alloy surface.
5. EDS elemental map analysis of the PMEDM-modified
surface confirmed that idea of material migration from
the suspended powder particles in the dielectric fluid
adhered to the workpiece surface, playing a main role in
the biocompatibility improvement by generating favorable
surface chemistry of oxides and carbides. At higher concen-
tration of Si powder (8 g/l), the PMEDM-modified surface
expected to compose of Ti oxide, Nb oxide, Ti carbide, Si
oxide, and Si carbide like phases.
6. PMEDM significantly improved the surface finish (by
reducing SR) and machining performance by enhancing
MRR and reducing TWR at same working conditions.
The 4 g/l Si powder concentration is the optimum level at
which the surface characteristics and machining efficiency
are best.
7. In overall, PMEDM can be considered as potential tech-
nique to improve the surface characteristics and chemistry
without sacrificing machining efficiency.
References
[1] Zaman, H.A.; Safian, S.; Idris, M.H.; Kamarudin, A. Metallic bioma-
terial for medical implant applications: a review. Applied Mechanics
and Materials 2015, 735, 1925. doi:10.4028/www.scientific.net/
AMM.735.19.
[2] Li, Y.; Yang, C.; Zhao, H.; Qu, S.; Li, X.; Li, Y. New developments of
Ti-based alloys for biomedical applications. Materials 2014, 7 (3),
17091800. doi:10.3390/ma7031709.
[3] Niinomi, M.; Narushima, T.; Naka, M. Advances in Metallic Bioma-
terials, Springer Berlin Heidelberg: Berlin, Germany, 2015, pp. 348.
[4] Pramanik, A. Problems and solutions in machining of titanium
alloys. The International Journal of Advanced Manufacturing Tech-
nology 2014, 70 (5), 919928. doi:10.1007/s00170-013-5326-x.
[5] Klocke, F.; Zeis, M.; Klink, A.; Veselovac, D. Technological and
economical comparison of roughing strategies via milling, EDM
and ECM for titanium-and nickel-based blisks. Procedia CIRP
2012, 2 (1), 98101. doi:10.1016/j.cirpj.2013.02.008.
[6] Kumar, S.; Singh, R.; Batish, A.; Singh, T.P. Electric discharge
machining of titanium and its alloys: a review. International Journal
of Machining and Machinability of Material 2012, 11 (1), 84111.
doi:10.1504/IJMMM.2012.044922.
[7] Nee, Andrew Y.C. Handbook of Manufacturing Engineering and
Technology, Springer, London, 2015, 3485 pp.
[8] Prakash, C.; Kansal, H.K.; Pabla, B.S.; Puri, S.; Aggarwal, A. Electric
discharge machining a potential choice for surface modification of
metallic implants for orthopedics applications: a review. Proceedings
of the Institution of Mechanical Engineers, Part B: Journal of
 284 C. PRAKASH ET AL.
Engineering Manufacture 2016, 230 (2), 331353. doi:10.1177/
0954405415579113.
[9] Peng, P.W.; Ou, K.L.; Lin, H.C.; Pan, Y.N.; Wang, C.H. Effect of
electrical-discharging on formation of nanoporous biocompatible
layer on titanium. Journal of Alloys and Compounds 2010,
492 (12), 625630. doi:10.1016/j.jallcom.2009.11.197.
[10] Yang, T.S.; Huang, M.S.; Wang, M.S.; Lin, M.H.; Tsai, M.Y.; Wang,
P.Y. Effect of electrical discharging on formation of nanoporous
biocompatible layer on Ti-6Al-4V alloys. Implant Dentistry 2013,
22 (4), 374379. doi:10.1097/ID.0b013e31829a170a.
[11] Lee, W.F.; Yang, T.S.; Wu, Y.C.; Peng, P.W. Nanoporous biocompa-
tible layer on Ti6Al4V alloys enhanced osteoblast-like cell
response. Journal of Experimental and Clinical Medicine 2013,
5 (3), 9296. doi:10.1016/j.jecm.2013.04.002.
[12] Bin, T.C.; Xin, L.D.; Zhan, W.; Yang, G. Electro-spark alloying using
graphite electrode on titanium alloy surface for biomedical applica-
tions. Applied Surface Science 2011, 257 (15), 63646371.
doi:10.1016/j.apsusc.2011.01.120.
[13] Harcuba, P.; Baakova, L.; Strasky, J.; Baakova, M.; Novotna, K.;
Janeek, M. Surface treatment by electric discharge machining of
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
Ti-6Al-4V alloy for potential application in orthopaedics. Journal
of the Mechanical Behavior of Biomedical Materials 2012, 7,
96105. doi:10.1016/j.jmbbm.2011.07.001.
[14] Janecek, M.; Novy, F.; Strasky, J.; Harcuba, P.; Wagner, L. Fatigue
endurance of Ti-6Al-4V alloy with electro-eroded surface for
improved bone in-growth. Journal of the Mechanical Behavior of Bio-
medical Materials 2011, 4, 41722. doi:10.1016/j.jmbbm.2010.12.001.
[15] Strasky, J.; Janecek, M.; Harcuba, P., et al. The effect of microstruc-
ture on fatigue performance of Ti6Al4V alloy after EDM surface
treatment for application in orthopaedics. The Journal of the Mech-
anical Behavior of Biomedical Materials 2011, 4, 19551962.
doi:10.1016/j.jmbbm.2011.06.012.
[16] Muthuramalingam, T.; Mohan, B. Influence of discharge current
pulse on machinability in electrical discharge machining. Materials
and Manufacturing Processes 2013, 28 (4), 375380. doi:10.1080/
10426914.2012.746700.
[17] Yadav, U.S.; Yadava, V. Experimental modelling and optimisation of
process parameters of hole drilling by electrical discharge machining
of aerospace titanium alloy. International Journal of Manufacturing
Technology and Management 2015, 29 (34), 211234. doi:http://dx.
doi.org/10.1504/IJMTM.2015.069256.
[18] Mover, T.M. Degradation of titanium 6Al4V fatigue strength due
to electrical discharge machining. International Journal of Fatigue
2014, 64, 8496. doi:10.1016/j.ijfatigue.2014.02.018.
[19] Ntasi, A.; Mueller, W.D.; Eliades, G.; Zinelis, S. The effect of Electro
Discharge Machining (EDM) on the corrosion resistance of dental
alloys. Dental Materials 2010, 26 (12), 237245. doi:10.1016/j.
dental.2010.08.001.
[20] Shabgard, M.R.; Alenabi, H. Ultrasonic assisted electrical discharge
machining of Ti-6Al-4V alloy. Materials and Manufacturing Pro-
cesses, 2015, 30 (8), 9911000. doi:991-1000
[21] Dwivedi, A.P.; Choudhury, S.K. Effect of Tool Rotation on MRR,
TWR and Surface Integrity of AISI-D3 Steel using Rotary EDM Pro-
cess. Materials and Manufacturing Processes 2016. doi:10.1080/
10426914.2016.1140198.
[22] Pirani, C.; Iacono, F.; Generali, L.; Sassatelli, P.; Nucci, C.; Lusvarghi,
L.; Gandolfi, M.G.; Prati, C. HyFlex EDM: superficial features, met-
allurgical analysis and fatigue resistance of innovative electro dis-
charge machined NiTi rotary instruments. International
Endodontic Journal 2015. doi:10.1111/iej.12470.
[23] Krishna, M.E.; Patowari, P.K. Parametric study of electric discharge
coating using powder metallurgical green compact electrodes. Mate-
rials and Manufacturing Processes 2014, 29 (9), 11311138.
doi:10.1080/10426914.2014.930887.
[24] Muthuramalingam, T.; Mohan, B.; Jothilingam, A. Effect of tool
electrode resolidification on surface hardness in electrical discharge
machining. Materials and Manufacturing Processes 2014, 29 (1112),
13741380.
[25] Gill, A.S.; Kumar, S. Surface roughness and microhardness evalu-
ation for EDM with CuMn powder metallurgy tool. Materials
and Manufacturing Processes 2016, 31 (4), 514521. doi:10.1080/
10426914.2015.1070412.
[26] Shen, Y.; Liu, Y.; Zhang, Y.; Dong, H.; Sun, P.; Wang, X.; Zheng, C.;
Ji, R. Effects of an electrode material on a novel compound machin-
ing of inconel718. Materials and Manufacturing Processes 2016, 31
(7), 845851. doi:10.1080/10426914.2015.1019133.
[27] Ahmed, A. Deposition and analysis of composite coating on alumi-
num using TiB4C powder metallurgy tools in EDM. Materials and
Manufacturing Processes 2016, 31 (6), 467474. doi:10.1080/
10426914.2015.1025967.
[28] Rahang, M.; Patowari, P.K. Parametric optimization for selective
surface modification in EDM using Taguchi analysis. Materials
and Manufacturing Processes 2016, 31 (4), 422431. doi:10.1080/
10426914.2015.1025967.
[29] Dhakar, K.; Dvivedi, A. Parametric evaluation on near-dry electric
discharge machining. Materials and Manufacturing Processes 2016,
31 (4), 413421.
[30] Jothimurugan, R.; Amirthagadeswaran, K.S. Performance of additive
mixed keroseneservotherm in electrical discharge machining of
Monel 400. Materials and Manufacturing Processes 2016, 31 (4),
432438, doi:10.1080/10426914.2014.984202.
[31] Kansal, H.K.; Singh, S.; Kumar, P. Effect of silicon powder mixed
EDM on machining rate of AISI D2 die steel. Journal of
Manufacturing Processes 2007, 9 (1), 1322. doi:10.1016/S1526-
6125(07)70104-4.
[32] Kuriachen, B.; Mathew, J. Effect of powder mixed dielectric on
material removal and surface modification in micro electric
discharge machining of Ti-6Al-4V. Materials and Manufacturing
Processes 2016, 31 (4), 439446 doi:10.1080/10426914.2015.1004705.
[33] Kumar, H. Development of mirror like surface characteristics using
nano powder mixed electric discharge machining (NPMEDM).
International Journal of Advanced Manufacturing Technology
2014, 76 (14), 105113.
[34] Sidhu, S.S.; Batish, A.; Kumar, S. Study of surface properties in
particulate-reinforced metal matrix composites (MMCs) using pow-
der-mixed electrical discharge machining (EDM). Materials and
Manufacturing Processes 2014, 29 (1), 4652.
[35] Singh, B.; Kumar, J.; Kumar, S. Influences of process parameters on
MRR improvement in simple and powder-mixed EDM of AA6061/
10%SiC composite. Materials and Manufacturing Processes 2014,
30 (1), 303312.
[36] Singh, B.; Kumar, J.; Kumar, S. Experimental investigation on
surface characteristics in Powder-Mixed Electro discharge Machin-
ing of AA6061/10%SiC Composite. Materials and Manufacturing
Processes 2014, 29 (3), 287297. doi:10.1080/10426914.2014.880463.
[37] Li, L.; Zhao, L.; Li, Z.Y.; Feng, L.; Bai, X. Surface characteristics of
Ti-6Al-4V by SiC abrasive mixed EDM with magnetic stirring.
Materials and Manufacturing Processes 2016. doi:10.1080/
10426914.2016.1151043.
[38] Chen, S.L.; Lin, M.H.; Huang, G.X.; Wang, C.C. Research of the
recast layer on implant surface modified by micro-current electrical
discharge machining using deionized water mixed with titanium
powder as dielectric solvent. Applied Surface Science 2014, 311,
4753. doi:10.1016/j.apsusc.2014.04.204.
[39] Prakash, C.; Kansal, H.K.; Pabla, B.S.; Puri, S. Processing and
characterization of novel biomimetic nanoporous bioceramic
surface on -Ti implant by powder mixed electric discharge machin-
ing. Journal of Material Engineering and Performance 2015, 24,
36223633. doi:10.1007/s11665-015-1619-6.
[40] Ekmekci, N.; Ekmekci, B. Electrical discharge machining of Ti6Al4V
in hydroxyapatite powder mixed dielectric liquid. Materials and
Manufacturing Processes 2015. doi:10.1080/10426914.2015.1090591.
[41] Marashia, H.; Sarhana, A.A.D.; Hamdia, M. Employing Ti nano-
powder dielectric to enhance surface characteristics in electrical dis-
charge machining of AISI D2 steel. Applied Surface Science 2015,
357, 892907. doi:10.1016/j.apsusc.2015.09.105.
[42] Singh, B.; Kumar, J.; Kumar, S. Investigation of the tool wear rate in
tungsten powder-mixed electric discharge machining of AA6061/
10%SiCp composite. Materials and Manufacturing Processes 2016,
31 (4), 456466. doi:10.1080/10426914.2015.1025965.

[43] Mumjitha, M.; Raj, V. Fabrication of TiO2SiO2 bioceramic
coatings on Ti alloy and its synergetic effect on biocompatibility
and corrosion resistance. Journal of the Mechanical Behavior of Bio-
medical Materials 2015, 46, 205221. doi:10.1016/j.jmbbm.
[44] Qiu, D.; Wang, A.; Yin, Y. Characterization and corrosion behavior
of hydroxyapatite/zirconia composite coating on NiTi fabricated by
Downloaded by [University of Nebraska, Lincoln] at 02:59 04 August 2017
MATERIALS AND MANUFACTURING PROCESSES 285
electro chemical deposition. Applied Surface Science 2010, 257,
17741778. doi:10.1016/j.apsusc.2010.09.014.
[45] Pauline, S.A.; Rajendran, N. Biomimetic novel nanoporous
niobium oxide coating for orthopaedic applications. Applied
Surface Science 2014, 290, 448457. doi:10.1016/j.apsusc.2013.
11.112.