Experimental investigations in powder mixed electric discharge machining of Ti–35Nb–7Ta–5Zrβ-titanium alloy

The present research is the first type of study in which the application of powder mixed electrical discharge machining (PMEDM) for the machining of β-phase titanium (β-Ti) alloy has been proposed. β-Ti alloys are new range of titanium alloys, which has a wide-spread application in dental, orthopedics, shape memory, and stents. The aim of the present study is to fabricate submicro- and nanoscale topography by PMEDM process to enhance the biocompatibility without affecting machining efficiency. The effect of Si powder concentration along with pulse current and duration on the surface and machining 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 β-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 200–500 nm was observed. Moreover, at Si powder concentrations of 2 g/l and 4 g/l, the recast layer thickness is 8 µm and 2–3 µm, respectively. Elemental mapping analysis confirmed that PMEDM also generated carbides and oxides enriched surface, a favorable surface chemistry to enhance the biocompatibility of β-Ti alloy. Furthermore, PMEDM also enhances the machining performance by improving material removal rate and reducing tool wear rate.