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Investigation into microdefects and corrosion resistance of nickel-titanium shape memory alloy using electrical discharge coating process

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Abstract

Nickel-titanium shape memory alloy is a novel material with outstanding properties suitable for biomedical applications such as implantation devices. Unfortunately, the high composition of nickel in this alloy can be harmful to the human body, if its exposure exceeds a threshold value. Therefore, an innovative electrical discharge coating technique was investigated and proposed in this study to develop minimal microdefect formation with high corrosion resistance through fractional factorial design of experiment. The results showed that discharge duration mostly dominated the material deposition, microcracks, and porosity fraction up to 72%, due to the impact of the intensity of discharge energy. There was also a pronounced effect of titanium powder concentration in the deionized water on the percentage of titanium and nickel elements and microcrack formation. The powder suspension enhanced the recast layer formation through the increment of layer density, which covered up the Ni-rich region and diminished the microcrack formation. An optimized substrate recorded the lowest corrosion current, \({\text{I}}_{\text{corr}}\), and highest corrosion voltage, \({\text{E}}_{\text{corr}}\), at 3.43 × \({10}^{-{6}}\) µA/cm2 and − 0.07 V respectively, thus exhibiting an outstanding corrosion resistance rate at only 8.57 µm/year in phosphate-buffered saline solution, due to the low nickel concentration, low microcracks, and low porosity fraction in the recast layer. Therefore, the results obtained within this styud presented an initial step towards assessing the feasibility of applying the electrodischarge process to biomaterials, including nickel-titanium shape memory alloy. Further exploration, involving both in-vitro and/ or in-vivo studies, is essential to thoroughly evaluate the performance of the coating obtained from the process.

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Funding

The authors gratefully acknowledge the financial support from Fundamental Research Grant Scheme FRGS/1/2017/TK03/UNIMAP/03/5 under UniMAP Project Code 9003–00633, which was granted by Ministry of Higher Education, Malaysia.

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Authors and Affiliations

  1. Department of Manufacturing, Faculty of Mechanical Engineering & Technology, Universiti Malaysia Perlis, Pauh Putra Campus, 02600, Arau, Perlis, Malaysia

    Ahmad Fairuz Mansor & Azwan Iskandar Azmi

  2. Department of Engineering, Centre for Engineering Research, University of Hertfordshire, Hatfield, AL10 9AB, England, UK

    Sikiru Oluwarotimi Ismail

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All authors have read and agreed to the published version of the manuscript. Conceptualization, methodology, writing, review, and editing for this research were performed by all of the authors. Data curation, analysis, and validation were conducted by Ahmad Fairuz Mansor, and research supervision was performed by Azwan Iskandar Azmi.

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Correspondence to Ahmad Fairuz Mansor or Azwan Iskandar Azmi.

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Mansor, A.F., Azmi, A.I. & Ismail, S.O. Investigation into microdefects and corrosion resistance of nickel-titanium shape memory alloy using electrical discharge coating process. Int J Adv Manuf Technol 132, 2587–2599 (2024). https://doi.org/10.1007/s00170-024-13507-w

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