Spark erosion behavior in the machining of MoSi2-SiC ceramic composites for improving dimensional accuracy.

The novel applications of MoSi2 and SiC as matrix and reinforcing materials in the creation of high-performance composites were investigated in this work. In particular, Spark Erosion Machining's geometric tolerances were studied in order to shed light on the technique's potential for precision manufacture in the realm of MoSi2-SiC composites. Our research focused on evaluating critical parameters and their impact on machining performance, including material removal rate, surface roughness, wear rate and drilled hole accuracy. In-depth research revealed the critical input factors that had the greatest impact on the machining procedure. Notably, parameters such as current (32%), sparking on time (23%), sparking gap voltage (12%), dielectric pressure (12%), and sparking off time (17%) emerged as the most influential factors, as determined by ANOVA analysis. These findings provide valuable insights into optimizing the Sparking EDM approach for MoSi2-SiC composite materials. This study further demonstrated the improvement in composite desirability ratings across multiple performance criteria, highlighting the effectiveness of Sparking EDM in enhancing machining outcomes (e.g., from 0.8523 to 0.9527). Correlations between the EDM's output responses were found to be quite high when geometric tolerances and the coefficient of determination (R2) were used (0.7858, 0.9625, 0.8427, 0.8678, 0.8474, 0.8368, 0.8344, 0.8671). Consider that, for the sake of a more complete understanding of the procedure's approach, the emphasis is on the methodology rather than the multifaceted metal removal mechanisms involved. This research doesn't dive further into the physical concerns of Spark Erosion Machining, but it does provide insights into the practical application of this technique in the precision manufacturing of MoSi2-SiC composite materials. For real-world medical applications such implanted devices, dental implants, surgical instruments, biological sensors and diagnostics, this study provides a valuable and encouraging approach. A validation experiment verifies the results, proving the feasibility of improved spark erosion in high-precision production. The results of this research show that EDM methods can be fine-tuned to produce ceramic composites with much greater MRR, superior surface finishes and a marked decrease in subsurface cracking and microstructural modifications. This is essential for protecting the integrity of materials used in life-saving medical equipment.

Developing Meso and Microholes by Spark-Erosion Based Drilling Processes: A Critical Review.

The increased demand for miniature components has drawn the attention of researchers, engineers, and industry users to manufacture precision micro and mesoholes on foils, sheets, and plates made from a variety of engineering materials. These days, micro-drilling is extensively being adopted as a fundamental operation in all kinds of smart manufacturing industries to make different types of microholes, such as through holes, blind holes, and taper holes on micro-parts and components. Drilled holes with a diameter of less than 1 mm are referred to as microholes, while drilled holes whose diameter ranges between 1 and 10 mm are known as mesoholes. Meso and microholes are commonly referred to as fine-holes. Modern or advanced drilling processes are mostly used to drill microholes from a variety of materials. This paper presents an extensive review of the previous research conducted on the drilling of fine holes (meso and micro size) by spark- erosion-based processes along with highlighting work and tool electrode materials, specifications of drilled holes, types of microholes (through or blind holes), process parameters, performance measures, and key findings. The paper aims to facilitate researchers and scholars by highlighting the capabilities of spark erosion machining, drilling, and its variants to fabricate miniature holes. The paper ends with a conclusion and future research directions to encourage further work in this area.

High Effective Preparation of Amorphous-Like Si Nanoparticles Using Spark Erosion Followed by Bead Milling.

This work aims to prepare the silicon nanoparticles with the nanocrystal-embedded amorphous structure through spark erosion followed by bead milling. Spark erosion breaks up monocrystal silicon ingots into micro/nanoparticles, refines the crystal grains, makes the crystals randomly disordered, and increases isotropic character. Bead milling further refines the crystal grains to a few nanometers and increases the amorphous portion in the structure, eventually forming an amorphous structure with the nanocrystals embedded. Spark erosion saves much time and energy for bead milling. The crystallite size and the amount of amorphous phase could be controlled through varying pulse durations of spark discharge and bead milling time. The final particles could contain the nanocrystals as small as 4 nm and the content of amorphous phase as high as 84% and could be considered as amorphous-like Si nanoparticles. This processing route for Si nanoparticles greatly reduced the production time and the energy consumption and, more importantly, is structure-controllable and scalable for mass production of the products with higher purity.

3D metal printing in dentistry: An in vitro biomechanical comparative study of two additive manufacturing technologies for full-arch implant-supported prostheses.

The use of 3D technologies is progressing in the dental field. However, little is known about the biomechanical behavior of the additive manufacturing of full-arch fixed dental prostheses (FAFDPs) for the establishment of clinical protocols. We investigated the influence of three CAD/CAM technologies: milling (control), Selective Laser Melting (SLM) and Electron Beam Melting (EBM) for FAFDP manufacturing. Also, the effects of ceramic veneer and spark erosion on marginal misfits of FAFDPs, the stability of prosthetic screws, strain and stress on the implant-supported system, as well as the effect of chewing simulation on screw stability were evaluated. Fifteen Ti-6Al-4V alloy FAFDPs were obtained by means of CAD/CAM systems: milling, SLM and EBM (n = 5/group). The marginal misfit was analyzed according to the single-screw test protocol. Screw stability was analyzed by screw-loosening torque. Strain-gauge analysis investigated the strain on the mini-abutment analog, and photoelastic analysis investigated the stress on the peri-implant region. Subsequently, all frameworks underwent ceramic veneer and spark erosion procedures. Marginal misfit, screw-loosening and strain and stress analyses were assessed after each evaluation time: initial, ceramic veneer and spark erosion. Finally, all prostheses were subjected to 106 mechanical cycles (2 Hz/150 N), and screw-loosening was re-evaluated. Data were subjected to two-way ANOVA for repeated measures, and the Bonferroni test as a post hoc technique (α = 0.05). At the initial time, the milling group presented the lowest marginal misfit (p < 0.001). Ceramic veneer did not alter marginal misfit for all groups (p > 0.05); spark erosion decreased the misfit values for the SLM and EBM groups (p < 0.05). Evaluation time did not alter screw-loosening values for all groups (p = 0.191), although the milling group presented the highest screw-loosening values (p < 0.05). Ceramic veneer and spark erosion reduced strain in the components regardless of the manufacturing technology used (p < 0.05). The milling group presented the lowest stress values regardless of evaluation time (p = 0.001), and lower stress values were found after spark erosion regardless of the manufacturing group (p = 0.016). In conclusion, although milled frameworks exhibited the best biomechanical behavior, frameworks manufactured by additive technologies presented acceptable values of screw-loosening torque, strain and stress. Ceramic veneer did not negatively interfere in the biomechanical tests of the study, and clinically acceptable marginal misfit was achieved after spark erosion. Therefore, such 3D printing technologies seem to be feasible for the manufacturing of full-arch implant-supported frameworks.

Biomechanical behavior of CAD/CAM cobalt-chromium and zirconia full-arch fixed prostheses.

PURPOSE: To verify the influence of computer-aided design/computer-aided manufacturing (CAD/CAM) implant-supported prostheses manufactured with cobalt-chromium (Co-Cr) and zirconia (Zr), and whether ceramic application, spark erosion, and simulation of masticatory cycles modify biomechanical parameters (marginal fit, screw-loosening torque, and strain) on the implant-supported system. MATERIALS AND METHODS: Ten full-arch fixed frameworks were manufactured by a CAD/CAM milling system with Co-Cr and Zr (n=5/group). The marginal fit between the abutment and frameworks was measured as stated by single-screw test. Screw-loosening torque evaluated screw stability, and strain analysis was explored on the implant-supported system. All analyses were performed at 3 distinct times: after framework manufacturing; after ceramic application in both materials' frameworks; and after the spark erosion in Co-Cr frameworks. Afterward, stability analysis was re-evaluated after 106 mechanical cycles (2 Hz/150-N) for both materials. Statistical analyses were performed by Kruskal-Wallis and Dunn tests (α=.05). RESULTS: No difference between the two materials was found for marginal fit, screw-loosening torque, and strain after framework manufacturing (P>.05). Ceramic application did not affect the variables (P>.05). Spark erosion optimized marginal fit and strain medians for Co-Cr frameworks (P<.05). Screw-loosening torque was significantly reduced by masticatory simulation (P<.05) regardless of the framework materials. CONCLUSION: Co-Cr and Zr frameworks presented similar biomechanical behavior. Ceramic application had no effect on the biomechanical behavior of either material. Spark erosion was an effective technique to improve Co-Cr biomechanical behavior on the implant-supported system. Screw-loosening torque was reduced for both materials after masticatory simulation.

Effect of Laser Etching and Spark Erosion on Retention and Resistance of Partial Veneer Crown Copings Luted with Adhesive Resin Cement.

PURPOSE: There has been less focus on methods to improve the clinical performance of partial veneer crowns. In this study, we wanted to explore the potential of two new surface treatment modalities (laser etching and spark erosion) for improving the longevity of partial veneer crowns. MATERIAL AND METHODS: Conventional partial veneer crown preparation was done on 90 extracted premolars by a single operator. All the samples used in the study were divided into three groups. Group A were samples to be treated by sandblasting alone, Group B were samples to be treated by sandblasting followed by laser etching, and Group C were samples to be treated by sandblasting followed by spark erosion. Each group consisted of two Sub Groups: Sub Group I-Retention test group, Sub Group: II-Resistance test group. The prepared teeth were randomly allotted to the three groups and subgroups using lot method. Partial veneer crown copings were fabricated for testing retention and resistance. Castings in each subgroup were luted with resin cement to their respective tooth preparations. Retention and resistance testing of samples were done with the use of an Instron Universal testing machine. RESULTS: The two surface treatments, laser etching and spark erosion (Groups B and C) of metal copings significantly improved the retention and resistance compared to sandblasted surfaces alone (P ≤ 0.05). Retention and resistance of copings which were sandblasted and spark eroded (Group C) were found to be highest among the three groups (P ≤ 0.05). CONCLUSION: Within the limitation of this study, it can be concluded that the combination of spark erosion and sandblasting significantly improves the retention and resistance values of partial veneer crown. This study helps to provide better knowledge about the surface treatment required for success of partial veneer crowns.

Reabilitação maxilomandibular utilizando próteses protocolo com infraestruturas metálicas fresadas pelo sistema CAD/CAM e submetidas ao processo de eletroerosão / Maxillomandibular rehabilitation using complete fixed, implant-supported restorations with metallic CAD/CAM frameworks under the spark erosion process

Este trabalho teve como meta ilustrar um caso clínico que oferece noções da sequência clínica e alguns passos explicativos das fases laboratoriais para a aplicação do processo de eletroerosão em infraestruturas de próteses protocolo fresadas pelo sistema CAD/CAM, colaborando com a literatura e clínicos interessados, dando um diagnóstico da situação atual do tema. O trabalho executado atendeu às expectativas de estética da paciente e aos anseios profi ssionais em relação à passividade clínica obtida pela prótese.

This article aimed to illustrate a case that off ers notions of the clinical and laboratorial steps of the spark erosion technique in implant-supported metallic CAD/CAM milled frameworks and thus contribute to literature and clinicians interested in that, providing a diagnosis of the current status of the subject. The work performed met the expectations of the patient's aesthetic desires and professionals wishes towards the clinical passivity in the prosthesis.

Nanoparticles formation mechanisms through the spark erosion of alloys in cryogenic liquids.

Mechanisms of the formation of nanoparticles of some B2 shape memory intermetallic compounds, glass-forming Zr-based alloy, and pure Ti obtained by spark erosion method in liquid nitrogen and argon are considered. One of peculiarity is a foam-like structure, which covers the surface of micron-sized particles that appear during spark erosion. Such morphology is related to the nanosized particles gathered in agglomerates. Detailed examination of those particles allows proposed several mechanisms of their formation. The mechanisms explains two kinds of nanosized particles: particles of several tens and even hundreds of nanometers are formed due to explosion of molten droplets while the smaller particles having in turn a different structure and morphology are formed as a result of condensation of evaporated constituents under different conditions. The latter have the composition usually different from the target composition while the composition of the former is very close to the target (master alloy) composition.

Application of spark erosion technology in manufacture of implant prosthesis / 北京大学学报(医学版)

Objective:To evaluate the influence of the implant-supported porcelain bridges made from non-precious metals using spark erosion techniques, and to discuss the feasibility and details of making the implant restoration by spark erosion technique.Methods: The study included 12 patients ( 9 males and 3 females) with 92 units implant-supported non-precious porcelain bridge from Sep.2011 to Feb. 2013.All the patients received implant treatment in Department of Oral Implantology, Peking University School and Hospital of Stomatology.The total of 52 implants, were from Nobel Biocare implant system, Camlog implant system and Ankylos implant system.The implant analogs were connected in sequence with a copper wire to guarantee conductivity.The implant electrodes represented one electrode and the superstructure the other.During spark-erosion machining, the cast holding the implant electrodes and the prosthetic framework were moved toward one another, causing an electrical erosion of the protruding ele-ments.Results:After the spark-erosion machining, the minimum gap between the framework and abut-ment was 0.21 mm, which was two units bridge.The maximum was 2.59 mm, which was 11 units bridge with 6 implants.The average gap was 0.68 mm.After the spark-erosion machining, the bridge fitted well with the passive position stability.Conclusion: The method of making implant-supported non-precious porcelain bridge reduces costs on patients.Spark erosion has the potential to provide implant framework with an excellent fit.The patients are satisfied with the clinical results.