Surface characteristics and machining rate of SS 316L coating developed using hydroxyapatite-mixed EDM process

Hydroxyapatite (HA) or bioceramic-based coatings on stainless steel (SS) 316L significantly enhance the biofunctionality of the base material’s surface. However, HA’s low thermal conductivity and brittleness limit its effectiveness as a coating material. This study investigates HA coating on SS 316L using electric discharge machining (EDM) with varying discharge energies and powder concentrations. Surface morphology, elemental composition, and phase analysis of untreated and coated samples were characterised using field emission scanning electron microscopy (FESEM), energy dispersive X-ray (EDX), and X-ray diffraction (XRD). The results demonstrate that the HA-assisted EDM process creates a coating comprising biocompatible oxides, phosphates, carbides, and intermetallic compounds. The coating exhibits a thin resolidified layer of 10.74 μm, characterised by redeposited spherical debris, shallow cavities, and a surface texture of 2.688 μm. The layer’s hydrophilic nature is confirmed by a minimum contact angle of 47.68°. Taguchi analysis indicates that the machining rate is optimised at an HA powder concentration of 16 g/l, with peak current and HA powder concentration being the most influential parameters affecting resolidified layer thickness, surface texture, and wetting angle. The research intends to motivate SS 316L medical device manufacturers to implement the HA-assisted EDM process for bioimplant’s dual machining and coating.