The Journal of prosthetic dentistry · 2026
Effect of plasma electrolytic polishing on the fatigue performance of additive manufactured Ti-6Al-4V removable partial denture clasps.
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Xu Minrui, Lin Zhenxiang, Cheng Hui, Lin Yan
Аннотация
STATEMENT OF PROBLEM: Plasma electrolytic polishing (PEP) offers a promising alternative to conventional polishing methods for additively manufactured (AM) Ti-6Al-4V (Ti64) removable partial denture (RPD) frameworks. However, its effect on the fatigue performance of AM Ti64 RPD clasps remains unclear.
PURPOSE: The purpose of this in vitro study was to evaluate the effect of PEP on the fatigue behavior of AM Ti64 RPD clasps and compare it with that of mechanical polishing.
MATERIAL AND METHODS: AM Ti64 specimens were fabricated and divided into 4 groups: untreated (Raw), mechanical polishing (MP), pure plasma electrolytic polishing (PEP), and mechanical grinding followed by PEP (MG +PEP). Cylindrical specimens (Ø10×5 mm) were prepared for Vickers hardness testing. Clasp-shaped specimens were prepared for intaglio surface roughness assessment (n=10), X-ray diffraction (XRD) residual stress analysis (n=5), mercury intrusion porosimetry (MIP) porosity measurement (n=10), and fatigue testing across displacements from 0.30 mm to 1.00 mm for 10⁵ cycles (n=5 per displacement). Clasp fracture surfaces were examined using a scanning electron microscope (SEM). Finite element analysis (FEA) was conducted using Abaqus 2019 to evaluate the stress distribution and maximum principal stress of AM Ti64 clasp under simulated displacement. Statistical analyses were performed using 1-way ANOVA and Kruskal-Wallis tests (α=.05).
RESULTS: No significant differences in Vickers hardness were observed among groups (P>.05), except between the Raw and MG +PEP groups (P=.012). The PEP group exhibited significantly rougher intaglio surfaces compared to the MP group (P=.001), while no difference was found between MP and MG +PEP groups (P=.433). The polished groups demonstrated similarly low porosity levels (MP: 0.427%, PEP: 0.372%, MG +PEP: 0.335%), in contrast to the Raw group (1.838%). Fatigue testing revealed significantly improved performance in the MP group compared to the Raw group (P=.044); no significant differences were found among the polished groups (P>.05). SEM analysis showed fatigue cracks originating from surface and subsurface defects. FEA indicated that regions of stress concentration corresponded to observed fracture sites.
CONCLUSIONS: Although pure PEP treatment was not found to provide an optimal surface finish for AM Ti64 RPD clasps, its combination with mechanical grinding resulted in surface characteristics comparable to mechanical polishing. PEP-treated AM Ti64 clasps demonstrated fatigue resistance similar to that of mechanically polished counterparts.
PURPOSE: The purpose of this in vitro study was to evaluate the effect of PEP on the fatigue behavior of AM Ti64 RPD clasps and compare it with that of mechanical polishing.
MATERIAL AND METHODS: AM Ti64 specimens were fabricated and divided into 4 groups: untreated (Raw), mechanical polishing (MP), pure plasma electrolytic polishing (PEP), and mechanical grinding followed by PEP (MG +PEP). Cylindrical specimens (Ø10×5 mm) were prepared for Vickers hardness testing. Clasp-shaped specimens were prepared for intaglio surface roughness assessment (n=10), X-ray diffraction (XRD) residual stress analysis (n=5), mercury intrusion porosimetry (MIP) porosity measurement (n=10), and fatigue testing across displacements from 0.30 mm to 1.00 mm for 10⁵ cycles (n=5 per displacement). Clasp fracture surfaces were examined using a scanning electron microscope (SEM). Finite element analysis (FEA) was conducted using Abaqus 2019 to evaluate the stress distribution and maximum principal stress of AM Ti64 clasp under simulated displacement. Statistical analyses were performed using 1-way ANOVA and Kruskal-Wallis tests (α=.05).
RESULTS: No significant differences in Vickers hardness were observed among groups (P>.05), except between the Raw and MG +PEP groups (P=.012). The PEP group exhibited significantly rougher intaglio surfaces compared to the MP group (P=.001), while no difference was found between MP and MG +PEP groups (P=.433). The polished groups demonstrated similarly low porosity levels (MP: 0.427%, PEP: 0.372%, MG +PEP: 0.335%), in contrast to the Raw group (1.838%). Fatigue testing revealed significantly improved performance in the MP group compared to the Raw group (P=.044); no significant differences were found among the polished groups (P>.05). SEM analysis showed fatigue cracks originating from surface and subsurface defects. FEA indicated that regions of stress concentration corresponded to observed fracture sites.
CONCLUSIONS: Although pure PEP treatment was not found to provide an optimal surface finish for AM Ti64 RPD clasps, its combination with mechanical grinding resulted in surface characteristics comparable to mechanical polishing. PEP-treated AM Ti64 clasps demonstrated fatigue resistance similar to that of mechanically polished counterparts.