Enhanced Bioactivity and Antibacterial Properties of Ti-6Al-4V Alloy Surfaces Modified by Electrical Discharge Machining

Bacterial infections and the lack of bioactivity of titanium implants and their alloys remain critical challenges for the long-term performance and clinical success of these devices. These issues arise from the undesirable combination of early microbial adhesion and the limited ability of metallic surfaces to form a bioactive interface capable of supporting osseointegration. To address these limitations simultaneously, this study employed electrical discharge machining (EDM), which enables surface topography modification and in situ incorporation of bioactive ions from the dielectric fluid. Ti-6Al-4V ELI surfaces were modified using two dielectric fluids, a fluorine/phosphorus-based solution (DF1-F) and a calcium/phosphorus-based solution (DF2-Ca), under positive and negative polarities. The recast layer was characterized by SEM and EDS, while bioactivity was evaluated through immersion in simulated body fluid (SBF) for up to 21 days. Antibacterial performance was assessed against Staphylococcus aureus at 6 h and 24 h of incubation. The results demonstrated that dielectric composition and polarity strongly influenced ionic incorporation and the structural stability of the modified layers. The DF2-Ca(+) condition exhibited the most favorable bioactive response, with Ca/P ratios closer to hydroxyapatite and surface morphologies typical of mineralized coatings. In antibacterial assays, Ca/P-containing surfaces significantly decreased S. aureus attachment (>80–90%). Overall, EDM with Ca/P-containing dielectrics enables the fabrication of Ti-6Al-4V surfaces with enhanced mineralization capacity and anti-adhesive effects against Gram-positive bacteria, reinforcing their potential for multifunctional biomedical applications.