HyFlex EDM rotary Ni-Ti prototypes: the effect of an innovative machining technology on Ni-Ti wear

Aim. HyFlex EDM files were recently introduced pre- senting an innovative electro discharge machining (EDM) process of fabrication. The aim of this study was to evalua- te the surface and microstructural alterations of new and in vitro used HyFlex EDM Ni-Ti rotary prototypes. Methods. The surface and microstructural characteristi- cs of 15 new HyFlex EDM instruments were analyzed by ESEM equipped with energy dispersive x-ray spectropho- tometry (EDS) and optical metallographic imaging. Instru- ments were subjected to instrumentation tests on severely curved root canals (ranging between 50° and 70°) of ex- tracted multi-rooted teeth. Once that canal patency was verified with a #10 K-file, the working length was determi- ned by subtracting 1mm. HyFlex EDM files were used with a 16:1 reduction handpiece X-Smart (Dentsply Maillefer, Baillagues, Switzerland) following the manufacture’s direc- tion, at 500 rpm and 2.5Ncm, with slightly apical pressure and pecking motion. The operative sequence was: 25/12 at 2/3 of the WL, 10/05 and 25/08 at WL. Irrigation was per- formed at every change of instrument, with a total amount of3mlof5%NaOCland3mlof10%EDTA(Ogna,Mug- giò, Italy). Each instrument was used in 10 curved canals, washed in an ultrasonic bath containing detergent for 10 min and then autoclaved at 134°C. Surface and microstruc- tural characterizations were repeated on used instruments at same points and with same angulations to compare the pre- and postoperative micrographs, in order to verify the appearance of fractures, unwinding, microcracks, blade di- sruption and tip deformation. Results. Surface and microstructural characteriza- tion of new instruments revealed the typical features of a NiTi ED-Machined alloy with an irregular and “craters-like” surface. High magnification microgra- phs disclosed a non-uniform structure were pits, po- res and voids caused the peculiar aspect of a “rough- spark-machined” surface. No fractures were registered during instrumentation of curved canals. Surface and microstructural characterization of used files revealed no wear and no degradation of the 25.12 and 25.08 files. The tip segment was confirmed as the most me- chanically stressed portion of 10.05 prototypes. All the instruments, after several uses, well-preserved the “craters-like” irregular surface without cutting edge al- terations. The metallographic inspection on the cross section of brand new HyFlex EDM files showed an homogeneous martensitic phase. The microstructure appeared uniform from the surface to the bulk, and no microcracks or defect were identified, even at high optical magnification (1000X). Conclusion. Unaltered spark-machined surface and low microstructural degradation are the main features of recently introduced HyFlex EDM. Caution would be re- commended regarding reuse of small HyFlex EDM files. Instruments exhibited a safe in vitro use in presence of severely curved canals.