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In this paper, the selected results of measurements and analysis of the active surfaces of a new generation of coated abrasive tools obtained by the use of focus-variation microscopy (FVM) are presented and discussed. The origin of this technique, as well as its general metrological characteristics is briefly described. Additionally, information regarding the focus variation microscope used in the experiments -InfiniteFocus ® IF G4 produced by Alicona Imaging, is also given. The measurements were carried out on microfinishing films (IMFF), abrasive portable belts with Cubitron™ II grains, and single-layer abrasive discs with Trizact™ grains. The obtained results were processed and analyzed employing TalyMap 4.0 software in the form of maps and profiles, surface microtopographies, AbbottFirestone curves, and calculated values of selected areal parameters. This allowed us to describe the active surfaces of the coated abrasive tools, as well as to assess the possibility of applying the FVM technique in such kinds of measurements.

In the present research, a composite layer of TiO2-TiC-NbO-NbC was coated on the Ti-64 alloy using two different methods (i.e., the electric discharge coating (EDC) and electric discharge machining processes) while the Nb powder were mixed in dielectric fluid. The effect produced on the machined surfaces by both processes was reported. The influence of Nb-concentration along with the EDC key parameters (Ip and Ton) on the coated surface integrity such as surface topography, micro-cracks, coating layer thickness, coating deposition, micro-hardness has been evaluated as well. It has been noticed that in the EDC process the high peak current and high Nb-powder concentration allow improvement in the material migration, and a crack-free thick layer (215 μm) on the workpiece surface is deposited. The presence of various oxides and carbides on the coated surface further enhanced the mechanical properties, especially, the wear resistance, corrosion resistance and bioactivity. The surface hardness of the coated layer is increased from 365 HV to 1465 HV. Furthermore, the coated layer reveals a higher adhesion strength (~118 N), which permits to enhance the wear resistance of the Ti-64 alloy. This proposed technology allows modification of the mechanical properties and surface characteristics according to an orthopedic implant’s requirements.

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