Basic Research—Technology
Effect of Electropolishing ProFile Nickel–Titanium Rotary
Instruments on Cyclic Fatigue Resistance, Torsional
Resistance, and Cutting Efficiency
Tung B. Bui, DDS,* John C. Mitchell, PhD,† and J. Craig Baumgartner, DDS, PhD‡
Abstract
This study investigated the effect of electropolishing
ProFile nickel titanium rotary instruments on torque
resistance, fatigue resistance, and cutting efficiency.
Size 25/.04 ProFile files (Dentsply Maillefer, Switzer-
land) that were nonpolished for the control group (n ⫽
15) and electropolished for the experimental group
(n ⫽ 15) were used for each experiment. Cyclical
fatigue was determined by counting rotations until
breakage with an applied 30°, 45°, and 60° curve with
a 5-mm radius. Torque and angle at failure were mea-
sured by rotating clamped files at 2 rpm until breakage.
Cutting efficiency was determined by measuring the
velocity of file advancement into plastic blocks with
100-g constant force for 5 seconds. Data were analyzed
by either an unpaired t test or analysis of variance
followed by a Fisher probable least-square difference
test. Electropolishing significantly reduced resistance to
cyclic fatigue but did not affect torsional resistance.
However, electropolishing reduced the angle at failure
and amount of unwinding. Electropolishing did not
significantly affect cutting efficiency. (J Endod 2008;34:
190 –193)
Key Words
Cutting efficiency, cyclical fatigue, electropolish, nickel-
titanium, torque resistance
From *Private Practice, Tucson, Arizona; and the Depart-
ments of †Biomaterials and Biomechanics and ‡Endodontol-
ogy, Oregon Health and Science University, Portland, Oregon.
Address requests for reprints to Dr J. Craig Baumgartner,
Department of Endodontology, 611 S.W. Campus Drive, School
of Dentistry, Oregon Health & Science University, Portland, OR
97239. E-mail address: baumgarc@ohsu.edu.
0099-2399/$0 - see front matter
Copyright © 2008 by the American Association of
Endodontists.
doi:10.1016/j.joen.2007.10.007
190 Bui et al.
S ince 1988, the use of nickel-titanium (NiTi) endodontic rotary instruments has
increased (1). However, these instruments are prone to separation without
warning. Breakage of NiTi endodontic files is commonly caused by overuse or
improper use of the instruments (2). Separated instrument fragments impede the
ability to débride the infected root canal apical to the fragment and may increase
the risk of treatment failure (3). Furthermore, because NiTi alloy is softer than
stainless steel, extended use often dulls the files, and reduces cutting efficiency (4).
Thus, the search for NiTi files with increased toughness and ultimate strength is
warranted to minimize these disadvantages (5).
One strategy to reduce instrument separation is to modify the surface of the
instrument to maximize their mechanical properties of torsional strength and cyclical
fatigue resistance without affecting superelasticity. During manufacturing of NiTi files,
machining of the flutes causes work hardening of the surface (6). The grinding process
results in selected areas that are work hardened and more brittle (7). Machining also
produces microcracks and tool marks that are thought to be crystalline dislocation
centers. These may initiate fracture propagation and contribute to the degradation of the
mechanical properties of NiTi (6, 7).
It has been suggested that coating these machined flaws may strengthen the
NiTi files (5). Ion-beam surface modification using boron implantation has been
shown to enhance surface hardness of NiTi alloy (8). Improved wear resistance and
cutting efficiency of NiTi files has also been shown after a thermal nitridation
process (9). Nitrogen ion implantation and thermal nitridation techniques also
showed improved wear resistance (10). Hardening of the surfaces of files by
thermal metal organic chemical vapor deposition technique has been attempted
(11). A physical vapor deposition of titanium nitride (Ti3N4) particles showed
increased wear resistance (12).
An alternative to coating surfaces of files is to dissolve away these defects. A
common method used in tool manufacturing is the process of electropolishing.
This involves the removal of a very thin surface layer by immersing the material in
a highly ionic solution with an electric current (13). It has been described as
“reverse plating” (13). Electropolishing levels grain boundaries, optimize the
material’s mechanical properties, and reduce dimensions (13). This process re-
moves surface pitting and machine grooves that can act as centers of fracture
propagation. It is believed that electropolishing may result in improved torsional
strength and cyclical fatigue resistance. Electropolishing may also reveal hidden
gross defects that can be detected and removed from the assembly line during
quality control processing (13).
Manufacturers claim that electropolishing eliminates surface imperfections
that weaken other files and that the process increases file sharpness (14, 15). The
purpose of this investigation was to study the effect of electropolishing on NiTi
rotary files. This was accomplished by evaluating the static cyclic fatigue resistance,
torque strength, and cutting efficiency of electropolished files. Environmental scan-
ning electron microscope (ESEM) images of the surface and subsequent fracto-
graphic analysis of the surfaces were used for analysis. The null hypothesis was that
there is no significant difference between either the nonpolished or electropolished
Profile NiTi rotary files (Dentsply Maillefer, Switzerland).
JOE — Volume 34, Number 2, February 2008

Materials and Methods
For all parts of this study, control samples consisted of the follow-
ing: Profile 0.04 taper, size #25, 25 mm, machined files, (Dentsply) and
experimental samples were Profile 0.04 taper, size #25, 25 mm, elec-
tropolished files (Dentsply).
As modified from Pruett et al. (16), three artificial canals were
constructed by bending a 16-gauge stainless steel Monojet blunt needle
(Tydall; Tyco Health Care Group, Mansfield, MA). The three canals were
bent to a 5-mm radius of curvature and angles of curvature of 30°, 45°,
and 60°. The center of radius in the curved section of the canal was 7
mm from the tip of the file. The tip of the file protruded approximately
2 mm from the end of the tube. The files were rotated at 300 rpm (TCM
ENDO, NOUVAG; Maillefer, Dentsply, Switzerland), which was within the
manufacturer’s recommended speed. Fifteen instruments from the ex-
perimental and control group were tested. Instruments were rotated
freely inside the three simulated canals until separation was detected
visually. The time to fracture was recorded in seconds with a stopwatch.
The rotation speed of 300 rpm was converted to 5 rotations per second.
The number of rotations to breakage for each file was calculated by
multiplying the seconds to fracture by five.
Fifteen files from each group were tested for torsional strength by
using a modified protocol of American National Standards Institute/
American Dental Association (ANSI/ADA) Specification #28 for stainless
steel endodontic files (17). At the time of this study, there were no ADA
specification testing protocols for NiTi rotary files. The handle end of
the rotary file was clamped to the chuck of the digital torque meter
accurate to 0.1 Ncm (Chatillon/Ametek, FL). The accuracy of 0.1 Ncm
on the torque meter is clinically acceptable because it matches the
torque setting resolutions on most rotary engines. Three millimeters of
the rotary file tip was secured to a jeweler’s minichuck (A&M Jewels
Tools & Supply Company, New York, NY) with jaws made of soft brass
alloy. This minichuck was attached to a reversible geared motor (Zero-
Max, Plymouth, MN). The files were rotated clockwise at 2 rpm until
they fractured. The maximum torque (Ncm) and angle of rotation until
fracture (angle in degrees) were recorded. The files were examined at
10⫻ magnification to observe signs of physical deformation, such as
unwinding.
To measure cutting efficiency, a 75-cm long aluminum rod was
attached to a contra-angle handpiece such that an attached rotary in-
strument would be perpendicular to the length of the rod. A freely
rotating joint was secured to the rod at 55 cm from the head of the
hand-piece. The opposite end of the rod allowed the attachment of
counterweights to adjust instrumentation pressure to 100 g at the end-
odontic file. Our pilot study determined that a 100-g pressure was within
the recommended limit (18). An electric motor (TCM ENDO, NOUVAG)
and 1:8 reduction contra-angle handpiece (W&H, Austria, Dentsply)
were set at 300 rpm and torque level two. This was within the file
manufacturer’s recommended speed and torque range. The foot pedal
of the motor was clamped so that it was always on and the motor was
TABLE 1. Summary of Data of Cyclic Fatigue, Torsional Resistance, and Cutting Efficiency Tests
Experiment
1) Cyclic fatigue (# of rotations until breakage;
a ⫽ 30°, b ⫽ 45°, c ⫽ 60°)
2) Torsional resistance (a ⫽ maximum torque
until breakage, b ⫽ angle at failure)
3) Cutting efficiency
*Statistically significant; p ⬍ 0.05.
JOE — Volume 34, Number 2, February 2008
Basic Research—Technology
plugged into a digital timer that could be triggered for repeated 5-sec-
ond runs (Omega CT40; Omega-Satter, Hampstead, MD). An instru-
mentation time of 5 seconds was chosen because our pilot study showed
that longer cutting times caused the torque sensor to activate. The acti-
vation of the torque sensor causes the motor to stop and reverse and
thus introduces a confounding variable. A digital scale (Mettle, Toledo,
OH) was used as a platform on which a .04 taper rotary plastic training
block was secured (Tulsa Dental, Dentsply, OK). The digital scale al-
lowed constant monitoring of the pressure applied to the file. An instru-
ment was attached to the handpiece and allowed to rest in the orifice of
the secured practice block. The rod was adjusted so that it was hori-
zontal. The distance between the top of the plastic block and the hub of
the instrument was measured by using a digital caliper accurate to 0.001
mm (Mitutoyo Corp, Kawasaki, Japan) before and after activation of the
file. A new practice block was used for each test file. Fifteen files from
each group were tested. The cutting efficiency of each file was calculated
by subtracting the length before cutting from the length after cutting and
then dividing by 5 seconds to give a cutting rate in millimeters per
second.
Files from each group were photomicrographed. All images were
taken with an ESEM (FEI Quanta 200, Hillsboro, OR) using a working
distance of approximately 10 mm and a high voltage of 15 to 20 kV.
Fractography was performed for analysis of broken files.
Statistical significance was determined by using the unpaired t test
at a significance level of p ⬍ 0.05. To evaluate the differences among the
various canal curvatures in the cyclical fatigue study, an analysis of
variance (ANOVA) followed by a Fisher probable least-square difference
test (PLSD) at a significance level of p ⬍ 0.05 was performed.
Results
Results of all the cyclic fatigue, torque resistance, and cutting ef-
ficiency tests are summarized in Table 1. There was a statistically sig-
nificant difference in cyclic fatigue resistance. The nonpolished control
group was more resistant to cyclic fatigue when compared to the elec-
tropolished group. ANOVA followed by a Fisher PLSD test were used to
analyze the effects of varying canal curvatures to cyclical fatigue. In
general, there were statistically significant differences between 30°,
45°, and 60° curvatures for both the nonpolished and polished groups.
Files underwent more rotations until failure with a lesser canal angle of
curvature. There was an exception to this trend; the comparison be-
tween the 45° and 60° canal curvatures in the nonpolished group re-
sulted in no statistically significant differences.
Torsional resistance testing showed no statistically significant dif-
ference with respect to maximum torque until breakage. However, the
nonpolished control group was able to sustain a significantly larger
angle of rotation until failure. During torque testing, 13 of 15 machined
files evidenced signs of significant plastic deformation, whereas none
was found in the electropolished group. This phenomenon is shown in
Figure 1K in which the nonpolished file shows obvious signs of unwind-
Mean ⴞ Standard Deviation
p Value
Nonpolished Polished
a) 21,966 ⫾ 19,284 a) 5,675 ⫾ 1682 a) 0.0029*
b) 2,845 ⫾ 970 b) 1,513 ⫾ 358 b) ⬍0.001*
c) 500 ⫾ 49 c) 426 ⫾ 89 c) 0.0084*
a) 0.79 Ncm ⫾ 0.12 a) 0.82 Ncm ⫾ 0.18 a) 0.06363
b) 510° ⫾ 93 b) 415° ⫾ 61 b) 0.0035*
0.613 mm/s ⫾ 0.145 0.719 mm/s ⫾ 0.185 0.0921
Effect of Electropolishing Profile Ni-Ti Instruments 191
Basic Research—Technology

Figure 1. The following are scanning electron microscope micrographs of the experimental files. (A) The tip of a nonpolished file shows machining grooves and pits.
The cutting edges appear sharp (magnification 512⫻). (B) A close-up of the nonpolished surface with the arrow showing a deep groove (magnification 3,446⫻).
(C) The arrow shows cracks on the side of a nonpolished file follow machining grooves in cyclic fatigue testing (magnification 1,291⫻). (D) A cyclic fatigue
nonpolished file showing an overload zone revealing dimpled ruptures that is characteristic of ductile failure. The arrow shows a microvoid. (magnification 3,538⫻).
(E) The tip of electropolished file appears smooth with rounded cutting edges (magnification 510⫻). (F ) A close-up of electropolished file lack machining grooves
and pits (magnification 3,432⫻). (G) Cracks in electropolished file form a zigzag pattern in cyclic fatigue testing (magnification 1,073⫻). (H) Dimpled ruptures
found in cyclic fatigue testing of an electropolished file. The arrow points to a microvoid. (magnification 3,973⫻). (I) Circular shear pattern with a center core of
ruptured dimples in torsional failure of a nonpolished file (magnification 2,218⫻). ( J ) Circular shear pattern also found in torsional failure of an electropolished
file (magnification 3,149⫻). (K ) The arrow points to unwinding of a nonpolished file after torsional failure (magnification 105⫻). (L) The arrow shows minimal
plastic deformation of electropolished file after torsional failure (magnification 176⫻).

ing and reverse winding. In contrast, in Figure 1L, the electropolished
file has minimal plastic deformation.
For the cutting efficiency testing, there was a slight increased cut-
ting speed in the electropolished file group. However, there were no
statistically significant differences found between the two groups.
Figure 1 presents a selection of ESEM micrographs of the files.
Electropolished files showed a smoother surface, with the cutting edges
rounded (Fig. 1E, F). The nonpolished files appeared rough with ma-
chined grooves and pits, with sharp cutting edges (Fig. 1A, B). Both
nonpolished and polished groups showed typical patterns of torque and
fatigue failure. In both groups, cyclic fatigue testing resulted in a large
catastrophic overload zone of microvoid coalescence characteristic of
ductile failure; however, the fatigue striation zone was minimal (Fig. 1D,
H). The microvoids present may have formed from oxidized inclusion
particles (Fig. 1D, H). Surface cracks followed machining grooves in
the nonpolished file, whereas the electropolished file had cracks of a
“zigzag” pattern (Fig. 1C, G). Similarly for both groups, torsional resis-
tance testing showed a smooth circular shear failure surface with a
center zone of dimples (Fig. 1H, I).
Discussion
This study assessed the effect of electropolishing ProFile NiTi ro-
tary instruments with respect to cyclic fatigue resistance. An unexpected
statistically significant finding was that the polished files failed sooner in
all canal curvatures. This did not correlate to previous results that
showed increased resistance to cyclical fatigue (19, 20). We hypothe-
size that electropolishing is very technique sensitive and may have a
varying affect on the mechanical properties among different batches of
files.
We also analyzed the general effects of increasing the canal
angle of curvature. As expected, files had significantly reduced
cyclical fatigue resistance as the canal angle of curvature increased.
When there is an increase in canal curvature, the file experiences
greater compression and tensile forces and hence fatigues faster.
This coincides with another study that showed this phenome-
non (21).
With respect to torque resistance, we found a slight increase in the
ultimate torsional strength of electropolished files, but there were no
statistically significant differences. This closely corresponded to a re-
cent study (20). This was expected because electropolishing does not
affect the core of the material in which most of the mechanical proper-
ties reside. Interestingly, the electropolished group showed a decreased
angle of rotation before breaking. It was also found that the electropol-
ished group sustained less plastic deformation. These observations can
be interpreted as a reduction in toughness in the electropolished group.
The minimal plastic deformation of the polished files could be a clinical

192 Bui et al. JOE — Volume 34, Number 2, February 2008


disadvantage because one looks for these signs to discard files before
they break (22).
There was a slight increase in cutting efficiency when the ProFile
instruments were electropolished; however, this increase was not sta-
tistically significant. There are several methods of measuring cutting
efficiency (9, 12, 23, 24). In this study, we chose to simulate a file’s
clinical use. The swing arm has an arc that can influence the direction of
force and direction of the file. To minimize this effect, a long arm was
used. A 5-second cutting time does not allow the arm to move through
the arc significantly. Plastic blocks were used for their consistency but
future studies may be more clinically relevant by using bilaterally
matched pairs of extracted human teeth.
Under the ESEM, the surface of electropolished files appeared
smoother than the nonpolished files. Cracks tended to follow machining
grooves and pits of the nonpolished files, whereas “zig-zag” crack pat-
terns were seen on electropolished files (Fig. 1G). There were no dif-
ferences when we compared the mode of fracture of torque and fatigue
testing between the groups. Electropolishing did not affect the behavior
of the core of the material.
Electropolishing only affects the surface of the NiTi material. The
unaltered core contains inclusion particles such as titanium carboni-
tride and nickel titanium oxide from the manufacturing process of NiTi
alloy (25). Along with surface machining defects, core particles can also
act as centers of crack propagation. This was shown by a study pe-
formed by Herold et al. (26) in which they showed that electropolishing
did not inhibit the formation of microfractures. It was also shown that
electropolishing did not protect the instrument from low-cycle fatigue
(27). Because electropolishing removes a layer of the surface of NiTi,
there are concerns that it reduces the dimensions of the rotary files and
may also alter the sharpness of the file. This study showed rounding of
cutting edges, but this had no significant effect on cutting efficiency.
Perhaps reducing the machining process altogether may be a better
solution. Lightspeed LSX files are stamped instead of being machined
(28). Developing novel superelastic materials, alloying methods, and
manufacturing methods may allow the instruments to be twisted into
shape and thus avoiding the machining process.
In conclusion, electropolishing of ProFile NiTi instruments does
not offer the benefits marketed by other manufacturers. Further studies
need to compare the effect of electropolishing on other file systems. File
design may have an effect on the results.
Acknowledgment
The authors would like to thank Ai Leen Chong, Dave Phillips,
Mary Waller, David Mahler, and In-Bog Lee for their valuable tech-
nical support. The ProFile NiTi rotary instruments used in this study
were a gift from Tulsa Dentsply, OK. This research project was
funded by the Leslie A. Morgan Endowment Fund.
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Effect of Electropolishing Profile Ni-Ti Instruments 193