Basic Research—Technology

Effects of Electropolishing Surface Treatment on the Cyclic

Fatigue Resistance of BioRace Nickel-Titanium Rotary
Instruments
Hélio P. Lopes, LD,* Carlos N. Elias, PhD,† Victor T.L. Vieira, DDS,‡ Edson J.L. Moreira, PhD,‡
Raquel V.L. Marques, DDS,* Julio C. Machado de Oliveira, PhD,* Gilberto Debelian, PhD,§
and José F. Siqueira, Jr., PhD*

Abstract
Introduction: This study evaluated the influence of
electropolishing surface treatment on the number of
cycles to fracture of BioRace rotary nickel-titanium
endodontic instruments. Methods: BioRace size BR5C
instruments with or without electropolishing surface
treatment were used in an artificial curved canal under
rotational speed of 300 rpm until fracture. Fractured
surfaces and the helical shafts of fractured instruments
were analyzed by scanning electron microscopy (SEM).
Results: Polished instruments displayed a significantly
higher number of cycles to fracture when compared
with nonpolished instruments (P < .001). Actually, the
number of cycles to fracture of a polished BR5C instru-
ment was 124% higher than that of a nonpolished
instrument. SEM analysis showed that the fractured
surface of both polished and nonpolished BR5C instru-
ments had ductile morphologic characteristics. Evalua-
tion of the separated fragments after cyclic fatigue
testing showed the presence of microcracks near the
fracture surface. Polished instruments exhibited fine
cracks that assumed an irregular path (zigzag crack
pattern), whereas nonpolished instruments showed
cracks running along the machining grooves. Conclu-
sions: Electropolishing surface treatment of BioRace
endodontic instruments significantly increased the cyclic
fatigue resistance. (J Endod 2010;36:1653–1657)
Key Words
Chemomechanical preparation, cyclic fatigue, electropo-
lishing surface treatment, endodontic instruments
C yclic fatigue fracture occurs when an endodontic instrument rotates in a curved
canal. In this condition, the instrument under elastic deformation is subjected to
a mechanical load represented by alternating tensile and compressive stresses. The
cyclical repetition of the load leads to instrument fracture through low-cycle fatigue
(1–4). The cyclic fatigue resistance comprises the number of cycles that an
instrument can endure under a specific loading condition until fracture occurs.
Because the number of cycles to fracture is cumulative, it can be calculated by
multiplying the rotation speed by the time elapsed until fatigue fracture occurs
(4–6).
Several factors can influence the cyclic fatigue resistance of an endodontic instru-
ment subjected to flexural fatigue (2, 4, 5, 7–10). One of these factors includes defects
in surface finishing resulting from the machining process used for manufacturing
nickel-titanium (NiTi) endodontic instruments. These defects are mostly grooves that
work as stress concentration factors. Once fatigue cracks initiate on the instrument
surface, stress concentration factors favor nucleation, growth, and propagation of
cracks (3, 11).
Electropolishing is a method of surface finishing used by manufacturers of rotary
NiTi instruments to remove surface defects that might remain after the machining
process. Some previous studies showed that the surface finishing process increases
the fatigue resistance of rotary NiTi instruments (7, 10, 12–14). However, other
studies reported that surface finishing defects do not influence the fatigue life of
rotary NiTi instruments (15–18). The purpose of the present study was to analyze
the influence of electropolishing surface treatment on the number of cycles to
fracture of BioRace (FKG Dentaire, La Chaux-de-Fonds, Switzerland) rotary NiTi
endodontic instruments.
Materials and Methods
Instrument Dimensions
BioRace rotary NiTi endodontic instruments size BR5C, which have a nominal size
at D0 of 0.40 mm, a taper of 0.02 mm/mm, and total length of 25 mm, were used in this
experiment. Ten instruments were provided by the manufacturer with an electropol-
ished working part, whereas the other 10 instruments presented no surface treatment.
Specimens were from the same batch, with nonpolished instruments being removed
from the production line before the surface treatment approach.

From the *Department of Endodontics, Faculty of Dentistry, Estácio de Sá University, Rio de Janeiro, RJ, Brazil; †Department of Materials Science, Military Institute of
Engineering, Rio de Janeiro, RJ, Brazil; and ‡Department of Endodontics, Faculty of Dentistry, Grande Rio University, Rio de Janeiro, RJ, Brazil; and §Department of
Endodontics, University of Oslo, Oslo, Norway.
Address requests for reprints to José F. Siqueira Jr, DDS, MSc, PhD, Faculty of Dentistry, Estácio de Sá University, Av. Alfredo Baltazar da Silveira, 580/cobertura,
Recreio, Rio de Janeiro, RJ, Brazil 22790-710. E-mail address: jf_siqueira@yahoo.com.
0099-2399/$0 - see front matter
Copyright ª 2010 American Association of Endodontists.
doi:10.1016/j.joen.2010.06.026

JOE — Volume 36, Number 10, October 2010 Electropolishing Surface Treatment and Fatigue 1653
Basic Research—Technology
Figure 1. Schematic drawing of the artificial canal used in the cyclic fatigue
experiment.
For standardization of the instruments used, their diameters at D3
and D13 as well as their total lengths were determined by means of
a stereomicroscope (Pantec-Panambra, Cambuci, SP, Brazil). The taper
of the working part was obtained on the basis of D3 and D13 measure-
ments according to Stenman and Spangberg (19), following the equa-
tion: Taper = D13 – D3/10. The diameter at D0 was then calculated on
the basis of the values of D3 and taper (T) by using the following equa-
tion: D0 = D3 – T  3.
Surface Finishing
Surface finishing of the instrument’s working parts was assessed
under scanning electron microscopy (SEM) (Jeol JSM 5800, Tokyo,
Japan). Instruments were cleaned in acetone under ultrasonication,
and then photomicrographs were taken at magnifications of 150
and 500 for further analysis.
Bending Resistance
The bending resistance of the test instruments was evaluated by the
cantilever-bending test, as described by Serene et al (20). Briefly,
a universal testing machine (DL 10.000; Emic, São José dos Pinhais,
PR, Brazil) was used. Load was applied by means of a flexible stainless
steel wire (with length of 50 cm and diameter of 0.34 mm), with one of
the extremities fastened to the testing machine head and the other end 3
mm away from the instrument tip. The bending test was conducted until
the tip of each specimen underwent an elastic displacement of 45
degrees. The test speed was 15 mm/min, and the load cell used was
20 N. Data were statistically analyzed by using the Student t test, with
the significance level set at 5%.
Cyclic Fatigue
An artificial canal was made out of a cylindrical tube of stainless
steel with inner diameter of 1.4 mm, total length of 19 mm, arc located
between the two straight segments of the canal, and curvature radius of
6 mm. The arc measured 9 mm, the longest straight part 7 mm, and the
shortest straight part 3 mm. The curvature radius of the artificial canal
was measured, taking into account the concave surface of the interior of
the tube (Fig. 1).
TABLE 1. Means of Length, Diameter at D0, and Taper for the BR5C
Instruments (in millimeters) Used in this Study
Instrument Length D0 Taper
Polished BR5C 25.3 0.39 0.018
Nonpolished BR5C 25.1 0.41 0.018
1654 Lopes et al.
Figure 2. Nonpolished BR5C instrument showing machining grooves. (A)
Tip (original magnification, 150); (B) helical shaft (original magnification,
500).
A stainless steel apparatus was constructed with a square base and
a vertical axis. The vertical axis contained a structure that allowed for the
fixture and movement of the micromotor/contra-angle. At the apparatus
base, a bench vise was used to hold the stainless steel tube. A gap at the
base of the apparatus allowed for the movement of the bench vise in
a horizontal direction, allowing for a coincidence between the axis of
the instrument and the straight part of the stainless steel canal.
During the test, the artificial canal was filled with glycerin to reduce
the friction of the instrument against the canal wall and to minimize the
release of heat. Each instrument was placed in a contra-angle at speed
reduction of 10:1 (TC–Motor 3000; Nouvag AG/AS/LTD, Goldach,
Switzerland) and introduced into the canal until the tip touched a shield
positioned at the end of the canal (3-mm-long straight part). This shield
was thereafter removed because its main purpose was to standardize the
distance the instrument penetrated in the artificial canal.
Subsequently, BR5C instruments of each group (polished and
nonpolished) were worked in clockwise rotation at nominal speed of
300 rpm until fracture. The time to fracture was measured by the
same operator by using a digital stopwatch (Leroy) and was established
when there was visual observation of the instrument separation. The
number of cycles was obtained by multiplying the rotational speed by
the time (in seconds) until the fracture of each instrument occurred.
Data obtained on the number of cycles to fracture of the BioRace
BR5C polished and nonpolished instruments were statistically analyzed
by the Student t test, with significance level set at 5%. The fractured
surface and the helical shaft of fractured instruments were analyzed
JOE — Volume 36, Number 10, October 2010
 Basic Research—Technology
TABLE 3. Mean ( standard deviation) of the Time and the Number of Cycles
to Fatigue Fracture (NCF) of Polished and Nonpolished BR5C Instruments
Instrument Time (sec) NCF
Polished BR5C 86.8 (9.4) 434 (47.0)
Nonpolished BR5C 38.8 (6.7) 194 (33.5)

in Table 2. No significant difference was observed between them (P

= .67).

Cyclic Fatigue
The average and standard deviation of the time and number of
cycles until the instrument fracture occurred are shown in Table 3. Pol-
ished instruments displayed a significantly higher number of cycles to
fracture when compared with nonpolished instruments (P < .001).
SEM analysis showed that the fractured surface of both polished
and nonpolished BR5C instruments had ductile morphologic charac-
teristics. No plastic deformation occurred in the helical shaft of the
instruments tested (Fig. 4). Evaluation of the separated fragment after
fatigue test showed the presence of microcracks near the fracture
surface. Fine cracks that assumed an irregular path (zigzag crack
pattern) were noted in polished instruments (Fig. 5), whereas nonpol-
ished instruments showed cracks running along the machining
grooves (Fig. 6).

Figure 3. Polished BR5C instrument exhibiting a smooth surface with limited

presence of manufacturing marks. (A) Tip (original magnification, 150);
(B) helical shaft (original magnification, 500).

by means of SEM (JEOL JSM 5800) to determine the type of fracture,

presence of fatigue cracks, and plastic deformation in the helical shaft.

Results
Instrument Dimensions
The average length, diameter at D0, and taper of the BR5C instru-
ments are shown in Table 1.

Surface Finishing
SEM analysis revealed that the surfaces of the working part of all
nonpolished instruments exhibited prominent transversal machining
marks (Fig. 2). Polished instruments in turn showed smooth surfaces
with limited presence of manufacturing marks (Fig. 3).

Bending Resistance
The average bending resistance as measured by the maximum
force (gf) to bend polished and nonpolished instruments is depicted

TABLE 2. Mean ( standard deviation) of Maximum Force (gf) to Bend

Polished and Nonpolished BR5C Instruments
Instrument Maximum force Figure 4. Fractured instruments. (A) Fracture surface of instruments
showing morphology characteristics of the ductile type (original magnification,
Polished BR5C 117.2 (8.1)
1500); (B) absence of plastic deformation is observed on the helical shaft
Nonpolished BR5C 118.6 (7.2)
(original magnification, 100).

JOE — Volume 36, Number 10, October 2010 Electropolishing Surface Treatment and Fatigue 1655
Basic Research—Technology
Figure 5. Polished BR5C instrument. Cracks in a zigzag pattern are seen near
the fracture surface. (A) Original magnification, 1000; (B) original magni-
fication, 1200; (C) original magnification, 1500.
Discussion
In this study, only 1 type of instrument was selected for testing to
eliminate other variables that could possibly interfere with the results.
Therefore, the only variable was the one under study, ie, instruments
with or without electropolishing surface treatment. All measurements
of instruments performed in this study revealed that the data obtained
1656 Lopes et al.
Figure 6. Nonpolished BR5C instrument. Cracks following machining grooves
are observed near the fracture surface. (A) Original magnification, 1000; (B)
original magnification, 1500; (C) original magnification, 2500.
for diameter and taper were within the tolerance limits permitted (ISO
3630-1, 1992). These evaluations were done to guarantee that all tested
instruments had similar dimensions in spite of being of the same size as
reported by the manufacturer. In this regard it is interesting to point out
that the instruments to be polished are usually manufactured a little
overdimensioned, so that after the electropolishing process they fall
within the ISO tolerance limits.
JOE — Volume 36, Number 10, October 2010

As to these measurements, our results are in disagreement with
Bui et al (16), who stated that because electropolishing removes layers
of the surface of NiTi instruments, there are concerns that it reduces the
dimensions of rotary files. However, reduction in the instrument dimen-
sions caused by polishing appeared to be almost intangible, and the
variations observed in this study were within the tolerance limits for
endodontic instruments (ISO 3630-1, 1992).
SEM analysis of nonpolished BR5C instruments before the fatigue
test revealed machining grooves, which ran almost perpendicularly to
the long axis of the instrument. Polished instruments in turn showed
reduced surface irregularities, with remnants of the transverse-
running machining grooves vaguely discernible. These findings are in
consonance with other studies (7, 10, 12, 21).
Bending resistance was tested by using the nondestructive
cantilever-bending assay. The proposed displacement of the instrument
tip was 15 , so that the deformation induced by the applied load re-
mained within the elastic limit of the NiTi alloy. Our findings showed
no significant difference between polished and nonpolished instru-
ments with regard to bending resistance. These findings conferred
sample homogeneity to the next assay (cyclic fatigue), because the
instrument bending resistance can directly interfere with its perfor-
mance in the cyclic fatigue test (3).
The present findings demonstrated that electropolishing surface
treatment significantly increased the instrument resistance to cyclic
fatigue. Consequently, it can be inferred that surface finishing defects
can influence the number of cycles to fracture. The number of cycles
to fracture of a polished BR5C instrument was 124% higher than that
of a nonpolished instrument. Overall, these findings are in line with
several previous studies (7, 10, 12, 14, 21). However, they are in
disagreement with others (15–18).
Electropolishing surface treatment might have beneficial effects by
prolonging fatigue life of rotary NiTi instruments (10). The benefits of
electropolishing are likely to be caused by reduction in surface irregu-
larities that serve as points for stress concentration and crack initiation.
On the other hand, one study (18) reported that electrochemical polish-
ing did not increase the mechanical resistance of NiTi K3 endodontic
files. The electrochemical treatment affected neither resistance to flex-
ural fatigue nor torsional resistance of K3 instruments. According to their
SEM analysis, the surface of K3 files was not affected by electrochemical
polishing. However, it is important to point out that since 1920 it has
been widely recognized that surface finishing defects act as points of
stress concentration, reducing the number of cycles to fracture (11).
According to Callister (3), instruments with finishing surface
defects present tensile resistance significantly lower than the theoretical
fracture resistance of the material. This behavior is related to the fact
that defects act as stress concentration factors and are sites highly
conducive to the formation and propagation of cracks. When no finish-
ing surface defects are present, the theoretical fracture resistance of the
material is equal to the tensile stress of the material determined by
mechanical assays.
SEM analysis showed that the fractured surface of both polished
and nonpolished BR5C instruments had ductile morphologic character-
istics. Evaluation of the separated fragment after cyclic fatigue test re-
vealed microcracks near the fracture surface. Surface cracks
followed machining grooves in nonpolished instruments, whereas pol-
ished instruments exhibited cracks in a zigzag pattern. As for the latter,
its irregular path is typical of intergranular fracture, where propagation
of cracks occurs along the grain boundaries.
JOE — Volume 36, Number 10, October 2010
Basic Research—Technology
In conclusion, the electropolishing surface treatment of BioRace
endodontic instruments significantly increased the number of cycles
to fracture under rotating-bending conditions within an artificial curved
canal.
Acknowledgments
The authors thank FKG Dentaire for providing the instruments
used in this study, including the nonpolished instruments that are
not commercially available. This study was supported in part by
grants from Conselho Nacional de Desenvolvimento Cientı´fico e
Tecnolo´gico (CNPq) and Fundaça˜o Carlos Chagas Filho de Amparo
a` Pesquisa do Estado do Rio de Janeiro (FAPERJ), Brazilian Govern-
mental Institutions.
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