Long-term implantation of titanium-based alloy, Ti6Al4V can be harmful in human bodies due to the release of aluminium and vanadium elements. Thus, a biocompatible barrier coating can be applied towards corrosion and wear resistance of the implant. In this research, the surface of a biomedical grade of Ti6Al4V was coated with a thin film of biomaterial ceramic by the electrical discharge coatings (EDC) using a pure graphite electrode. Polarity, discharge duration and pulse interval were varied to investigate the formation of recast layer thickness (RLT) on the surface of titanium alloys. RLT was measured from cross-sectioned samples using a high magnification optical microscopy. From the statistical analyses of variance, the response was significantly influenced by the pulse interval, followed with electrode polarity. Additionally, the interaction of polarity to discharge duration and pulse interval also significantly affect the RLT. In order to obtain a more uniform recast layer formation, the process condition should be in reverse polarity with a low setting of pulse interval.
