Optimal design and experimental study of Mg alloy electrodes for tissue welding

Objective: To investigate electrode weight reduction through structural modifications, focusing on variations in the thickness of circular electrodes to meet mechanical requirements. Additionally, optimal welding parameters were identified via experimental methods. Methods: Three electrode thicknesses were designed: 0.2 mm (T1), 0.3 mm (T2), and 0.4 mm (T3). The finite element method was used to analyze the stress, strain, and thermal effects on the surrounding tissue. In vitro tissue experiments assessed the mechanical strength of the anastomosis by measuring tear force and rupture pressure. Results: Among the three designs, the T3 electrode exhibited the lowest strain (1.2%) and stress (122.26 MPa). Thermal simulations showed maximum tissue damage of 53.3% and minimum damage of 48.6%. The maximum tear force (9.87±0.83 N) and rupture pressure (222.88±13.48 mmHg) were achieved with a compression force of 20 N, welding power of 160 W, and welding time of 8 seconds. Conclusion: T3 electrode demonstrated superior mechanical performance in the finite element analysis and successfully completed in vitro welding while minimizing electrode weight. Optimal welding parameters were identified.