Fabrication of Solid Lubricant Coating and Its Optimization Using Response Surface Methodology

Abstract

The present paper elaborates process for production of solid-lubricating coating over the mild steel by electrical discharge technique through green compact electrode made of MoS₂ + Cu powder. Electrical discharge coating which is based on EDM principle and performed with the help of powder compact electrode formed via hot mounting press. The transportation of material occurred through electrical discharges which helps in melting and simultaneous deposition of powder. The loose bonding between particles facilitates the material deposition over the substrate. The effect of input parameters variation on the output parameters, such as, tool wear rate, mass deposition rate, and coating layer thickness is investigated by response surface methodology (RSM). The experiments results achieved from this work show that experimental values are in good agreement with the predictive results. The morphology study showed minimum amount of defects at the top coated surface. EDS study confirmed the successful deposition of principal elements presence in the coating.