Advertisement

Synthesis of electrical discharge metal matrix composite coating through compacted semi-sintered electrode and its tribological studies

  • Ilangovan ArunEmail author
  • C. Yuvaraj
  • P. Selvarani
  • J. S. Senthilkumaar
  • S. Thamizhmanii
  • P. Muruganandam
Technical Paper
  • 21 Downloads

Abstract

Electric discharge coating is an alternative process for surface modification/alloying/coating requirements to improve mechanical and metallurgical properties of the materials. The high-pressure compacted electrode is made of the semi-sintered nickel and tungsten during the electric discharging process which influences the material migration towards substrate. In this proecess addtiton of pyrolysis carbon from dielectric togeather with the alloying elements and substrate material results in formation of metal matrix composite coating. It depended on the stabilization pressure of spark which increases the deposition rate of alloying materials and reduces the carbon, brittleness, cracks, voids, blowhole on the surface and made the layer to be desired metallurgical properties. Modified layer shows higher in hardness value of 1100 HV0.5 and reduction in specific wear to 0.082 × 10−5 mm3/Nm compared with uncoated substrate material. Inclusion of the alloying material and reduction of the carbon percentage consequences in self-lubricant properties which alter the wear rate and coefficient of friction. Surfaces topography obtained during alloying, material migration and the mechanism have been characterized through scanning electron microscopy and energy-dispersive X-ray spectroscopy. The wear behaviour has been analysed by using pin-on-disc tribometer.

Keywords

Electrical discharge alloying Material migration Metal matrix composite Specific wear Coefficient of friction 

Notes

Acknowledgements

The work was financially supported by the Department of Science and Technology (DST), Government of India with the reference number SERB/ECR/2016/000470, dated 21.09.2016.

References

  1. 1.
    McGeough JA (1988) Advanced methods of machining. Chapman and Hall, LondonGoogle Scholar
  2. 2.
    Liu Y, Chang H, Zhang W, Ma F, Sha Z, Zhang S (2018) A simulation study of debris removal process in ultrasonic vibration assisted electrical discharge machining (EDM) of deep holes. Micromachines 9(8):378.  https://doi.org/10.3390/mi9080378 CrossRefGoogle Scholar
  3. 3.
    Kuneida M, Lauwers B, Rajurkar KP, Schumacher BM (2005) Advancing EDM through fundamental insight into the process. Ann CIRP 54(2):599–622Google Scholar
  4. 4.
    Ximao J, Lee HG, Aspinwall DK, Dewes RC, Aspinwall EM (2003) Workpiece surface modification using electrical discharge machining. Int J Mach Tools Manuf 43:121–128.  https://doi.org/10.1016/S0890-6955(02)00187-6 CrossRefGoogle Scholar
  5. 5.
    Mohri N, Fukusima Y, Fukuzawa Y, Tani T, Saito N (2003) Layer generation process on workpiece in electrical discharge machining. Ann CIRP 52(1):157–160.  https://doi.org/10.1016/s0007-8506(07)60554 CrossRefGoogle Scholar
  6. 6.
    Furutani K, Saneto A, Takezawa H, Mohri N, Miyake H (2001) Accretion of titanium carbide by electrical discharge machining with powder suspended in working fluid. Precision Eng 2001(25):138–144.  https://doi.org/10.1016/S0141-6359(00)00068-4 CrossRefGoogle Scholar
  7. 7.
    Moro T, Goto A, Mohri N, Saito N, Matsukawa K, Miyake H (2001) Surface modification process by electrical discharge machining with TiC semi sintered electrode. J Jpn Soc Precis Eng 67(1):114–119.  https://doi.org/10.1016/S0924-0136(02)00597-6 CrossRefGoogle Scholar
  8. 8.
    Gangadhar A, Shunmugam MS, Philip PK (1991) Surface modification in electro discharge processing with a powder coMPact tool electrode. Wear 143:45–55.  https://doi.org/10.1016/0043-1648(91)90084-8 CrossRefGoogle Scholar
  9. 9.
    Lin Hung-Mao, Kuralay Stambekova, Uan Jun-Yen (2011) Microstructural and corrosion characteristics of iron-silicon alloyed layer on 5083 Al alloy by electrical discharge alloying processing. Mater Trans 52(3):514–520.  https://doi.org/10.2320/matertrans.M2010363 CrossRefGoogle Scholar
  10. 10.
    Ekmekci N, Ekmekci B (2016) Electrical discharge machining of Ti6Al4V in hydroxyapatite powder mixed dielectric liquid. Mater Manuf Process.  https://doi.org/10.1080/10426914.2015.1090591 CrossRefGoogle Scholar
  11. 11.
    Aspinwall DK, Dewes RC, Lee HG, Simao J (2003) Electrical discharge surface alloying of Ti and Fe workpiece materials using refractory powder compact electrodes and Cu wire. Ann CIRP 52(1):151–160.  https://doi.org/10.1016/S0007-8506(07)60553-8 CrossRefGoogle Scholar
  12. 12.
    Ching-Yuan Bai, Chun-Hao Koo (2006) Effects of kerosene or distilled water as dielectric on electrical discharge alloying of superalloy Haynes 230 with Al-Mo composite electrode. Surf Coat Technol 200:4127–4135.  https://doi.org/10.1016/j.surfcoat.2005.03.022 CrossRefGoogle Scholar
  13. 13.
    Chang-bin Tang, Dao-xin Liu, Zhan Wang, Yang Gao (2011) Electro-spark alloying using graphite electrode on titanium alloy surface for biomedical applications. Appl Surf Sci 257:6364–6371.  https://doi.org/10.1016/j.apsusc.2011.01.120 CrossRefGoogle Scholar
  14. 14.
    Simao Jorge, Aspinwall David, El-Menshawy Fawzy, Meadows Ken (2002) Surface alloying using PM composite electrode materials when electrical discharge texturing hardened AISI D2. J Mater Process Technol 127:211–216.  https://doi.org/10.1016/S0924-0136(02)00144-9 CrossRefGoogle Scholar
  15. 15.
    Arun I, Duraiselvam M, Senthilkumar V, Narayanasamy R, Anandakrishnan V (2014) Synthesis of electric discharge alloyed nickel–tungsten coating on tool steel and its tribological studies. Mater Des 63:257–262.  https://doi.org/10.1016/j.matdes.2014.06.029 CrossRefGoogle Scholar
  16. 16.
    Arun I, Vaishnava P, Duraiselvam M, Senthilkumar V, Anandakrishnan V (2014) Development of carbide intermetallic layer by electric discharge alloying on AISI- D2 tool steel and its wear studies. Int J Mater Res 105:1–8.  https://doi.org/10.3139/146.111067 CrossRefGoogle Scholar
  17. 17.
    Öpöz TT, Yasar H, Ekmekci N, Ekmekci B (2018) Particle migration and surface modification on Ti6Al4V in SiC powder mixed electrical discharge machining. J Manuf Process 31:744–758.  https://doi.org/10.1016/j.jmapro.2018.01.002 CrossRefGoogle Scholar
  18. 18.
    Tijo D, Kumari S, Masanta M (2018) Ceramic-metal composite coating on steel using a powder compact tool electrode by the electro-discharge coating process. Silicon 10:1625–1637.  https://doi.org/10.1007/s12633-017-9646-6 CrossRefGoogle Scholar
  19. 19.
    Prakash V, Shubham, Kumar P, Singh PK, Das AK, Chattopadhyaya S, Mandal A, Dixit AR (2019) Surface alloying of miniature components by micro electrical discharge process. Mater Manuf Process 33(10):1051–1061.  https://doi.org/10.1080/10426914.2017.1364755 CrossRefGoogle Scholar
  20. 20.
    Algodi SJ, Murray JW, Clare AT, Brown PD (2018) Wear performance of TiC/Fe cermet electrical discharge coatings. Wear 15: 402–403, 109–123.  https://doi.org/10.1016/j.wear.2018.02.007 CrossRefGoogle Scholar
  21. 21.
    Tyagi R, Das AK, Mandal A (2018) Electrical discharge coating using WS2 and Cu powder mixture for solid lubrication and enhanced tribological performance. Tribol Int 120:80–92.  https://doi.org/10.1016/j.triboint.2017.12.023 CrossRefGoogle Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2019

Authors and Affiliations

  1. 1.Center for Advanced Material ProcessingMadanapalle Institute of Technology and ScienceMadanapalleIndia
  2. 2.Government Polytechnic CollegeDharmapuriIndia
  3. 3.Aabonsmit Alloys Pvt LimitedChennaiIndia

Personalised recommendations