Skip to main content
SpringerLink
Log in

Surface alloying of H11 die steel by tungsten using EDM process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The objective of this study is to investigate the phenomenon of surface alloying by electrical discharge machining (EDM) process using tool electrodes manufactured by powder metallurgy (PM) process. Efforts have been made to find out the machining conditions that facilitate the transfer of desirable alloying elements (tungsten and carbon) to the machined surface. The quality of the machined surface is the key issue while surface alloying in EDM process. The Taguchi method and L18 orthogonal array are used to find the best level of process parameters in order to achieve the high surface finish and microhardness. Experiments are conducted on hot die steel H11 using electrode (copper-tungsten) manufactured by PM process. Six input parameters are considered, and their significance is investigated by analysis of variance (ANOVA). Different techniques like scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD) have been used to ascertain the characteristics of the machined surface. Results show improvement in microhardness of the alloyed surface by 83 %. Surface machined at optimal setting of machining parameters for best surface roughness gives Ra value of 4.08 μm. EDS of the machined surface confirms the material migration from tool, as the alloyed layer shows significant increase in percentage of tungsten and carbon. The XRD shows the formation of cementite (Fe3C) and tungsten carbide (W3C) on the machined surface which is responsible for the substantial increase in microhardness. SEM shows a crack-free surface which indicates that surface alloying has been carried out without any adverse impact on surface quality.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Clijsters S, Liu K, Reynaerts D, Lauwers B (2010) EDM technology and strategy development for the manufacturing of complex parts in SiSiC. J Mater Process Technol 210:631–641

    Article  Google Scholar 

  2. Ji R, Liu Y, Zhang Y, Wang F (2011) Machining performance of silicon carbide ceramic in end electric discharge milling. Int J Refract Met Hard Mater 29:117–122

    Article  Google Scholar 

  3. Boothroyd G, Winston AK (1989) Non-eonventional machining processes. In: Fundamentals of machining and machine tools. Marcel Dekker, New York, p 491

  4. Marafona J, Chousal JAG (2005) A finite element model of EDM based on the Joule effect. Int J Mach Tools Manuf 46:1–8

    Google Scholar 

  5. Hamilton S Overview of surface treatments currently available to the moulding industry. In: 21st Mould making Conference ‘95—Innovative Technology for Mould Manufacturers & Users, Solihull, UK, Institute of Materials, 1995

  6. Simao 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

    Article  Google Scholar 

  7. Batish A, Bhattacharya A, Singla VK, Singh G (2012) Study of material transfer mechanism in die steels using powder mixed electric discharge machining. Mater Manuf Process 27:449–456

    Article  Google Scholar 

  8. Kumar A, Maheshwari S, Sharma C, Beri N (2009) Performance evaluation of silicon additive in electrical discharge machining of EN 24 steel based on Taguchi method. J Mech Eng 60(5–6):298–304

    Google Scholar 

  9. Kumar S, Singh R (2010) Investigating surface properties of OHNS die steel after electrical discharge machining with manganese powder mixed in the dielectric. Int J Adv Manuf Technol 50:625–633

    Article  Google Scholar 

  10. Beri N, Maheshwari S, Sharma C, Kumar A (2008) Performance evaluation of powder metallurgy electrode in electrical discharge machining of AISI D2 steel using Taguchi method. Int J Mech Ind Aerosp Eng 2(2):167–171

    Google Scholar 

  11. Chen YF, Chow HM, Lin YC, Lin CT (2008) Surface modification using semi-sintered electrodes on electrical discharge machining. Int J Adv Manuf Technol 36:490–500

    Article  Google Scholar 

  12. Ho SK, Aspinwall DK, Voice W (2007) Use of powder metallurgy (PM) compacted electrodes for electrical discharge surface alloying/modification of Ti–6Al–4V alloy. J Mater Process Technol 191:123–126

    Article  Google Scholar 

  13. Yan BH, Tsai HC, Huang FY (2005) The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium. Int J Mach Tools Manuf 45:194–200

    Article  Google Scholar 

  14. Kumar S, Singh R, Singh TP, Sethi BL (2009) Surface modification by electrical discharge machining: a review. J Mater Process Technol 209:3675–3687

    Article  Google Scholar 

  15. Kumar S, Batra U (2012) Surface modification of die steel materials by EDM method using tungsten powder-mixed dielectric. J Manuf Process 14:35–40

    Article  Google Scholar 

  16. Singh AK, Kumar S, Singh VP (2014) Optimization of parameters using conductive powder in dielectric for EDM of super Co 605 with multiple quality characteristics. Mater Manuf Process 29(3):267–273

    Article  Google Scholar 

  17. Samuel MP, Philip PK (1996) Properties of compacted, pre-sintered and fully sintered electrodes produced by powder metallurgy for electrical discharge machining. Indian J Eng Mater Sci 3:229–233

    Google Scholar 

  18. El-Taweel TA (2009) Multi-response optimization of EDM with Al–Cu–Si–TiC P/M composite electrode. Int J Adv Manuf Technol 44:100–113

    Article  Google Scholar 

  19. Patowari PK, Saha P, Mishra PK (2010) Artificial neural network model in surface modification by EDM using tungsten–copper powder metallurgy sintered electrodes. Int J Adv Manuf Technol 51:627–638

    Article  Google Scholar 

  20. Li L, Wong YS, Fuh JYH, Lu L (2001) EDM performance of TiC copper-based sintered electrodes. Mater Des 22:669–678

    Article  Google Scholar 

  21. Simao J, Aspinwall D, Menshawy FE, Meadows K (2002) Surface alloying using PM composite electrode materials when electrical discharge texturing hardened AISI D2. J Mater Process Technol 127:211–216

    Article  Google Scholar 

  22. Aspinwall DK, Dews RC, Lee HG, Slmao J (2003) Electrical discharge surface alloying of Ti and Fe workpiece materials using refractory powder compact electrodes and Cu wire. CIRP Ann Manuf Technol 52:151–156

    Article  Google Scholar 

  23. Bai C-Y, Koo C-H (2006) Effects of kerosene or distilled water as dielectric on electrical discharge alloying of superalloy Haynes 230 with Al–Mo composite electrode. Surf Coati Technol 200:4127–4135

    Article  Google Scholar 

  24. Hwang Y-L, Kuo C-L, Hwang S-F (2010) The coating of TiC layer on the surface of nickel by electric discharge coating (EDC) with a multi-layer electrode. J Mater Process Technol 210:642–652

    Article  Google Scholar 

  25. Patowari PK, Saha P, Mishra PK (2011) Taguchi analysis of surface modification technique using W-Cu powder metallurgy sintered tools in EDM and characterization of the deposited layer. Int J Adv Manuf Technol 54:593–604

    Article  Google Scholar 

  26. Suzuki T, Kobayashi S (2013) Mechanisms of TiC layer formation on high speed steel by a single pulse in electrical discharge machining. Electrochim Acta 114:844–850

    Article  Google Scholar 

  27. Gill AS, Kumar S (2014) Surface roughness evaluation for EDM of En31 with Cu-Cr-Ni powder metallurgy tool. Int J Mech Aerosp Ind Mechatron Eng 8(7):1297–1302

    Google Scholar 

  28. Prabhudev KH (2000) Handbook of heat treatment of steels. Tata McGraw Hill Publishing Company, New Delhi

    Google Scholar 

  29. DiBitonto DD, Eubank PT, Patel MR, Barrufet MA (1989) Theoretical models of the electrical discharge machining process-II: a simple cathode erosion model. J Appl Phys 66(9):4095–4103

    Article  Google Scholar 

  30. Koenig W, Wertheim R, Zvirin Y, Toren M (1975) Material removal and energy distribution in electrical discharge machining. CIRP Ann Manuf Technol 24(1):95–100

    Google Scholar 

  31. Patel MR, Barrufet MA, Eubank PT, DiBitonto DD (1989) Theoretical models of the electrical discharge machining process-II: the anode erosion model. J Appl Phys 66(9):4104–4111

    Article  Google Scholar 

  32. Kruth JP, Stevens L, Froyen L, Lauwers B (1995) Study on the white layer of a surface machined by die sinking electro-discharge machining. Ann CIRP 44(1):169–172

    Article  Google Scholar 

  33. Erden A (1983) Effect of materials on the mechanism of electric discharge machining (EDM). J Eng Mater Technol 105:132–138

    Article  Google Scholar 

  34. Ogata I, Mukoyama Y (1993) Carburizing and decarburizing phenomena in EDM’d surface. Int J Jpn Soc Precis Eng 27(3):197–202

    Google Scholar 

  35. Janmanee P, Muttamara A (2012) Surface modification of tungsten carbide by electrical discharge coating (EDC) using a titanium powder suspension. Appl Surf Sci 258:7255–7265

    Article  Google Scholar 

  36. Sidhom H, Ghanem F, Amadou T, Gonzalez G, Braham C (2013) Effect of electro discharge machining (EDM) on the AISI316L SS white layer microstructure and corrosion resistance. Int J Adv Manuf Technol 65:141–153

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, PEC University of Technology, Chandigarh, 160012, India

    Amoljit Singh Gill & Sanjeev Kumar

Authors
  1. Amoljit Singh Gill
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sanjeev Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Amoljit Singh Gill.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gill, A.S., Kumar, S. Surface alloying of H11 die steel by tungsten using EDM process. Int J Adv Manuf Technol 78, 1585–1593 (2015). https://doi.org/10.1007/s00170-014-6743-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6743-1

Keywords

Search

Navigation