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Process Optimisation and Tribological Behaviour Studies on Surface Modified Al 6061-T6 Alloy Deposited with WS2 Solid Lubricant Layer Through Electrical Discharge Approach

  • RESEARCH ARTICLE - SPECIAL ISSUE - Impact of Advanced Tribological Technologies on Modern Industry
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Abstract

In this present work, an attempt has been made to deposit the WS2 layer on the Al 6061-T6 alloy surface through the electrical discharge deposition (EDD) technique. Specified deposition parameters, namely powder concentration (Cp), pulse-on time (Pon), and gap voltage (Vg) with various levels considered during the EDD process. The experimentation was performed for analysing the results of deposition parameters on material deposition rate (MDR), surface roughness (SR), microhardness (MH), layer thickness (LT), and surface characteristics of the WS2 layer were examined. The results addressed the various intermetallic compounds formed on the deposited surface. A multi-objective optimisation using Box–Behnken design of response surface methodology was utilised to conduct the deposition process. To predict and optimise the appropriate MDR, SR, MH, and LT, the quadratic model was developed using regression analysis and analysis of variance. Based on the developed model, the interaction effects of deposition parameters on the EDD process were explored. The optimal depositing parameters are determined by maximising the MDR and MH and minimising the SR and LT. The validation test results confirm that experimental data are good in agreement with the predicted results, and hence, the model is feasible to predict the responses adequately. The tribological study was carried out for the optimised condition, and surface characteristics on the worn-out surface were analysed. When compared to the base material, the obtained results show a lower coefficient of friction and specific wear rate.

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Acknowledgements

The authors thank the management of SASTRA Deemed to be University for allowing us to carry out the research work and Shanmugha Precision Forging, Thanjavur, India, for providing the EDM & infrastructure facility to conduct the experimental studies. The authors also thank Multifunctional Materials & Devices laboratory (Anusandhan Kendra II-107), SASTRA Deemed to be University, Thanjavur, India, for providing the testing facilities.

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Authors and Affiliations

  1. School of Mechanical Engineering, SASTRA Deemed to be University, Tirumalaisamudram, Thanjavur, Tamilnadu, 613401, India

    R. Rajeshshyam, R. Venkatraman & S. Raghuraman

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  1. R. Rajeshshyam
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  2. R. Venkatraman
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  3. S. Raghuraman
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R. Rajeshshyam involved in conceptualization, methodology, validation, and writing—original draft. R. Venkatraman participated in investigation, formal analysis, and supervision. S. Raghuraman involved in writing, review and editing, supervision, and visualisation.

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Correspondence to R. Rajeshshyam.

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The author(s) declared that they have no conflict of interest concerning the present research work.

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Rajeshshyam, R., Venkatraman, R. & Raghuraman, S. Process Optimisation and Tribological Behaviour Studies on Surface Modified Al 6061-T6 Alloy Deposited with WS2 Solid Lubricant Layer Through Electrical Discharge Approach. Arab J Sci Eng 47, 8009–8030 (2022). https://doi.org/10.1007/s13369-021-05908-w

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  • DOI: https://doi.org/10.1007/s13369-021-05908-w

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