Skip to main content

Advertisement

SpringerLink
Log in

An experimental investigation of surface modification of C-40 steel using W–Cu powder metallurgy sintered compact tools in EDM

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

Abstract

Surface modification is essential to enhance the surface properties of engineering components. This may be accomplished either in the form of altering the surface chemistry or by providing a protective layer over the work surface. In this paper, the surface modification phenomenon by depositing a protective layer over the work surface by electrical discharge machining (EDM) is presented. The potential of EDM, which is otherwise a useful non-conventional machining process, has been explored for surface alteration by depositing material over work surface using tungsten–copper (W–Cu) sintered powder metallurgy tools. The photographic presentation of the EDMed surface at different parameter settings is given. The variations of mass transfer rate (MTR), deposited layer thickness (LT), and average surface roughness (R a) with various parameter combinations are presented in graphical form and their effects are discussed. A wide spectrum of MTR ranging from nearly 1 to 191 mg/min and average surface roughness values ranging from 3 to 15 μm have been achieved. A wide range of deposited layers with thickness varying from 3 to 785 μm has been achieved by various combinations of process parameters. The microstructure of the deposited layers with microhardness at different zones is presented. It has been observed that the microhardness is gradually increasing from the base material to the deposited layer and its maximum value is found to be 15.7 GPa at the hardest zone. SEM, EDX, and XRD analyses has been also performed for further characterization of the deposited layer. A quantitative analysis of the layer has been carried out by EDX and it is found that the inner part of the layer is richer in tungsten than the superficial surface. This contributed towards the higher hardness of the layer at the core.

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. Rajurkar KP, Pandit SM (1984) Quantitative expressions for some aspects of surface integrity of electro discharge machined components. Trans ASME J Eng Ind 106:171–177

    Article  Google Scholar 

  2. Lim LC, Lee LC, Wong YS, Lu HH (1991) Solidification microstructure of electrodischarge machined surfaces of tool steels. Mater Sci Technol 7:239–248

    Article  Google Scholar 

  3. Rebelo JC, Dias AM, Kremer D, Lebrun JL (1998) Influence of EDM pulse energy on the surface integrity of martensite steels. J Mater Process Technol 84:90–96

    Article  Google Scholar 

  4. Cusanelli G, Wyser AH, Bobard F, Demellayer R, Perez R, Flükiger R (2004) Microstructure at submicron scale of the white layer produced by EDM technique. J Mater Process Technol 149:289–295

    Article  Google Scholar 

  5. Gangadhar A, Shunmugam MS, Philip PK (1991) Surface modification in electrodischarge processing with a powder compact tool electrode. Wear 143(1):45–55

    Article  Google Scholar 

  6. Shunmugam MS, Philip PK, Gangadhar A (1994) Improvement of wear resistance by EDM with tungsten carbide P/M electrode. Wear 171:1–5

    Article  Google Scholar 

  7. Samuel MP, Philip PK (1997) Power metallurgy tool electrodes for electrical discharge machining. Int J Mach Tools Manuf 37:1625–1633

    Article  Google Scholar 

  8. Mohri N, Saito N, Tsunekawa Y, Kinoshita N (1993) Metal surface modification by electrical discharge machining with composite electrode. Anal CIRP 42(1):219–222

    Article  Google Scholar 

  9. Fukuzawa Y, Kojima Y, Sekiguchi E, Mohri N (1993) Surface modification of stainless steel by electrical discharge machining. ISIJ Int 33(9):996–1002

    Article  Google Scholar 

  10. Fukuzawa Y, Kojima Y, Tani T, Sekiguti E, Mohri N (1995) Fabrication of surface modification layer on stainless steel by electrical discharge machining. Mater Manuf Process 10(2):195–203

    Article  Google Scholar 

  11. Mohri N, Fukusima Y, Fukuzawa Y, Tani T, Saito N (2003) Layer generation process on work-piece in electrical discharge machining. Anal CIRP 52(1):157–160

    Article  Google Scholar 

  12. Moro T, Mohri N, Otsubo H, Goto A, Saito N (2004) Study on the surface modification system with electrical discharge machine in the practical usage. J Mater Process Technol 149:65–70

    Article  Google Scholar 

  13. Tsunekawa Y, Okumiya M, Mohri N (1994) Surface modification of aluminium by electrical discharge alloying. Mater Sci Eng A174:193–198

    Article  Google Scholar 

  14. Tsunekawa Y, Okumiya M, Mohri N, Kuribe E (1997) Formation of composite layer containing TiC precipitates by electrical discharge alloying. Mater Trans JIM 38(7):630–635

    Article  Google Scholar 

  15. Pantelis DI, Vaxevanidis NM, Houndri AE, Dumas P, Jeandin M (1998) Investigation into application of electrodischarge machining as steel surface modification technique. Surf Eng 14(1):55–61

    Article  Google Scholar 

  16. Simao J, Aspinwall D, El-Menshawy F, 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 

  17. 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 

  18. Aspinwall DK, Dewes RC, Lee HG, Simao J, McKeown P (2003) Electrical discharge surface alloying of Ti and Fe workpiece materials using refractory powder compact electrodes and Cu wire. Anal CIRP 52(1):151–156

    Article  Google Scholar 

  19. Lee HG, Simao J, Aspinwall DK, Dewes RC, Voice W (2004) Electrical discharge surface alloying. J Mater Process Technol 149:334–340

    Article  Google Scholar 

  20. Wang ZL, Fang Y, Wu PN, Zhao WS, Cheng K (2002) Surface modification process by electrical discharge machining with a Ti powder green compact electrode. J Mater Process Technol 129:139–142

    Article  Google Scholar 

  21. Tsai HC, Yan BH, Huang FY (2003) EDM performance of Cr/Cu-based composite electrodes. Int J Mach Tools Manuf 43(3):245–252

    Article  Google Scholar 

  22. Akiyoshi M, Goto A, Mohri N, Saito N (2003) Planarization of a layer made by using electrical discharge machining. JSME Int J Ser A 46(3):496–501

    Article  Google Scholar 

  23. 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(2):194–200

    Article  Google Scholar 

  24. Zinelis S (2007) Surface and elemental alterations of dental alloys induced by electro discharge machining (EDM). Dent Mater 23(5):601–607

    Article  Google Scholar 

  25. 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 

  26. Patowari PK, Mishra UK, Saha P, Mishra PK (2010) Surface modification of C40 steel using WC-Cu P/M green compact electrodes in EDM. Int J Manuf Technol Manag 21(1/2):83–98

    Google Scholar 

  27. 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 

  28. Patowari PK, Mishra UK, Saha P, Mishra PK (2011) Surface integrity of C-40 steel processed with WC-Cu powder metallurgy green compact tools in EDM. Mater Manuf Process 26:668–676

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology, Silchar, 788010, Assam, India

    P. K. Patowari

  2. Department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, 721302, West Bengal, India

    P. Saha

  3. Department of Mechanical Engineering, Indian Institute of Technology, Bhubaneswar, 751013, India

    P. K. Mishra

Authors
  1. P. K. Patowari
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Saha
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. P. K. Mishra
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. K. Patowari.

Additional information

P. K. Patowari is associate professor, National Institute of Technology Silchar, and holds a PhD.

P. Saha is associate professor, Indian Institute of Technology Kharagpur, and holds a PhD.

P. K. Mishra is professor emeritus, Indian Institute of Technology Bhubaneswar, and holds a PhD.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Patowari, P.K., Saha, P. & Mishra, P.K. An experimental investigation of surface modification of C-40 steel using W–Cu powder metallurgy sintered compact tools in EDM. Int J Adv Manuf Technol 80, 343–360 (2015). https://doi.org/10.1007/s00170-015-7004-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7004-7

Keywords

Search

Navigation