MATERIAL DEPOSITION ON ALUMINIUM BY ELECTRICAL DISCHARGE COATING (EDC) WITH A TUNGSTEN POWDER SUSPENSION
Abstract
In this research, material deposition on an aluminium mould and die material was carried out via electrical discharge coating (EDC) with a tungsten powder suspension. The effects of EDC parameters, such as peak current (IP), pulse-on time (TON) and discharge voltage (V), on the weight percentage of deposited elements and micro-hardness and surface topography of aluminium were experimentally investigated. Results showed that five elements, including carbon, aluminium, tungsten, oxygen and copper, were deposited on the aluminium surface. The amount of deposited materials was strongly affected by IP, TON and V. Bulk deposition and globules formed on the material surface after EDC, and the micro-hardness of the material increased twofold compared with that of the base aluminium under the conditions of IP = 3 A, TON = 150 µs and V = 40 V.
Downloads
References
S. Kalpakjian and S. Schmid, Manufacturing Engineering and Technology, SI Edition. Singapore: Pearson Publications, 2013.
C. Vargel, Corrosion of Aluminium, 1st Edition. Oxford: Elsevier, 2004.
R.F. Munawar, A.B. Arif, W.N.F.W.A. Shani, N. Mohamad, J.A. Razak, H.E.A. Maulod, Q. Ahsan, M.S. Salleh and N.H.M. Hassan, “Water-repellent improvement of green composite sheet surface by hydrophobic modified-silica coating”, Journal of Advanced Manufacturing Technology, vol. 12, no. 1(1), pp. 491–500, 2018.
M.H.M. Akmal, M.W.A. Rashid, U.A.A. Azlan and N.A. Azmi, “The effects of different annealing temperature and number of deposition layers on the crystallographic properties of potassium sodium niobate (KNN) thin films synthesized by sol-gel spin coating technique”, Journal of Advanced Manufacturing Technology, vol. 11, no. 1, pp. 91–102, 2017.
A.R. Nizam, M.Z. Izani, D. Fairuz and M. Mazliah, “Effect of substrate chemical surface treatment on surface energy and the influence towards coating adhesion”, Journal of Advanced Manufacturing Technology, vol. 7, no. 2, pp. 29–41, 2013.
Handbook of Aluminum: Alloy Production and Material Manufacturing, 1st ed., Marcel Dekker Inc., New York, 2003, pp. 549–551.
S. Kumari, “Study of TiC coating on different type steel by electro discharge coating,” M.Tech thesis, Department of Mechanical Engineering, National Institute of Technology, Rourkela, Odisha, 2015.
C. Prakash and M.S. Uddin, “Surface modification of β-phase Ti implant by hydroaxyapatite mixed electric discharge machining to enhance the corrosion resistance and in-vitro bioactivity”, Surface and Coatings Technology, vol. 326, pp. 134–145, 2017.
A.M. Abdul-Rani, A.M. Nanimina, T.L. Ginta and M.A. Razak, “Machined surface quality in nano aluminum mixed electrical discharge machining”, Procedia Manufacturing, vol. 7, pp. 510–517, 2017.
S.L. Chen, M.H. Lin, G.X. Huang and C.C. Wang, “Research of the recast layer on implant surface modified by micro-current electrical discharge machining using deionized water mixed with titanium powder as dielectric solvent”, Applied Surface Science, vol. 311, pp. 47–53, 2014.
W.F. Gale and T.C. Totemeier, Smithells Metals Reference Book, 8th Edition. Oxford: Elsevier Butterworth-Heinemann, 2004.
M.R.A. Razak, P.J. Liew, N.I.S. Hussein, Q. Ahsan, and J. Yan, “Effect of surfactants and additives on electrical discharge machining of Reaction Bonded Silicon Carbide”, ARPN Journal of Engineering and Applied Sciences, vol. 12, no. 14, pp. 4334–4339, 2017.
C.D. Collins, “Implementing phytoremediation of petroleum hydrocarbons”, Phytoremediation, vol. 23, no. 2, pp. 99–108, 2007.
S. Abdulkareem, A.A. Khan and M. Konneh, “Cooling effect on electrode and process parameters in EDM”, Materials and Manufacturing Processes, vol. 25, no. 6, pp. 462–466, 2010.
K.H. Syed and K. Palaniyandi, “Performance of electrical discharge machining using aluminium powder suspended distilled water”, Turkish Journal of Engineering and Environmental Sciences, vol. 36, no. 3, pp. 195–207, 2012.
R. Gangadhar, K.A. Jaleeli and A. Ahmad, “Energy dispersive x-ray analysis of ovine scapular cartilage”, International Journal of Science, Environment and Technology, vol. 4, no. 4, pp. 1195–1198, 2015.
Y.K. Wang, W.M. Wang, X.H. Cu, X.Y. Cheng, B.S. Li, L.F. Xia and T.Q. Lei, “A study of the oxide layer on the surface of a TiN coating”, Materials Chemistry and Physics, vol. 36, no. 1–2, pp. 80–83, 1993.
A. Das and J.P. Misra, “Experimental investigation on surface modification of aluminum by electric discharge coating process using TiC/Cu green compact tool-electrode”, Machining Science and Technology, vol. 16, no. 4, pp. 601–623, 2012.
B. Ekmekci, F. Ulusöz, N. Ekmekci and H. Yaşar, “Suspended SiC particle deposition on plastic mold steel surfaces in powder-mixed electrical discharge machining”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 229, no. 3, pp. 475–486, 2014.
A.S. Gill and S. Kumar, “Surface alloying of H11 die steel by tungsten using EDM process”, The International Journal of Advanced Manufacturing Technology, vol. 78, no. 9–12, pp. 1585–1593, 2015.
N.A.J. Hosni and M.A. Lajis, “The influence of Span-20 surfactant and micro-/nano-Chromium (Cr) powder mixed electrical discharge machining (PMEDM) on the surface characteristics of AISI D2 hardened steel,” in IOP Conference Series: Materials and Engineering, vol. 342, 2018, pp. 1-11.
N. Beri, H. Pungotra and A. Kumar, “To study the effect of polarity and current during electric discharge machining of inconel 718 with CuW powder metallurgy electrode”, in Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, Faridabad, Haryana, 2012, pp. 476-481.
C. Prakash, H.K. Kansal, B.S. Pabla and S. Puri, “Experimental investigations in powder mixed electric discharge machining of Ti–35Nb–7Ta–5Zrβ-titanium alloy”, Materials and Manufacturing Processes, vol. 32, no. 3, pp. 274–285, 2017.
R. Ranjan, “Surface modification by electro-discharge coating (EDC) with TiC-Cu P/M electrode tool,” B.Tech. thesis, Department of Mechanical Engineering, National Institute of Technology, Rourkela, Odisha, 2014.
D. Tijo and M. Masanta, “Surface modification of aluminum by electrical discharge coating with tungsten and copper mixed powder green compact electrodes”, in 5th International and 26th All India Manufacturing Technology, Design and Research Conference, Guwahati, Assam, 2014, pp. 190(1)-190(6).
P.J. Liew, J. Yan and T. Kuriyagawa, “Experimental investigation on material migration phenomena in micro-EDM of reaction-bonded silicon carbide”, Applied Surface Science, vol. 276, pp. 731–743, 2013.
R. Knight. (2014). The oxidation of aluminum [Online]. Available: http://www.corrosionpro.com/blog/the-oxidation-of-aluminum/
W.D. Callister, Materials Science and Engineering: An Introduction, Eighth Edition. New Jersey: John Wiley and Son, Inc, 2010.
MatWeb. (2018). Search MatWeb for property information [Online]. Available: http://www.matweb.com/search/search.aspx
A. Ahmed, “Deposition and analysis of composite coating on aluminum using Ti-B4C powder metallurgy tools in EDM”, Materials and Manufacturing Processes, vol. 31, no. 4, pp. 467–474, 2016.
S.J. Algodi, J.W. Murray, M.W. Fay, A.T. Clare and P.D. Brown, “Electrical discharge coating of nanostructured TiC-Fe cermets on 304 stainless steel”, Surface and Coatings Technology, vol. 307, pp. 639–649, 2016.
