The purpose of this project is to study the encouragement of three machining parameters on wire electrical discharge machining that consist of peak current (IP), pulse OFF time (OFF) and wire tension (WT) to three machining responses which are cutting rate (CR), material removal rate (MRR) and surface roughness (SR) on high carbon steel (S50C). Brass wire with diameter 0.25 mm was used as the cutting tool for machining a high carbon steel (S50C) using Mitsubishi FX Wire Electrical Discharge Machine (WEDM). The machining parameters such as pulse off time, wire tension and peak current were determined by referring from the guideline in the manual book for Mitsubishi FX Wire Electrical Discharge Machine (WEDM). The calculation of material removal rate and cutting rate were obtained using mathematical equation. The surface roughness was measured using optical measurement “Alicona Infinite Focus” machine. The relationship between material removal rate and surface roughness shows that the optimum machine parameter using brass wire as the electrode is C1. From the spark analysis using brass wire as the machine’s electrode, the deeper the spark occurred, the higher value of the surface roughness.

This investigation was conducted to study on the effect of shot blasting on the case depth of boride layers produced and microhardness after performing paste boronizing on 316L stainless steel. 250 micron diameter of glass beads had been used in the process of shot blasting with variation in the blasting pressure. Paste boronizing was performed at 850°C with 8 hours of soaking time. The samples involved were tested and analyzed on the microstructure and microhardness. Boride layers of FeB and Fe2B formed due to paste boronizing improve the microhardness of 316L stainless steel and the effect of shot blasting with increasing the blasting pressure increase both of case depth of boride layers and microhardness on the studied metal.

This research investigates and analyzes wear properties of 316 stainless steel before and after applying paste boronizing process and to investigate the effect of shot blasting process in enhancing boron dispersion into the steel. In order to enhance the boron dispersion into 316 stainless steel, surface deformation method by shot blasting process was deployed. Boronizing treatment was conducted using paste medium for 8 hours under two different temperatures which were 850 0 C and 950 0 C. Wear behaviour was evaluated using pin-on-disc test for abrasion properties. The analysis on microstructure, X-ray Diffraction (XRD) and density were also carried out before and after applying boronizing treatment. Boronizing process that had been carried out on 316 stainless steel increases the wear resistance of the steel compared to the unboronized 316 stainless steel. The effect of boronizing treatment together with the shot blasting process give a greater impact in increasing the wear resistance of 316 stainless steel. This is mainly because shot blasted samples initiated surface deformation that helped more boron dispersion due to dislocation of atom on the deformed surface. Increasing the boronizing temperature also increases the wear resistance of 316 stainless steel. In industrial application, the usage of the components that have been fabricated using the improved 316 stainless steel can be maximized because repair and replacement of the components can be reduced as a result of improved wear resistance of the 316 stainless steel.

In this research, analysis on microstructure, hardness and surface roughness of 316 austenitic stainless steel were conducted before and after boronizing process. Boronizing treatment was conducted using a paste medium at a temperature of 8500C, with and without shot blasting. Microstructures of the specimens were observed under Olympus BX60 Optical Microscope. Vickers Micro Hardness Tester was used to determine the hardness of the specimens while Optical 3D Surface Metrology Sys was used to measure the surface roughness of the specimens. The process of boronizing diffuses boron into the surface of steel which resulted in the formation of the boride layers that consist of FeB and Fe2B. Shot blasting process increased the boron diffusion which resulted in increment of the boride layer thickness and hardness value while the surface roughness was fluctuated. Increment in the hardness value of 316 stainless steel causes the steel to be able to withstand a heavy load.