OPTIMIZATION AND SURFACE MODIFICATION OF Al-6351 ALLOY USING SiC–Cu GREEN COMPACT ELECTRODE BY ELECTRO DISCHARGE COATING PROCESS

Abstract

This paper introduces the surface modi¯cation of Al-6351 alloy by green compact SiC-Cu electrode using electro-discharge coating (EDC) process. A Taguchi L-16 orthogonal array is employed to investigate the process by varying tool parameters like composition and compaction load and electro-discharge machining (EDM) parameters like pulse-on time and peak current. Material deposition rate (MDR), tool wear rate (TWR) and surface roughness (SR) are measured on the coated specimens. An optimum condition is achieved by formulating overall evaluation criteria (OEC), which combines multi-objective task into a single index. The signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) is employed to investigate the e®ect of relevant process parameters. A con¯rmation test is conducted based on optimal process parameters and experimental results are provided to illustrate the e®ectiveness of this approach. The modi¯ed surface is characterized by optical microscope and X-ray di®raction (XRD) analysis. XRD analysis of the deposited layer con¯rmed the transfer of tool materials to the work surface and formation of inter-metallic phases. The micro-hardness of the resulting composite layer is also measured which is 1.5-3 times more than work material's one and highest layer thickness (LT) of 83.644 m has been successfully achieved.

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

“…2e, f, it can be inferred that when P on and V g are increasing, more amount of heat results in high spark energy which is responsible for the formation of the broader and deeper crater with a rough surface, thereby increasing in SR of 9.14 µm was observed at C p = 6 g/L, P on = 90 µs and V g = 40 V. Higher MDR with the formation of deep craters is sometimes responsible for high SR values, as shown in Fig. 2c, d [19]. At higher C p , however, the sparking energy is dispersed with multiple sparks, reducing the impacting force on the depositing surface.…”

“…2a, b, it is evidenced that resolidified layer with the formation of craters and voids, including the agglomeration of WS 2 particles, increases the MDR with the rough surface and also results in increased LT of 55. 19 µm was observed at C p = 10 g/L, P on = 50 µs and V g = 40 V. Figure 2c, e witnessed the formation of resolidified debris with uniform deposition and globulus debris on the deposited surface. Figure 2e, f shows micro-voids, craters and globulus debris with agglomerated WS 2 particles, and it is also confirmed with EDS mapping as indicated in Figs.…”

“…2c, d, e [15]. A significant reduction in MDR of 0.0013 mg/min was observed at C p = 8 g/L, P on = 90 µs, and V g = 60 V; this occurred due to higher energy according to high P on time, and uniform energy is enforced for a longer time [19].…”

Integrating Operator Information for Manual Grinding and Characterization of Process Performance Based on Operator Profile

“…Depending on the purposes and applications, different types of S/N ratios exist [22]. Here the desirable objectives are to lower the cutting forces and the surface roughness.…”

Investigation of Surface Modification of 60CrMoV18-5 Steel by EDM with Cu-ZrO2 Powder Metallurgy Green Compact Electrode

“…There is a high scientific interest in the surface modification by EDC using sintered and green PM electrodes [13][14][15]. In more details, Patowari et al [16] studied the surface integrity of C-40 steel in EDM.…”