Suitability of Eroded Particles from Die-Sink Electro Discharge Machining for Additive Manufacturing—Review, Characterization and Processing

Voigt, Oliver; Peuker, Urs A.

doi:10.3390/met12091447

Cited by 6 publications

(4 citation statements)

References 68 publications

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Section: Resultsmentioning

confidence: 99%

“…When the shear rate decreases, the linear form of shear stress decreases, which is attributed to the structure destroyed by strong shear stress gradually recovering to its original structure. The 3D network structure formed by Ag particles is explained in detail below [35][36][37]. Next, Figure 8a shows the results of frequency sweep measurements, which are used to characterize the structure formed by the WP and DP Ag.…”

Section: Rheological Characteristics and Screen Printing Of Ag Pastementioning

confidence: 99%

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Physical Properties of Paste Synthesized from Wet- and Dry-Processed Silver Powders

Nam,

Shin,

Koo

et al. 2024

Materials

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This study compares the characteristics and low-temperature curing properties of pastes prepared from silver (Ag) powders synthesized by either wet powder (WP) or dry powder (DP) processing. The WP synthesis of electrode particles has the advantage of controlling the average particle size and particle size distribution but the disadvantage of producing low-purity, crystalline particles because they are synthesized through chemical reduction at less than 100 °C. Conversely, the DP synthesis of electrode particles has the advantage of producing pure, highly crystalline particles (due to synthesis at high temperatures) but the disadvantage of a high processing cost. WP and DP were used to manufacture pastes for low-temperature curing, and the physical properties of the pastes and the electrode characteristics after low-temperature curing were compared between powder types. Shear stress as a function of the shear rate shows that the WP paste is a plastic fluid, whereas the DP paste is a pseudoplastic fluid, closer to a Newtonian fluid. Screen printing the Ag pastes and curing for 30 min at 130 °C produces a nonconductive WP paste, whereas it produces a DP paste with a conductivity of 61 mΩ/sq, indicating that the highly crystalline DP paste is advantageous for low-temperature curing.

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Section: Resultsmentioning

confidence: 99%

Section: Rheological Characteristics and Screen Printing Of Ag Pastementioning

confidence: 99%

Physical Properties of Paste Synthesized from Wet- and Dry-Processed Silver Powders

Nam,

Shin,

Koo

et al. 2024

Materials

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“…In this context, the titanium alloy Ti-6Al-4V has a pivotal role, influencing critical industries like the aerospace and biomedical industries with nuclear applications [1]. Micro-EDM, as an advanced iteration of this technology, has gained prominence due to its ability to handle intricate shapes and microscopic dimensions, offering a transformative approach to precision machining [2][3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Investigating Technological Parameters and TiN-Coated Electrodes for Enhanced Efficiency in Ti-6Al-4V Micro-EDM Machining

Pham,

Nguyen,

Shailesh

et al. 2024

Metals

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Micro-electrical discharge machining (micro-EDM) stands out as a transformative methodology, offering substantial progress in both technical and economic efficiency through the integration of coated electrodes. This study meticulously analyzes various technological parameters in micro-EDM, focusing specifically on Ti-6Al-4V, a widely employed titanium alloy. The application of a titanium nitride (TiN) coating material on a tungsten carbide (WC) electrode is investigated using the Taguchi method of experimental design. This study employs an ANOVA and factorial design methodology to scrutinize the influence of key parameters, namely voltage (V), capacitance (C), and spindle rotation (in revolutions per minute) (RPM) on the tool wear rate (TWR), overcut (OVC), and Z coordinate (depth) within the micro-EDM process. The findings unveil a noteworthy increase in the TWR with an elevated V, C, and RPM, with capacitance exerting a pronounced influence while voltage exhibits the least impact. OVC exhibits notable variations, revealing an inverse relationship with RPM. The Z coordinate (depth) is significantly affected by capacitance, with voltage and RPM each having a relatively negligible impact. A surface quality analysis exposes similarities and numerous defects in both coated and uncoated electrodes, emphasizing the need for further exploration into the effectiveness of coated electrodes in enhancing post-micro-EDM machined surface layers. This study contributes valuable insights to optimize and advance micro-EDM processes, laying groundwork for future innovations in precision machining.

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“…A non-traditional setup was built to process the Ni-alloy for this purpose. Electric discharge machining (EDM), wire-EDM, electric discharge drilling, and milling are examples of nonconventional processes [11,12]. Because of its new qualities, the EDM die sinker was chosen over all other choices.…”

Section: Introductionmentioning

confidence: 99%

Evaluating Surface Quality of Inconel 617 by Employing Deep Cryogenically Treated Electrodes in Surfactant-Added Dielectrics of Transformer Oil

Ishfaq

Sana

Mahmood

et al. 2023

Metals

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Over the past few decades, better surface quality has remained of great interest to researchers. It deteriorates the fatigue life of the workpiece. The criticality arises when a material of greater strength is selected to work in high-temperature areas such as nickel (Ni)-based superalloys, categorically Inconel 617. Conventional machining operations are not the best choice for the machining of this alloy because of its low density and greater strength. Therefore, electric discharge machining (EDM) is generally engaged. Still, there is a great necessity to make a more reliable surface using EDM, which performs better even in harsh working areas. Therefore, this study examined the potential of deep-cryogenically treated electrodes under the modified dielectrics of transformer oil in the said context, which has not been discussed so far. A set of 30 experiments was performed, designed using the full factorial technique. Deep-cryogenically treated electrodes provided better surface quality in comparison to the non-treated electrodes. Amongst the deep-cryogenically treated electrodes, brass performed outstandingly and provided the lowest value of surface roughness (SR), 6.65 µm, in the modified dielectric of transformer oil with Span 80. The surface finish of deep-cryogenically treated brass is 28.72% better compared to the average value of the overall deep-cryogenically treated electrodes. The lowest value of SR (8.35 µm) was gained by engaging a non-cryogenically treated Cu electrode with a T-20–transformer oil-modified dielectric. The said value of SR is 17.7% better than the highest value of SR achieved in the case of S-80–transformer oil with a non-cryogenically treated Cu electrode.

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Suitability of Eroded Particles from Die-Sink Electro Discharge Machining for Additive Manufacturing—Review, Characterization and Processing

Cited by 6 publications

References 68 publications

Physical Properties of Paste Synthesized from Wet- and Dry-Processed Silver Powders

Physical Properties of Paste Synthesized from Wet- and Dry-Processed Silver Powders

Investigating Technological Parameters and TiN-Coated Electrodes for Enhanced Efficiency in Ti-6Al-4V Micro-EDM Machining

Evaluating Surface Quality of Inconel 617 by Employing Deep Cryogenically Treated Electrodes in Surfactant-Added Dielectrics of Transformer Oil

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