The effect of Titanium Carbide (TiC) addition on the performance of Cupro-Tungsten (Cu-W) alloy for spark erosion electrodes used in machining carbide materials

Abstract

This article focuses on the development and characterization of Copper-Tungsten (WCu) electrodes, enhanced with the addition of nickel and cobalt as activators and titanium carbide (TiC) for improved wear resistance. The electrodes were manufactured using powder metallurgy through cold pressing, followed by sintering-infiltration at 1250°C under a reducing atmosphere of H2. The characterization process involved measuring density, microhardness, electrical conductivity, and SEM/EDX microstructure. Additionally, technological tests were conducted on P35 carbide parts to assess parameters such as material removal rate (MRR), tool wear rate (TWR), and wear rate (WR). The results indicated that the W-Cu-Ni-TiC compact exhibited an improved density of 11.95, while the W-Cu-Co-TiC compact demonstrated the highest MRR. The W-Cu-Co-TiC compact also recorded a lower TWR. Overall, the W-Cu-Co-TiC compact offered the best compromise in terms of electrode-part wear, achieving superior microhardness values of 289Hv. These findings suggest that incorporating transition elements and TiC into WCu electrodes can significantly enhance their performance, making this study a valuable reference for future research aimed at improving electrode wear resistance through material and manufacturing advancements.