Journal of Materials Processing Technology 115 (2001) 359366

Surface modication of AlZnMg aluminum alloy using the combined process of EDM with USM
Yan Cherng Lin, Biing Hwa Yan*, Fuang Yuan Huang
Department of Mechanical Engineering, National Central University, Chung-Li 32054, Taiwan, ROC Received 12 October 1999

Abstract This paper presents a novel technique to improve the machined surface of AlZnMg aluminum alloy by a combined machining process of electrical discharge machining (EDM) with ultrasonic machining (USM). In these experiments, SiC particles were added into the dielectric uid to produce a particle-reinforced mechanism and solid solution strengthened structure to form a modied layer on the machined surface in a short working time. The experimental investigation also discusses the inuence of machining polarity on the modied layer of aluminum alloy. Furthermore, quantitative analysis of element content has been carried out by electron probe micro-analyzer (EPMA) to determine the thickness of the modied layer and the distribution of silicon and carbon in the cross-section of the machined zone. Moreover, micro-hardness tests and wear tests were also conducted to evaluate the effects of surface modication by the combined process. From the experimental results, it can be seen that the combined process of EDM with USM can achieve an 80 mm deep modied layer on the machined surface of aluminum alloy in 240 s, and that such layer can signicantly improve the hardness and wear resistance of the machined surface. # 2001 Elsevier Science B.V. All rights reserved.
Keywords: Electrical discharge machining; Ultrasonic machining; Combined process; Surface modication

1. Introduction In general, aluminum alloys provide relatively lightweight and good specic strength that can minimize the weight and increase the potential usage of the components. Recently, aluminum alloy has become an important material, especially in the aeronautic and automobile industries. Although aluminum alloy has the previously mentioned advantages, its weakness is that its surface property cannot withstand wear under circumstances of high load. This may cause serious damage, especially of sliding components in direct contact. For this reason, it becomes increasingly more importance to develop a technique that can improve the wear resistance of the machined surface of aluminum alloy at lower cost and with a simpler operating process. Surface modication by electrical discharge machining (EDM) has been examined by some researchers. For example, Shunmugam and Philip [1] used a sintered electrode made of WC powder in EDM to transfer WC to the machined surface and form a modied layer on the

* Corresponding author. Tel.: 886-3-4267353; fax: 886-3-4254501. E-mail address: bhyen@cc.ncu.edu.tw (B. Hwa Yan).

workpiece surface, improving the surface wear resistance. Mohri et al. [2] used EDM with a green compact electrode of AlTi alloy to produce a modied layer that contained rich TiC on the machined surface. Tsunekawa et al. [3,4] found that the titanium from an electrode and the carbon decomposed from the dielectric uid were deposited on the machined surface during EDM. This result revealed that the wear property of the machined surface was improved signicantly after EDM since the effect of electric discharge alloying was occurring on the machined surface. Ogata and Mukoyama [5] examined carbonization and de-carbonization phenomena on the EDMed surface. They found that a carbonization layer was formed when using kerosene as the dielectric uid, but that a de-carbonization layer was obtained when using distilled water as the dielectric uid. Although the contents of the sintered electrode could be transferred to the machined surface of the workpiece, forming a modied layer during EDM, a high wear rate of the electrode is necessary to provide sufcient modied agents that would seriously affect the machining precision. The combined process of EDM with ultrasonic machining (USM) has been proven to facilitate the circulation of dielectric uid, thus avoiding the clustering of debris and improving the machining stability of EDM [6,7]. In addition,

0924-0136/01/$ see front matter # 2001 Elsevier Science B.V. All rights reserved. PII: S 0 9 2 4 - 0 1 3 6 ( 0 1 ) 0 1 0 1 7 - 2

360

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366

USM can also assist with material removal from the workpiece. Therefore, the combined process of EDM with USM can promote overall machining efciency [6,7]. In the USM process, abrasive particles such as SiC, Al2O3 and B4C, etc. were added to the dielectric uid to create striking and hammering actions by ultrasonic vibration, leading to microchips and cracks on the workpiece surface for material removal [8]. The purpose of this research is to integrate the machining mechanisms of EDM with USM as a combined process to produce a modied layer on the machined surface. The thickness of this modied layer can be easily and efciently controlled by varying the discharge current and gap voltage of the EDM conditions. Furthermore, the shape and dimensions of the workpiece can also be well maintained during this surface modication process. 2. Experimental method 2.1. Experimental procedure To determine the effects of the combined process of EDM with USM on the modied layer of AlZnMg alloy, this research integrated EDM with USM for a series of related experiments. This method used a conventional EDM machine with transistor circuit and attached a magneto-strict ultrasonic transducer as integration. The copper electrode was fastened on a step horn that acted as an amplier and was rmly connected to the transducer by a screw. The ultrasonic transducer was actuated by a resonant frequency of 17.522.5 kHz to provide USM power. Four liters of commercial dielectric uid used for EDM was employed in each experiment. In addition, abrasive particles (SiC) of 20 mm diameter were added to the dielectric uid and maintained at a concentration of 35 wt.% in the dielectric. The dielectric uid was recycled by a pump and circulated by an agitator to ensure that the abrasive particles were uniformly suspended in the dielectric uid. The experimental set-up is shown in Fig. 1. The working conditions listed in Table 1 were varied to determine the inuence on surface modication. Qualitative and quantitative analysis of the modied layer was obtained by EPMA (using a Jeol JXA-8800M EPMA) to determine the modied layer's thickness and to explore the distribution of silicon and carbon in the cross-section of the machined surface. In addition, SEM and OM were used to observe the microstructure of the machined surface and the modied layer. The hardness distribution in the cross-section of the machined surface was obtained by using a Vickers microhardness test instrument. Furthermore, a wear test was performed using a Falex Model No. 6 wear device to evaluate the wear resistance of the modied layer. The upper counter-face specimen was ADI, made in accordance with ASTM D3702. For each 30 m sliding distance, the specimen was taken down and cleaned in an ultrasonic bath. After that,
Fig. 1. Schematic diagram of the experimental equipment.

the specimen was dried and weighed using a precise electric balance to evaluate the wear resistance of the modied layer by weight loss. 2.2. Experimental material The material used for experiments was AlZnMg alloy, the chemical composition of which was obtained using an inductively coupled plasma atomic emission spectrometer (ICP-AES) and is shown in Table 2. The workpiece dimensions were f38 mm 10 mm for the wear test and f19 mm 10 mm for the other tests. The electrode material was electrolytic copper of dimensions f8 mm 43 mm, and
Table 1 Experimental conditions Work condition Discharge current (A) Pulse duration (ms) Gap voltage (V) Duty factor Polarity Abrasive size (mm) Ultrasonic amplitude (mm) Abrasive concentration (wt.%) Working time (s) Symbol Ip tp Eg DF pp tw Description 327 1001250 40110 0.55 Positive/negative 20 30 35 20

Table 2 Chemical composition of the aluminum workpiece (obtained by ICP-AES) Element (wt.%) Zn 1.65 Mg 0.85 Si 0.20 Fe 0.21 Cu 0.57 Al Remainder

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366 Table 3 Properties of SiCa Crystal form Density Hardness Maximum usable temperature
a

361

Hexagonal system 3.20 22002800 (Knoop) 9.09.5 (Mohs) About 20008C

Source: Showa Denkou, 1990.

Table 4 Chemical composition of SiC (wt.%)a SiC Si SiO2 FC Fe2O3

a

>99.48 0.18 0.08 0.1

Source: Showa Denkou, 1990.

all electrodes were drilled with a f3 mm hole through the center to conduct the dielectric uid and make the abrasive particles disperse uniformly in the gap between the workpiece and the electrode. The added abrasive particles were SiC (99.5 wt.%) to provide appropriate particles for dispersed reinforcement and elements for solid solution strengthening in the modied layer. The mechanical properties and chemical composition of SiC are shown in Tables 3 and 4. 3. Results and discussion 3.1. Effect of polarity Fig. 2 shows the comparison of a single crater created by positive and negative machining polarity. From this gure, it is found that the center part of the single crater has obvious

differences between the positive and negative polarity machining. With positive polarity, some melted material was solidied on the crater center to form a bulging droplet, whilst for negative polarity, most of the melted material in the crater center was ushed away to form a deeper hollow in the center and a higher ridge around the crater. Fig. 3 shows the comparison of surface roughness and a typical machined surface for positive and negative machining polarity. From the SEM micrographs, it can be seen that the roughness of the surface machined by negative polarity Ra 8:8 mm is coarser than that machined by positive polarity Ra 5:1 mm. The reason for this may be that the cathode distributes more energy to produce a larger impinging force by ions in the discharge column and thus creates more melted material on the machined surface. Then, the melted material is ushed away from the center of the crater by impulsive force due to the burnt and vaporized dielectric uid. Finally, most of the melted material is splashed away and solidies around the crater to form a higher ridge. Therefore, the negative polarity secured a greater material removal rate (MRR) and produced a worse surface roughness than for positive polarity. Since improvement of MRR is not the main purpose of this subject, i.e. concern to obtain a dispersed particlereinforced mechanism and solid solution strengthening structure on the modied layer, the positive polarity machining method was adopted in the following experiments. Figs. 4 and 5 show the distribution of silicon (Si) and carbon (C) in the machined cross-section by the combined process of EDM with USM under positive and negative polarity in order to discuss the inuences of polarity on the modied layer. Fig. 4 shows that the silicon content produced by positive polarity is more than that produced by negative polarity. As measured 10 mm from the machined surface, the silicon content is 1.9 wt.% from positive polarity, but 1.0 wt.% from negative polarity. In addition, the

Fig. 2. Influence of machining polarity on a single crater (Ip: 12 A; tp: 500 ms; Eg: 100 V).

362

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366

Fig. 3. Typical SEM micrographs of a machined surface (Ip: 12 A; tp: 500 ms; Eg: 100 V).

depth of the silicon content in the substrate using positive polarity (approximately 80 mm) is deeper than that for negative polarity (approximately 60 mm). From Fig. 4, it is found that the silicon content was increased in the machined zone by both positive polarity and negative polarity using the combined process of EDM with USM, indicating that the combined process both inserted SiC particles into the melted zone of the workpiece and also transferred melted SiC to the machined surface. Therefore, the combined process of EDM with USM is a good method to improve the machined surface. Furthermore, positive polarity can secure greater silicon content, to a greater deeper depth, when compared with negative polarity.

Fig. 5 shows the distribution of carbon in the crosssection. The results show that the carbon content from positive polarity is greater than that from negative polarity. The carbon content from positive polarity was about 15 wt.% but from negative polarity was about 7 wt.% at 10 mm from the machined surface. Moreover, the solubility of carbon in aluminum is about 7.4 wt.% at 20508C [9]. This means that some carbon was dissociated into a free state in the modied layer. Further, the layer with carbon content produced by positive polarity (about 50 mm) is thicker than that produced by negative polarity (about 30 mm). Since there is more complete material removed by negative polarity, a thinner modied layer is obtained.

Fig. 4. Distribution of silicon content in the cross-section of the machined surface.

Fig. 5. Distribution of carbon content in the cross-section of the machined surface.

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366

363

Fig. 6. Characteristic X-ray images in the cross-section by electron probe microanalysis (Ip: 12 A; tp: 500 ms; Eg: 100 V).

3.2. Modified mechanisms of the combined process The SiC abrasive particles were passed into the gap between the electrode and the workpiece during the combined process of EDM with USM, stimulated by ultrasonic vibration of the electrode to create hammering and striking effects on the workpiece, thus increasing the MRR. Since the discharge column between the electrode and the workpiece becomes ionized plasma, the high heat from the plasma will melt the surface of the workpiece and the electrode, thus driving the ionized particles to impact the melted surface. After the melted substrate has cooled down, an alloying layer is formed on the machined zone. However, some SiC particles around the discharge column were cracked into sub-particles by thermal energy and inserted into the aluminum alloy substrate to form particle dispersing reinforcement. Fig. 6 shows typical SiC dispersed in the modied layer and silicon mapping obtained by EPMA. From this gure, it can be seen that the SiC dispersed in the modied layer can improve the mechanical properties of the machined surface to achieve the effect of reinforcement. Thus, the combined process of EDM with USM is an effective way to obtain surface modication. 3.3. Variation of chemical composition in modified layer Fig. 7 shows the comparison of silicon distribution in the cross-section of the machined surface by quantitative analysis of EPMA. The various processes chosen are: (a) conventional EDM using commercial dielectric uid; (b) conventional EDM with 35 wt.% SiC added to the dielectric uid; (c) the combined process of EDM with USM using 35 wt.% SiC added to the dielectric uid. As this gure demonstrates, the silicon content from the combined process reached a peak value of 1.9 wt.% at a depth of 10 mm from the machined surface. Below a depth of

approximately 80 mm, the silicon content approached the substrate value of 0.2 wt.%. Moreover, the conventional EDM with 35 wt.% SiC added to the dielectric uid had the same effect as the combined process. However, the increased silicon content in the modied layer from the conventional process with a peak value of 0.6 wt.% at 10 mm from the machined surface was signicantly less than that from the combined process. In addition, the silicon content had reduced to be the same as that of the substrate at a depth close to 70 mm. The variation in silicon content obtained by conventional EDM using commercial dielectric uid is very slight. The above results show that SiC added to the dielectric uid will be transferred to the machined zone during EDM. Therefore, the combined process will both transfer SiC into the machined zone and disperse the SiC within the gap more uniformly by ultrasonic vibration. Moreover, the SiC is inserted into the machined layer by ultrasonic vibration

Fig. 7. Distribution of silicon content in the cross-section by various processes.

364

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366

Fig. 8. The influence of the peak current on the depth of the modified layer.

Fig. 10. Vickers hardness in the cross-section of the modified layer for different processes.

to produce surface modication. In addition, the cavitation caused by ultrasonic vibration generates a micro-agitation in the melted zone, so the added SiC can penetrate more deeply and uniformly into the modied layer. 3.4. Influence of discharge energy on modified layer depth Figs. 8 and 9 depict the relationship of modied layer depth versus discharge current and gap voltage. The modied layer depth is dened as the depth within which the silicon content is higher than that of the substrate of aluminum by quantitative analysis of EPMA from the machined surface. Fig. 8 shows the inuence of discharge current on the modied layer depth, indicating that the silicon content increased with the discharge current. The maximum mod-

ied layer depth was produced with a discharge current of 12 A. When the current was more than 12 A, the modied layer depth showed a slight reduction. This may because the increased discharge current resulted in a deeper melted zone, so that the modied layer depth of the machined surface was increased. However, with a longer pulse duration (500 ms) the higher discharge current (above 12 A) will remove the melted material more completely. Therefore, there will be less melted material solidied on the machined zone, thus decreasing the modied layer depth. Fig. 9 shows the effect of gap voltage on the modied layer depth. From this gure, the modied layer depth increased with the gap voltage, reaching a peak when the voltage was about 80100 V. Then, the modied layer depth slightly reduced as the gap voltage increased. The increased modied layer depth may be due to the increasing gap

Fig. 9. The influence of the gap voltage on the depth of the modified layer.

Fig. 11. Weight losses versus sliding distance for different processes.

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366

365

voltage expanding the gap distance to include more SiC particles in the gap, thus leading to a thicker modied layer. However, when the gap distance is too large, the constriction in discharge gap will degrade and reduce the impulsive force caused by EDM. Therefore, the modied layer depth showed a slight decrease when the gap voltage exceeding the optimal quantity (100 V). 3.5. Micro-hardness test Fig. 10 depicts the distribution of micro-hardness in the cross-section of the surface machined by the combined

process of EDM with USM and machined by conventional EDM. As shown in the gure, a softened layer of about 80 mm was observed to be adjacent to the zone machined by conventional EDM. Since the aluminum alloy is a precipitated strengthening material, the precipitated reinforcement phase would dissolve in the matrix, resulting in over-aging by local high temperature due to EDM [10]. This could lead to a softened layer in the machined zone. In contrast, a hardened layer of about 40 mm was found in the layer machined using the combined process, with a softened layer adjoining the hardened layer. Because the zone machined by the combined process could produce both particles

Fig. 12. Comparison of the wear surface for different pre-processes.

366

Y. Cherng Lin et al. / Journal of Materials Processing Technology 115 (2001) 359366

reinforced and solid solution strengthened in the modied layer, the hardness could be signicantly improved by the combined process and a higher hardness obtained in the machined zone. 3.6. Wear test Fig. 11 is the wear test result of the workpiece machined by the following processes: (a) abrasive machining; (b) conventional EDM; (c) combined process of EDM with USM. The device for this test was Falex Model No. 6. The initial surface roughness values after the above-mentioned processes are all the same at 40 mm (Rmax). As shown in this gure, the wear resistance for the combined process is the best and that for the conventional EDM is the worst. This may be because the machined zone obtained by the combined process will have strengthening by particles reinforcement and AlSi solid solution strengthening structure in the modied layer and effectively improve its wear resistance. Moreover, the local high temperature results from conventional EDM will lead to over-aging and re-dissolution of the precipitated reinforcement phase, which could soften the machined surface of the aluminum alloy and reduce its wear resistance. Fig. 12 shows the micrographs of SEM for the specimen achieved from: (a) abrasive machining; (b) conventional EDM; (c) the combined process of EDM with USM. To compare the wear resistance of the machined surfaces from the three processes, all the samples have been wear tested. As shown in the gure, it is clear that the contact scars of the specimen after the wear test are different between the combined process and conventional EDM. The scars of the specimen from conventional EDM are the deepest and those from the combined machined are the attest, and maintaining smooth surface integrity after the wear test. This evidence shows that the combined process is able to improve the wear resistance of the machined surface. 4. Conclusions A series of experiments for surface modication has been conducted using the combined process of EDM with USM.

The results as compared with conventional EDM in terms of surface improvement are as follows: 1. The combined process of EDM with USM is a feasible and effective process for surface improvement. The machined surface can develop a modified layer of SiC particles within the machined zone, as well as an AlSi solid solution strengthening structure. This reinforced modified layer can be obtained in a very short time. 2. The silicon and carbon content in the machined zone developed by positive polarity EDM is greater than that by negative polarity, this indicates that positive polarity machining could provide significantly better surface modification. 3. The combined process can provide a hardened layer in the machined zone, which is very different from the layer provided by conventional EDM. 4. The wear resistance of the aluminum alloy could be effectively improved by the combined process, thus overcoming the softened layer of aluminum alloy caused by conventional EDM. Acknowledgements The authors would like to thank the National Science Council of the Republic of China for nancially supporting this research under Contract No. NSC 88-2212-E-008-004. References
[1] M.S. Shunmugam, P.K. Philip, Wear 171 (1994) 15. [2] N. Mohri, N. Saito, Y. Tsunekawa, Ann. CIRP 42 (1) (1993) 219222. [3] Y. Tsunekawa, M. Okumiya, N. Mohri, E. Kuribe, Mater. Trans. JIM 38 (7) (1997) 630635. [4] Y. Tsunekawa, M. Okumiya, N. Mohri, I. Takahashi, Mater. Sci. Eng. A 174 (1994) 193198. [5] I. Ogata, Y. Mukoyama, Int. J. Jpn. Soc. Prec. Eng. 27 (3) (1993) 197202. [6] B.H. Yan, M.D. Chen, J. Jpn. Inst. Light Met. 44 (5) (1994) 281285. [7] V.S.R. Murthy, P.K. Philip, Int. J. Mach. Tools Manuf. 27 (24) (1987) 469477. [8] T.B. Thoe, D.K. Aspinwall, M.L.H. Wise, Int. J. Mach. Tools Manuf. 38 (4) (1998) 239255. [9] H. Ginsberg, V. Sparwald, Aluminium 41 (1965) 181193. [10] M. Ramulu, M. Taya, J. Mater. Sci. 24 (1989) 11031108.