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Surface Modification by Electro-discharge Coating and Its Characterisation

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Trends in Mechanical Engineering & Technology
Volume 3, Issue 2, ISSN: 2231-1793
__________________________________________________________________________________________

Surface Modification by Electro-discharge Coating and

Its Characterisation
R.S. Pawar1*, S.B. Sharma2
1
Hi-Tech Institute of Technology, Aurangabad, M.S., India
2
S.G.G.S. College of Engg. & Technology, Nanded, M.S., India

Abstract
Applications of coated surface are swiftly increasing in present industrial context.
Recently, the electro-discharge route is being explored for surface modification in terms
of alloying and layer deposition. Electro-discharge machining parameters and response
to surface deposition is of the research interest in electro-discharge coating. In this
regard, electro-discharged surface modifications have been characterized in the present
investigations. The effect of relevant EDM parameters (current, Pulse duration, duty
factor, density of electrode material) on various surface alloying responses such as
surface micro hardness, chemical composition of the alloying surface, surface deposition
layer thickness has been studied. The EDM electrode is specially made of tungsten
powder by semi-sintering process. Negative or reverse polarity is used for better results
of layer deposition of electrode material of tungsten powder and carbon particles within
the dielectric liquid used for machining. Considering ample of general applications in
engineering, work piece is of low carbon steel/HSS has been identified. It is observed that
tungsten carbide layer has been deposited on the work piece which shows better
functional characteristics for the applications. Low to medium current (2–5 A), Low
density of electrode material (7.15–8.03 kg/cm3) and low duty factor (3–5) are favorable
conditions for better deposition of the layer.

Keywords: electro discharge coating, deposition, tungsten powder, characteristics

*Author for Correspondence: pawar_ramkisan@rediffmail.com, 9049989805

INTRODUCTION nitriding, chromium plating and in some

Electro-discharge (ED) is one of the most instances chemical/physical vapour deposition
successful non-traditional machining (CVD/PVD), ion beam technique and plasma
technologies. It is used for removing material arc spraying. Such processes are secondary
by application of heat energy by electrical operations which either require expensive in-
sparking between metal and electrode. For house equipments or the use of sub-contract
several decades, electrical-discharge companies. They add to cost and lead time
machining has been an important machining components; significantly in some instances
process for the tool, mould and dies industries. [1]. An alternative approach is deliberate
It is now increasingly used owing to its ability surface alloying/ modification during EDM.
to produce geometrically complex shapes, as
well as its ability to machine hard materials. In Working Principle Of Electro Discharge
the recent years, many advancements through Coating (EDC)
technology pull in EDM are being exercised
and experimented for EDM of non conducting
materials, dry EDM, micro ED machining,
production of micro-nano powders, coatings
etc. Recent innovative technology in ED is
electro-discharge coating. At present, the
available techniques for enhancing the
surface, mechanical/physical/topographical
properties of components subject to wear,
Fig. 1: Schematic Diagram of the Process.
corrosion/oxidation etc. include carburizing,

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 43
 Surface Modification by Electro-discharge Coating Pawar and Sharma
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With the EDM machine tool and hydrocarbon EXPERIMENTATION

dielectric fluid, Ti, W or other metallic
materials are used as the electrode. In the
process of EDC, a kind of hard carbide (Such
as TiC or WC) is formed in-situ through
chemical reaction between the worn electrode
material and carbon particles decomposed
from the dielectric fluid under high
temperature. The carbide or metal is piled up
on the oppositely charged work piece quickly
and becomes a hard layer of ceramic or metal
itself in several minutes [2, 3].
Electrodes Development for the Experimentation
Item
Electrode fabrication Process
Electrode material Composition
Diameter of Powder(µm)
Forming Pressure
Sintering Temperature
Size of Electrode(mm2)
A die-sinking EDM (General EDM Machine-
ZNC Eletronica) at Indo German Tool room,
Aurangabad, has been used for
experimentation. Schematic diagram of the
process is shown in Figure 1. Sintered P/M
tools at 800Ο C made of 94 % tungsten and 6%
cobalt powders have been used for deliberate
transfer of electrode material over work
surface. This has resulted in depositing a layer
of hard and composite material over the work
surface, thereby changing its surface
characteristics. The deposited layer has been
found to be composed of WC/C, W, and Fe
[4, 5].
Specification
Powder Metallurgy (semi sintering) process
Tungsten –Copper Powder
(W75-Cu25)
3µm
125, 188 , 251 Mpa- (N/mm2)
800o C
12.5 mm dia. and
8-10 mm height

Design of Experiment
Factors for Experimentation on EDM Machine [6]
Variable Factors Level Responses
Peak Current, Ip (A) 2,4,6 A Micro Hardness
Density of electrode 7.15,8.03, 8.925 kg/cm3
(Electrode Forming Pressure) (125, 188 , 251 Mpa) Layer Thicknes
Discharge Duration, Ton(µs) 50, 75,100 (µs)
Pulse Duty Factor (%) 3,5,7 Other Responses for Surface
Other Factors Characterization of the Coating-
Electrode Polarity Negative/Positive Composition and Microstructure of the
Discharge Voltage 50 V layer.
Working Fluid(Dielectric) EDM oil
Work piece Material M2 tool steel/EN-8/MS Experimentation will be carried on
Machining Time 5 min General EDM Machine-ZNC
Eletronica.
Electrode by PM as above Tungsten –copper powder
Specifications (W75-Cu25)

Design of experiment by L9 Orthogonal
Array
For experimentation L9 orthogonal Array is
selected as follows in which total 9
Exp. No. Current (A)
1 1
2 1
3 1
4 2
5 2
6 2
7 3
8 3
9 3
experiments are carried out [7]. Unused new
Tungsten-Copper Powder electrode is used for
each set of experiments under investigation.
Density (kg/cm3) Ton (µS) Tau
1 1 1
2 2 2
3 3 3
1 2 3
2 3 1
3 1 2
1 3 2
2 1 3
3 2 1

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 44
Trends in Mechanical Engineering & Technology
Volume 3, Issue 2, ISSN: 2231-1793
__________________________________________________________________________________________

RESULTS AND DISCUSSION

Photographs of the Work Pieces

(a) Low carbon steel (b)HSS

Fig. 2: Enlarged photos of EDC of Specimen 6 and 3.

1 2 6 7 8 9

3 4 5
Fig. 3: Photographs of the Coatings on Specimen 1- 9 Work Piece.

Experimental Result Matrix

Exp. Current Density of Ton Tau Hardness Layer
No. (A) Electrode kg/cm3 µs (Hv) thickness
(µm)

1 2 7.15 50 3 1020 280

2 2 8.03 75 5 910 15
3 2 8.925 100 7 998 26
4 4 7.15 75 7 1120 20
5 4 8.03 100 3 1211 40
6 4 8.925 50 5 987 25
7 6 7.15 100 5 1211 200
8 6 8.03 50 7 1280 18
9 6 8.925 75 3 1015 30

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 Surface Modification by Electro-discharge Coating Pawar and Sharma
__________________________________________________________________________________________

The micro hardness and thickness of the
coated layer are tested at S.N.Metallurgicals
Pvt. Ltd, which is total material testing
laboratory at MIDC, Waluj, Aurangabad. It is
observed that the hardness of the coating is
multi folds more than the parent work piece
material hardness. The layer thickness is
measured with Rapid-I Microscope with
magnification 71X for work piece samples 1-
9. The tungsten carbide layer is observed in
the coating.

Sample No.1 Carbide Layer of 0.015 mm Sample No.2 Carbide Layer of 0.018 mm

Sample No.3 Carbide Layer of 0.020 mm Sample No.4 Carbide Layer of 0.026 mm

Sample No.5 Carbide Layer of 0.030 mm Sample No.6 Carbide Layer of 0.280 mm

Sample No.7 Carbide Layer of 0.200 mm Sample No.8 Carbide Layer of 0.025 mm

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 46
Trends in Mechanical Engineering & Technology
Volume 3, Issue 2, ISSN: 2231-1793
__________________________________________________________________________________________

Sample No.9 Carbide Layer of 0.040 mm

Fig. 4: Micrographs (Sample 1-9) by Rapid-I Machine for Measuring Thickness of Carbide Layers.

Fig. 5: Microstructure at: 100 X Magnification (For Sample No. 6 for Plane Surface).

From Figure 5 it is observed that the white RESPONSE SURFACE ANALYSIS

color deposited layer is of electrode material
Tungsten and Tungsten Carbide having better
surface characteristics for application [8, 9]
AND TAGUCHI ANALYSIS
The response surface graphs are as shown in
1,2,3,4 in Figure 6, for hardness with the
factors electrode density –current, Ton –Tau
and for layer with factors density, current, Ton
and Tau, respectively.

1200
Har dness in Hv

1050
6

900 4
Cur r ent
7.5
8.0 2
8.5
9.0
Density of Electrode k g/cm3

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 47
 Surface Modification by Electro-discharge Coating Pawar and Sharma
__________________________________________________________________________________________

1200
Hardness in Hv

1050
100

900 75
T on µs
3.0
4.5 50
6.0
T au 7.5

300

200
Layer thick ness µm

100
100

0 75
T on µs
3.0
4.5 50
6.0
T au 7.5

300

200
ayer thick ness µm

100
6

0 4
Current
7.5
8.0 2
8.5
9.0
Density of Electrode k g/cm3

Fig. 6: Response Surface Graphs (1, 2, 3, 4).

Above response graphs study (Figure 6)
shows that hardness of the layer increases with
current but decreases with density of electrode
within a certain limit as shown Graph-1. In
Graph -2, it shows that hardness of the layer
good at lower values of discharge duration and
pulse duty factor.
Also the Graph -3 shows that layer thickness
is better at medium Tau and less at medium
Ton. The Graph -4 shows that layer thickness

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 48
Trends in Mechanical Engineering & Technology
Volume 3, Issue 2, ISSN: 2231-1793
__________________________________________________________________________________________

is better at medium current and at low density. 7. The optimal conditions for combined results
Similar results can be obtained with help of of hardness and layer thickness are also shown
response optimization plot as shown in Figure in the plot.

Optimal Current Density Ton Tau

D High 6.0 8.9250 100.0 7.0
Cur [5.4747] [7.150] [50.0] [3.0]
1.0000 Low 2.0 7.150 50.0 3.0

Composite
Desirability
1.0000

Hardness
Maximum
y = 1528.4019
d = 1.0000

Layer th
Maximum
y = 200.4154
d = 1.0000

Fig. 7: Response Optimization Plot.

Figure 8 shows the Main effects plots for SN
ratios for Taguchi analysis in which signal to
noise ratio as larger is better, describes
medium to high current, lower density, higher
Ton and lower Tau as favorable conditions for
the Coating hardness. Also from the main
effects table it clear that the ranking of factors
for layer thickness is current, density, Ton,
Tau in descending order.

Main Effects Plot for SN ratios

Data Means
Current Density of Electrode kg/cm3
62.0
61.5
61.0
Mean of SN ratios

60.5
60.0

2 3 4 6 7.150 7.700 8.925

Ton µs Tau
62.0
61.5
61.0
60.5
60.0

50 75 100 3 5 7

Signal-to-noise: Larger is better

Fig. 8 Main Effects Plot for SN Ratios for Hardness.

Figure 9 shows the main effects plots for SN
ratios for Taguchi analysis in which signal to
noise ratio as larger is better, describes lower
current, lower density, higher Ton and
medium Tau as favorable conditions for the
Coating layer thickness. Also from the main
effects table it clear that the ranking of factors
for layer thickness is density, Tau, Ton and
current in descending order.

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 49
 Surface Modification by Electro-discharge Coating Pawar and Sharma
__________________________________________________________________________________________

Main Effects Plot for SN ratios

Data Means
Current (A) Densit y kg/cm3
45
40
35
Mean of SN ratios

30
25
2 4 6 7.150 7.700 8.925
T on (µS) T au
45
40
35
30
25
50 75 100 3 5 7
Signal-to-noise: Larger is better

Fig. 9: Main Effects Plot for SN Ratios for Layer Thickness.

CONCLUSION 6. W.S. Zhao, Y. Fang, Z.L. Wang, L.H. Li,

This is observed that Surface modification by “A Surface Modification Method by EDM
layer deposition of EDM electrode material on and its
work piece is successfully done with the same Application to Cutting Tools” 2004.
EDM machine used for material removal 7. Douglas C.Montgomery, “Design and
under certain conditions. Current up to 6 A, Analysis of Experiments” 2001.
Ton up to 100 (µS) and with low density of a. P.K. Patowari, Partha Saha, P.K.Mishra,
powder metallurgy electrode i.e., 7.15 to “Taguchi Analysis of Surface
8.03kg/cm3 are favorable conditions for Modification using W-Cu powder Sintered
material deposition on work piece. The Tools in EDM and Characterization of
tungsten particle of the P/M electrode Layer” 2010.
combines with the carbon from the dielectric 8. P.K Patowari, Partha Saha, P.K.Mishra,
liquid in which carbon powder in the form of “Artificial Neural Network Model in
graphite may be mixed, the tungsten carbide Surface, Modification by EDM using W-
layer is formed having better surface Cu P/M Sintered Electrodes” 2010.
characteristics for coating application for dies
and punches etc.

REFERECES
1. Tshio Moro, Naotake Mohri, Hisashi
Otsubo, et al. “A Study on Surface
Modification System with EDM in
Practical Usage” 2004.
2. G. Lee, J. Simao, D.K. Aspinwall, R.C.
Dews, et al. “Electrical Discharge
Surface Alloying” 2004.
3. W.S. Zhao, Y. Fang, Z.L. Wang and L.H.
Li, “A Surface Modification Method by
EDM and its Application to Cutting
Tools” 2004.
4. Toshio Moro, Naotake Mohri, Hisashi
Otsubo, et al. , “A Study on
Surface Modification System with EDM in
Practical Usage” 2004.
5. G. Lee, J. Simao, D.K. Aspinwall, et al.
“Electrical Discharge Surface Alloying”
2004.

TMET (2013) 43-50 © STM Journals 2013. All Rights Reserved Page 50

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