This research paper presents a thermophysical model development and simulation of the electric discharge coating process (EDC). Many literatures are available for the electric discharge coating process from an experimental perspective. A 2-D axisymmetric model was initially developed with the realistic assumption with multi-spark overlap conditions considered in this work. The melt pool volume of the tool material is estimated from the 2D model. The 3D coating model was developed using COMSOL Multiphysics 5.4. This model predicts the temperature distribution on the green compact tool electrode and coating thickness on the substrate. To validate the simulation model, the experimental result from the literature is compared with the simulation result. The simulation and validation trials results reveal that the present developed coating model can predict the coating thickness with minimum error (4% -14%). The developed multi-spark model for the EDC process can be referenced to understand the coating mechanism for various tools and workpiece materials.
This paper reports solid lubricant coating on the M2 high-speed steel substrate with MoS2:Cu (50:50) green compact electrode by electric discharge coating (EDC) process. The influence of input parameters (peak current(I) and pulse duration(ton)) on the coating responses (thickness, microhardness, and surface roughness) have been investigated. The coated materials atomic weight percentage and chemical compounds are examined through EDS and XRD analysis. The maximum coating thickness (695.3µm) reported at ton - 750 µs and I- 5A. The coated samples microhardness exhibit between 217.8 HV – 669.43 HV, which is lesser than the substrate (750 HV). The adhesive strength of the coating surface was examined using scratch test with progressive load. The result shows, adhesive strength increased at higher current level.
This paper reports the effect of coating thickness on adhesive properties, and residual stresses by the electric discharge coating (EDC) process on Mg alloy with copper (Cu) nickel (Ni) powder metallurgical (P/M) electrodes. The composite coating layer thickness was measured by optical microscope and it ranges from 10.2 to 102.4 µm. The coating layer was characterized by a Field emission scanning microscope (FESEM) and Energy-dispersive spectroscopy (EDS). X-ray diffraction (XRD) and Fourier transform infrared spectroscopy (FTIR) analyses were made to identify the chemical composition and functional group. Residual stresses were evaluated by an ETA diffractometer and it revealed that compressive residual stress increases with a range of −458 ± 118 MPa to −1078 ± 125 MPa and tensile residual stresses decrease from 656 ± 113 MPa to 27 ± 11 MPa. The critical load is measured by scratch test. The result shows the adhesive strength of the coated surface was improved with an increase in layer thickness.
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