Electrical Discharge Coating a Potential Surface Engineering Technique: A State of the Art

Abstract

Electrical discharge coating (EDC) process is used to deposit material on workpiece surface from sacrificial or green compact tool electrode in an electrical discharge machine. The paper presents the mechanism of EDC using green compact electrode and powder mixed dielectric methods. The tool electrode material, electrode size, process parameters, and type of dielectrics can directly affect the surface integrity of workpiece. Here, a process map of EDC as a function of process parameters, its classification, advantages, and applications for a wide range of engineering materials offers a proper template for the evaluation of coating phenomena. This study shows that EDC is an economic process as compared to other costlier techniques. Additionally, the effect of various EDM and EDC parameters on surface integrity and tribological behavior of deposited coatings is studied with their pros and cons. Finally, the current research trends of EDC and its challenges are elaborated.

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

“…The active development of electrical erosion technologies is utilized with EDM's inherent tool wear or erosions. One such technology is electrical discharge coating (EDC), which utilizes tool wear/erosion to create functional coatings [19,26,59,60]. The quality of the coating and the percentage of the desired material depends largely on factors such as tool material and processing conditions (including dielectric flushing, electric arc, and reverse charges) [19,59,60].…”

“…One such technology is electrical discharge coating (EDC), which utilizes tool wear/erosion to create functional coatings [19,26,59,60]. The quality of the coating and the percentage of the desired material depends largely on factors such as tool material and processing conditions (including dielectric flushing, electric arc, and reverse charges) [19,59,60]. Surface modification represents a new dimension of EDM [26], involving the controlled transfer of material from the tool to the workpiece as an evolving area within EDM.…”

“…The current state of EDM and its promising development directions are often focusing on hybrid technologies [19,31,53,115]. These technologies introduce additional influences and phenomena to enhance workpiece material removal quality and rate while reducing tool wear.…”

“…Now electrical discharge machining (EDM) can be safely called on greatest breakthroughs of the 20th century. There are many studies aimed at rev the technological process and the trajectories of its development, classifying the m eas of research on EDM and existing machines, as well as the current state of the p from various points of view [15][16][17][18][19][20][21][22][23][24]. At the same time, most studies consider new opments from the components of the process such as experimentation, optimizati cessing of individual materials, surface morphology, modeling, application in scie technology, micro-electro erosive machining, surface modification, ecology, etc.…”

One-Step Fabrication of Iron Aluminide Containing Hydrophobic Modified Layers with Enhanced Anti-Corrosion Performance

“…Electrical Discharge Machining (EDM) is a practical and conventional technique in material processing that involve removal of material via short-duration electrical discharge and high current density between the tool electrode and the work piece. By altering the polarity of work pieces and materials of the electrode, conventional machining processes could be changed to fabricate coatings on working pieces, making electrical discharge alloying (EDA) a practical surface modification method on the basis of conventional EDM [19][20][21][22]. Algodi et al successfully fabricated a TiC/Fe coating on the surface of carbon steel and 304SS working piece by using semi-sintered electrode of titanium carbide [23].…”