Surface modification of aluminum with green compact powder metallurgy Inconel-aluminum tool in EDM

Sarmah, Ankita; Kar, Siddhartha; Patowari, Promod Kumar

doi:10.1080/10426914.2020.1765253

Cited by 23 publications

(8 citation statements)

References 27 publications

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“…Sarmah et al [ 69 ] mixed equal weight of Inconel 718 and Al powder to prepare green compact electrode in order to generate a surface over Al 7075 alloy using die-sinking EDM. The machined surface contained deposited layer, globules, voids, craters, and microcracks.…”

Section: Electro-discharge-based Surface Modification and Coating Tec...mentioning

confidence: 99%

Functional Surface Generation by EDM—A Review

Nafi

Jahan

2022

Micromachines

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Electro-discharge machining (EDM) removes electrically conductive materials by high frequency spark discharges between the tool electrode and the workpiece in the presence of a dielectric liquid. Being an electrothermal process and with melting and evaporation being the mechanisms of material removal, EDM suffers from migration of materials between the tool and the workpiece. Although unwanted surface modification was considered a challenge in the past for many applications, this inherent nature of the EDM process has recently become of interest to the scientific community. As a result, researchers have been focusing on using the EDM process for surface modification and coating by targeted surface engineering. In order to engineer a surface or generate functional coatings using the electro-discharge process, proper knowledge of the EDM process and science of electro-discharge surface modification must be understood. This paper aims to provide an overview of the electro-discharge surface modification and coating processes, thus assisting the readers on exploring potential applications of EDM-based techniques of surface engineering and coating generation. This review starts with a brief introduction to the EDM process, the physics behind the EDM process, and the science of the surface modification process in EDM. The paper then discusses the reasons and purposes of surface modification and coating practices. The common EDM-based techniques reported in the literature for producing coatings on the surface are discussed with their process mechanisms, important parameters, and design considerations. The characterization techniques used for the analysis of modified surfaces and coating layers, as well as the tribological and surface properties of modified surfaces or coatings are discussed. Some of the important applications of EDM-based surface modification and coating processes are generating surfaces for protective coating, for aesthetic purposes, for enhancing the biocompatibility of implants, for improving corrosion resistance, for improving wear resistance, and for improving tribological performance. The current state of the research in these application areas is discussed with examples. Finally, suggestions are provided on future research directions and innovative potential new applications of the electro-discharge-based surface engineering and coating processes.

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Section: Electro-discharge-based Surface Modification and Coating Tec...mentioning

confidence: 99%

Functional Surface Generation by EDM—A Review

Nafi

Jahan

2022

Micromachines

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“…Hence, the MTR pertains to the final material transfer balance, and it has to be studied not only as an absolute value, but comparatively as well. The positive values of MTR represent a dominant material removal mechanism that results in an overall material removal, while the negative values imply a dominant material deposition mechanism, and hence, a greater workpiece weight after its machining [22].…”

Section: Materials Transfer Ratementioning

confidence: 99%

“…The experimental results revealed that the surface roughness varied from 1.7 µm to 5.83 µm, which was affected by increased pulse-on time and peak current. Saemah, Kar, and Parowari [22] conducted experiments on surface modification of AA7075 using green P/M Inconel-aluminum electrodes by EDC. Experimental results show that MTR is related to the pulse-on time as Ton increases the MTR decreases.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Surface Modification of 60CrMoV18-5 Steel by EDM with Cu-ZrO2 Powder Metallurgy Green Compact Electrode

et al. 2021

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Electrical discharge machining (EDM) is a non-conventional machining process, which is mostly used for machining of difficult-to-cut materials. These materials are often used in engineering applications that require improved surface properties; thus, surface modification is desirable in these cases. In the recent past, it has been observed that EDM is an alternative surface modification process due to migration of material from the electrode to the workpiece surface. Surface modification can be done with powder metallurgy (P/M) electrode as tool. The aim of this work is to examine the surface modification of the tool steel Calmax (Uddeholm) by EDM process using Cu-30 wt.% ZrO2 P/M green compact electrode. The influence of peak current (Ip) and pulse-on (Ton) on the Material Transfer Rate (MTR) and Surface Roughness (SR) was investigated and the surface characteristics were also evaluated by scanning electron microscopy (SEM). The experimental results confirm the material migration from the electrode to the machined surface and show that the higher MTR of 46.5 mgr/min is achieved on the combination of Ip = 9 A and Ton = 25 μs and the Ra varies from 3.72 μm to 7.12 μm.

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“…Except the nature of the materials, COF mostly depends on the characteristics of the surface as well as lubrication condition [106][107][108][109]. Therefore, tailoring the surface characteristics and lubrication condition may optimize the performance of the components under friction [110][111][112].…”

Section: Frictionmentioning

confidence: 99%

Recent Progress in the Study of Thermal Properties and Tribological Behaviors of Hexagonal Boron Nitride-Reinforced Composites

et al. 2020

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Ever-increasing significance of composite materials with high thermal conductivity, low thermal expansion coefficient and high optical bandgap over the last decade, have proved their indispensable roles in a wide range of applications. Hexagonal boron nitride (h-BN), a layered material having a high thermal conductivity along the planes and the band gap of 5.9 eV, has always been a promising candidate to provide superior heat transfer with minimal phonon scattering through the system. Hence, extensive researches have been devoted to improving the thermal conductivity of different matrices by using h-BN fillers. Apart from that, lubrication property of h-BN has also been extensively researched, demonstrating the effectivity of this layered structure in reduction of friction coefficient, increasing wear resistance and cost-effectivity of the process. Herein, an in-depth discussion of thermal and tribological properties of the reinforced composite by h-BN will be provided, focusing on the recent progress and future trends.

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Surface modification of aluminum with green compact powder metallurgy Inconel-aluminum tool in EDM

Cited by 23 publications

References 27 publications

Functional Surface Generation by EDM—A Review

Functional Surface Generation by EDM—A Review

Investigation of Surface Modification of 60CrMoV18-5 Steel by EDM with Cu-ZrO2 Powder Metallurgy Green Compact Electrode

Recent Progress in the Study of Thermal Properties and Tribological Behaviors of Hexagonal Boron Nitride-Reinforced Composites

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