Use of powder metallurgy (PM) compacted electrodes for electrical discharge surface alloying/modification of Ti–6Al–4V alloy

Ho, Samantha; Aspinwall, D.K.; Voice, W.

doi:10.1016/j.jmatprotec.2007.03.003

Cited by 59 publications

(33 citation statements)

References 12 publications

(15 reference statements)

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“…Similarly, the existence of carbides (WC, W 2 C, TiC, Cr 23 C 6 , Al 4 C 3 and TaC), oxides (TaO and TiO 2 ), nitrides (TiN and TaN), elemental alloys (NiAl, Al 8 Mo 3 , Al 3 Mo 8 and AlMo 3 ), and directly the elements (Ti, W, C, Cu, Al, Mo, Cr and Ni) of the PM electrode powders were also reported in the literature. 2,5,6,11,[13][14][15][16]18,19,21,23 It is known that the formation of such hard and brittle intermetallic phases increases hardness and wear resistance; however, they have different thermal expansion coefficients and may develop high tensile stresses during solidification and cooling. Noncontinuous short surface cracks parallel to surface were observed only in some regions of zone A and the interface of zones A and B containing such intermetallic layers (Figure 9(f)).…”

Section: Characteristics Of Surface Layers Formed By Edmmentioning

confidence: 99%

Effect of powder metallurgy Cu-B₄C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Çoğun

Esen

Genç

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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The main aim of this study is to produce new powder metallurgy (PM) Cu-B 4 C composite electrode (PM/(Cu-B 4 C)) capable of alloying the recast workpiece surface layer during electric discharge machining process with boron and other hard intermetallic phases, which eventually yield high hardness and abrasive wear resistance. The surface characteristics of the workpiece machined with a PM/(Cu-B 4 C) electrode consisted of 20 wt% B 4 C powders were compared with those of solid electrolytic copper (E/Cu) and powder metallurgy pure copper (PM/Cu) electrodes. The workpiece surface hardness, surface abrasive wear resistance, depth of the alloyed surface layer and composition of alloyed layers were used as key parameters in the comparison. The workpiece materials, which were machined with PM/(Cu-B 4 C) electrodes, exhibited significantly higher hardness and abrasive wear resistance than those of machined with the E/Cu and PM/Cu. The main reason was the presence of hard intermetallic phases, such as FeB, B 4 C (formed due to the boron in the electrode) and Fe 3 C in the surface layer. The improvement of the surface hardness achieved for steel workpiece when using PM/(Cu-B 4 C) electrodes was significantly higher than that reported in the literature. Moreover, the machining performance outputs (workpiece material removal rate, electrode wear rate and workpiece average surface roughness (R a )) of the electrodes were also considered in this study.

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Section: Characteristics Of Surface Layers Formed By Edmmentioning

confidence: 99%

Effect of powder metallurgy Cu-B₄C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Çoğun

Esen

Genç

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…This is also due to inconsistent sparking at low compact load [5]. The unrestrained material transfer aids random deposition of material on the work surface and results a rough surface.…”

Section: Effects Of Compact Load (Cl)mentioning

confidence: 99%

“…Tool material is deposited by re-solidification process at the base of craters, which is heavily alloyed by the interaction of work material, tool material and the pyrolysis products of dielectric [3,4]. Higher amount of tool material migrates from a Powder Metallurgy (P/M) green compact tool to work surface than a solid tool [5]. The loose bonding between tool material particles and the low thermal conductivity aids this process.…”

Section: Introductionmentioning

confidence: 99%

Parametric Optimization for Selective Surface Modification in EDM Using Taguchi Analysis

Rahang

Patowari

2015

Materials and Manufacturing Processes

100

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This paper introduces selective modification of surface by Electric Discharge Machining process and its parametric optimization. A hard layer of tungsten and copper mixture is created at selected area of aluminum surface. The process is done using W-Cu Powder Metallurgical green compact tool and masking technique in die-sinking EDM. The modified surface is evaluated by the performance measures such as Tool Wear Rate, Material Transfer Rate, Surface Roughness and Edge Deviation from the pre-defined boundary line of deposited layer by Analysis of Variance using Taguchi Design of Experiment. Minimum surface roughness of 4.5 µm and minimum edge deviation of 37.29 µm is achieved. The hardness of the surface layer is increased more than three times of base metal. Overall effects of parameters are also analyzed considering multiple performance criteria using Overall Evaluation Criteria. The modified surface is characterized using Scanning Electron Microscopy and Energy Dispersive Spectroscopy analysis, which show the tool material transfer at the selected area of the surface.

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“…It was noticed that the material-removal rate was increased and the relative electrode-wear rate was decreased when distilled water was used as the dielectric, when compared to kerosene. Ho et al 11 investigated the use of a powder-metallurgy (PM) compacted electrode. It was observed that the PM electrode was more alloyed than the solid electrode.…”

Section: Introductionmentioning

confidence: 99%

Optimization of the parameters for the surfactant-added EDM of a Ti–6Al–4V alloy using the GRA-Taguchi method

Kolli¹,

Kumar²

2016

Mater. Tehnol.

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In this research, the Taguchi technique was applied to determine the optimum process parameters for the electrical discharge machining (EDM) of a titanium alloy with an added surfactant. The surfactant added to the dielectric fluid played an important role in the discharge gap, increasing the conductivity and suspending debris particles in the dielectric fluid, reducing abnormal discharge conditions of the machine and improving the overall machining efficiency. The performance characteristics were the material-removal rate (MRR) and the surface roughness (SR), which were experimentally explored for various input parameters such as the discharge current, the pulse-on time, the pulse-off time and the surfactant concentration in the dielectric fluid. The optimum setting of the parameters was verified through planned and conducted experiments and analysed using the Taguchi technique. Further, a multi-response optimisation was carried out, maximising the MRR and minimising the SR, using the Grey relational analysis (GRA). It was observed that the pulse-on time, the discharge current, the pulse-off time and the surfactant concentration contribute significantly to the multi-response optimisation. Conformation test results showed an improvement in the MRR by 20.69 % and in the SR by 11.09 %. A scanning-electron-microscope (SEM) analysis was conducted to study the recast layer that evolved during the electrical discharge machining process and the topography of surfaces was also observed. Keywords: surfactant, Ti-6Al-4V alloy, Grey-Taguchi method, material-removal rate, surface roughness, recast-layer thickness V~lanku je uporabljena Taguchi metoda za dolo~anje optimalnih parametrov procesa povr{insko aktivne elektroerozije (EDM) na titanovi zlitini. Povr{insko aktivne snovi, dodane dielektri~ni teko~ini, igrajo pomembno vlogo pri razelektritveni re`i, kar pove~a prevodnost in ustavi delce v dielektri~ni teko~ini, zmanj{a neobi~ajne razelektritve pri obdelavi in na splo{no pove~a u~inkovitost obdelave. Zna~ilnosti zmogljivosti sta hitrost odstranjevanja materiala (MRR) in hrapavost povr{ine (SR), ki sta bili eksperimentalno uporabljeni za razli~ne vhodne parametre, kot je: tok razelektritve, trajanje impulza, trajanje prekinitve in koncentracija povr{insko aktivne snovi v dielektri~ni teko~ini. Optimalna postavitev parametrov je bila preizku{ena z na~rtovanimi preizkusi in analizirana s Taguchi metodo. Izvr{ena je bila optimizacija z ve~odgovori, to je maksimiranje MRR in minimiziranje SR s pomo~jo uporabe Grey relacijske analize (GRA). Ugotovljeno je, da tok razelektritve, trajanje pulza,~as brez pulza in koncentracija povr{insko aktivne snovi, mo~no prispevajo k optimizaciji. Rezultati potrditvenih preizkusov so pokazali izbolj{anje MRR za 20,69 % in SR za 11,09 %. Z vrsti~nim elektronskim mikroskopom (SEM) je bila izvr{ena analiza (SEM) pretaljenega sloja, ki se je razvil med postopkom elektroerozije, opazovana pa je bila tudi topografija povr{ine. Klju~ne besede: povr{insko aktivne snovi, Ti-6Al-4V zlitina, Grey-Taguc...

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Use of powder metallurgy (PM) compacted electrodes for electrical discharge surface alloying/modification of Ti–6Al–4V alloy

Cited by 59 publications

References 12 publications

Effect of powder metallurgy Cu-B₄C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Effect of powder metallurgy Cu-B₄C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Parametric Optimization for Selective Surface Modification in EDM Using Taguchi Analysis

Optimization of the parameters for the surfactant-added EDM of a Ti–6Al–4V alloy using the GRA-Taguchi method

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Use of powder metallurgy (PM) compacted electrodes for electrical discharge surface alloying/modification of Ti–6Al–4V alloy

Cited by 59 publications

References 12 publications

Effect of powder metallurgy Cu-B4C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Effect of powder metallurgy Cu-B4C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Parametric Optimization for Selective Surface Modification in EDM Using Taguchi Analysis

Optimization of the parameters for the surfactant-added EDM of a Ti–6Al–4V alloy using the GRA-Taguchi method

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Product

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Effect of powder metallurgy Cu-B₄C electrodes on workpiece surface characteristics and machining performance of electric discharge machining

Effect of powder metallurgy Cu-B₄C electrodes on workpiece surface characteristics and machining performance of electric discharge machining