Effect of powder metallurgy copper electrode on surface modification of mild steel

Shakri, Muhammad Amin Izzat (2024) Effect of powder metallurgy copper electrode on surface modification of mild steel. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Mild steel, recognized for its exceptional ductility, weldability, and cost- effectiveness, is commonly used as a basic material in various industries. The ideal combination of strength and formability in mild steel makes it suitable for the fabrication of structural components, automotive bodies, pipelines, and various machinery. However, mild steel has low corrosion resistance. This is due to exposure to varying chemical compositions, temperature fluctuations, and mechanical stresses. Besides, mild steel also exhibits low wear resistance, making it susceptible to wear and abrasion under certain conditions. This characteristic is due to the softer nature of mild steel compared to other materials designed specifically for high wear resistance. Therefore, when subjected to conditions involving friction, abrasion or mechanical wear, mild steel may experience accelerated deterioration and reduced longevity. Therefore, in this study, surface modification of mild steel was done by using electrical discharge coating (EDC) with powder metallurgy (PM) copper electrodes. The effect of PM copper electrodes with varying compaction pressure and sintering temperature on the microhardness and thickness of the deposited layer was investigated. Vickers microhardness tester was used to measure the microhardness whereas the thickness of the deposited layer was determined by using scanning electron microscopy (SEM) after the polishing and etching process. From this study, it is found that maximum hardness occurs at 650°C and 3 tons, while maximum thickness is 12.5 μm at 550°C and 5 tons. Higher pressure generally reduces copper weight % and higher sintering temperature enhances the microhardness of the mild steel. Optimizing these parameters is crucial for desired material properties in EDC.

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