Characterization of deposited layer after electrical discharge coating (EDC) process

Mohammad Zainudin, Norhazeratul (2021) Characterization of deposited layer after electrical discharge coating (EDC) process. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In industry, aluminium 6000 series is widely used for fabrication of mold and die due to its unique characteristic. It has a great strength-to-weight ratio, good conductivity, resistance to wear and corrosion and also easy to form. Although aluminum is resistance to corrosion and wear, after some duration of time, it will degrade. In this research, surface modification of aluminium 6061 was carried out by using electrical discharge coating (EDC) with powder suspension or powder mixed electrical discharge machining (PMEDM). The average particle size and morphology of tungsten (W) powder was characterized by using Scanning Electron Microscopy (SEM) and the effect of peak current (Ip) and pulse on time (TON) on the coating layer thickness were investigated after the EDC process. Wpowder was used as an additive in the kerosene oil and the parameters of Ip were varied at 3A and 4A and TON at 150µs, 200 µs and 250 µs, while the other parameters such as discharge voltage (V) and powder concentration (g/L) and machining time remains constant. Sodick AQ35L die sinker machine was used to run the EDC experiment. Electrode was polished and clean first to get a flat surface on the base and the preparation of mixture was done before the experiment run. After the experiment, thickness of coating layer was investigated. The result shows that the average particle size of W powder is 1.29 µm and in irregular shape. On the other hand, thinnest coating layer was observed at 3A, 150 µs with the average value 6.724 µm, while thickest coating layer with the average value 17.239 µm was observed at parameter 4A and 250 µs. As a conclusion, a high value of Ip current and longer duration of TON increased the thickness of coating layer.

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