Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating
One of the widely used non-traditional machines for machining of hard materials into complex shapes and different sizes is the electrical discharge machine (EDM). Recently, the EDM has been used for deposition by controlling the input parameters (current and duty cycle). This work was carried out to...
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MDPI AG
2023-01-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/14/1/136 |
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| author | JagadeeswaraRao Maddu Buschaiah Karrolla Riyaaz Uddien Shaik Hassan Elahi Krishnaiah Arkanti |
| author_facet | JagadeeswaraRao Maddu Buschaiah Karrolla Riyaaz Uddien Shaik Hassan Elahi Krishnaiah Arkanti |
| author_sort | JagadeeswaraRao Maddu |
| collection | DOAJ |
| description | One of the widely used non-traditional machines for machining of hard materials into complex shapes and different sizes is the electrical discharge machine (EDM). Recently, the EDM has been used for deposition by controlling the input parameters (current and duty cycle). This work was carried out to evaluate the readily available bronze (88% Cu + 12% Sn) electrode for deposition of copper material on titanium alloy. Experiments were conducted according to Taguchi experimental design considering the input parameters of current, Ton, Toff and preheating temperature of substrates. Titanium alloy was further hardened by preheating at temperatures of 100 °C, 300 °C and 500 °C and quenching in brine, castor oil and vegetable oil in order to avoid workpiece erosion. After this treatment, hardness, grain area, grain diameter and number of grains were characterized to compare with pretreated substrates. Then, the treated substrates were taken for copper deposition with the EDM. Output parameters such as material deposition rate (MDR), electrode wear rate (EWR), coating thickness (CT), elemental composition and surface crack density (SCD) were found. Material characterization was carried out using a scanning electron microscope (SEM) with energy dispersive X-ray spectroscopy (EDX) and optical microscopy. Output parameters were optimized with technique for order of preference by similarity to ideal solution (TOPSIS) to find optimum parameters. A sixth experiment with parameter values of Ton of 440 µs, Toff of 200 µs, preheating temperature of 300 °C and quenching medium of castor oil was optimum with MDR of 0.00506 g/m, EWR of 0.00462 g/m, CT of 40.2 µm and SCD 19.4 × 10<sup>7</sup> µm<sup>2</sup>. |
| first_indexed | 2024-03-09T11:40:22Z |
| format | Article |
| id | doaj.art-88fbd226a26d4c69bf690ad84c5dba09 |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-09T11:40:22Z |
| publishDate | 2023-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-88fbd226a26d4c69bf690ad84c5dba092023-11-30T23:33:42ZengMDPI AGMicromachines2072-666X2023-01-0114113610.3390/mi14010136Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper CoatingJagadeeswaraRao Maddu0Buschaiah Karrolla1Riyaaz Uddien Shaik2Hassan Elahi3Krishnaiah Arkanti4Department of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad 500007, IndiaDepartment of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad 500007, IndiaDepartment of Astronautics Electrical and Energy Engineering, University of Rome “La Sapienza”, Via Eudossiana 18, 00184 Rome, ItalyDepartment of Mechanical and Aerospace Engineering, University of Rome “La Sapienza”, Via Eudossiana 18, 00184 Rome, ItalyDepartment of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad 500007, IndiaOne of the widely used non-traditional machines for machining of hard materials into complex shapes and different sizes is the electrical discharge machine (EDM). Recently, the EDM has been used for deposition by controlling the input parameters (current and duty cycle). This work was carried out to evaluate the readily available bronze (88% Cu + 12% Sn) electrode for deposition of copper material on titanium alloy. Experiments were conducted according to Taguchi experimental design considering the input parameters of current, Ton, Toff and preheating temperature of substrates. Titanium alloy was further hardened by preheating at temperatures of 100 °C, 300 °C and 500 °C and quenching in brine, castor oil and vegetable oil in order to avoid workpiece erosion. After this treatment, hardness, grain area, grain diameter and number of grains were characterized to compare with pretreated substrates. Then, the treated substrates were taken for copper deposition with the EDM. Output parameters such as material deposition rate (MDR), electrode wear rate (EWR), coating thickness (CT), elemental composition and surface crack density (SCD) were found. Material characterization was carried out using a scanning electron microscope (SEM) with energy dispersive X-ray spectroscopy (EDX) and optical microscopy. Output parameters were optimized with technique for order of preference by similarity to ideal solution (TOPSIS) to find optimum parameters. A sixth experiment with parameter values of Ton of 440 µs, Toff of 200 µs, preheating temperature of 300 °C and quenching medium of castor oil was optimum with MDR of 0.00506 g/m, EWR of 0.00462 g/m, CT of 40.2 µm and SCD 19.4 × 10<sup>7</sup> µm<sup>2</sup>.https://www.mdpi.com/2072-666X/14/1/136electrical discharge coatingmicrohardnessmaterial deposition rateTOPSIS |
| spellingShingle | JagadeeswaraRao Maddu Buschaiah Karrolla Riyaaz Uddien Shaik Hassan Elahi Krishnaiah Arkanti Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating Micromachines electrical discharge coating microhardness material deposition rate TOPSIS |
| title | Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating |
| title_full | Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating |
| title_fullStr | Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating |
| title_full_unstemmed | Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating |
| title_short | Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating |
| title_sort | evaluation of bronze electrode in electrical discharge coating process for copper coating |
| topic | electrical discharge coating microhardness material deposition rate TOPSIS |
| url | https://www.mdpi.com/2072-666X/14/1/136 |
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