A study on parametric optimization of Micro-electrical discharge coating process using response surface methodology

• Main Authors: Mohanty, Shalini, Bhushan, Brij, Kumar Das, Alok, Rai Dixit, Amit
• Format: Conference Proceeding
• Language: English
• Subjects: Coating; EDS; Micro-hardness; Powders; Roughness; RSM; Titanium
• ISSN: 2214-7853; 2214-7853
• DOI: 10.1016/j.matpr.2020.07.415

In the age of advanced materials, the need for developing the surface or modifying the surface of these materials is a challenge for researchers. The modification of surface includes enhancement of mechanical properties or addition of new properties to the surface by some techniques as such it can be used for various miniaturized components. Machining with electrical discharge machining (EDM) is possible and coating with the method is much more prevalent these days for obtaining enhanced surface properties. The present work includes powder mixed micro-electrical discharge coating (PMμ-EDC) for surface coating of titanium grade 5 (Ti6Al4V) as workpiece with brass as tool electrode. Molybdenum disulphide (MoS2) powders are used for suspension in de-ionised water as a dielectric as such formation of oxides on the recast layer shows enhanced property improvement. Box-Behnken design of experiments is used to carry out the experiments using input parameters as duty factor (DF), voltage (V), and powder concentration. A total of 15 experiments were conducted with three central points and response surface methodology (RSM) was used for mathematical modeling and correlating the input process parameters with the responses. The analysis of variance (ANOVA) results validated the response. Energy dispersive spectroscopy (EDS) was done to verify the migration of tool material and powders on the surface of workpiece.