Skip to main content
SpringerLink
Log in

Production of hard and lubricating surfaces on miniature components through micro-EDM process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The study acclaims the generation of hard, wear-resistant, and lubricating layer on Ti alloy using molybdenum disulfide (MoS2) powders mixed in dielectric (deionized water) using a brass tool electrode (diameter 800 μm) through the micro-electrical discharge process. The deposition rate, micro-hardness, recast layer, and surface roughness were studied for the surface generated through the process and correlated with the XRD, AFM, electron probe micro-analyzer, EDS analysis, and FESEM images. Results indicate that a higher voltage (60 V) and powder concentration (12 g/L) increase the material deposition rate in the form of intermetallic compounds deposited on the recast layer. The coated layer formed shows an increase in micro-hardness ranging from 426.42 to 714.25 HV, which is more when compared to the base material hardness of 417.61 HV. In addition to this, lower micro-cracks were seen at high powder concentration, voltage, and duty factor with improved surface quality. The pin-on-disc wear test of the coated samples was performed, and results indicated that the specific wear rate decreased with the increase in duty factor due to the formation of hard and wear-resistant intermetallic compounds as confirmed from the EDS and XRD plots.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

References

  1. Faisal N, Zindani D, Kumar K (2019) Micro and nano machining—an industrial perspective. In: Micro and nano machining of engineering materials. Springer, Cham, pp 9–29

    Chapter  Google Scholar 

  2. Patowari PK, Saha P, Mishra PK (2015) An experimental investigation of surface modification of C-40 steel using W–Cu powder metallurgy sintered compact tools in EDM. The Int J of Adv Manuf Tech 80(1–4):343–360

    Article  Google Scholar 

  3. Singh AK, Patowari PK, Deshpande NV (2019) Analysis of micro-rods machined using reverse micro-EDM. J of the Brazilian Soc of Mech Sci and Engg 41(1):15

    Article  Google Scholar 

  4. Scharf TW, Prasad SV, Dugger MT, Kotula PG, Goeke RS, Grubbs RK (2006) Growth, structure, and tribological behavior of atomic layer-deposited tungsten disulphide solid lubricant coatings with applications to MEMS. Acta Mater 54(18):4731–4743

    Article  Google Scholar 

  5. Prakash V, Kumar P, Singh PK, Hussain M, Das AK, Chattopadhyaya S (2017) Micro-electrical discharge machining of difficult-to-machine materials: a review. Proceedings of the Inst of Mech Engineers, Part B: J Engg Manuf 233(2):339–370

    Article  Google Scholar 

  6. Amorim FL, Dalcin VA, Soares P, Mendes LA (2017) Surface modification of tool steel by electrical discharge machining with molybdenum powder mixed in the dielectric fluid. The Int J of Adv Manuf Tech 91(1–4):341–350

    Article  Google Scholar 

  7. Mastud SA (2019) Reverse micro-EDM. In: Micro-electrical discharge machining processes. Springer, Singapore, pp 93–124

    Chapter  Google Scholar 

  8. Kuriachen B, Mathew J (2015) Experimental investigations into the effects of microelectric-discharge milling process parameters on processing Ti–6Al–4V. Materials and Manuf Processes 30(8):983–990

    Article  Google Scholar 

  9. Mohanty S, Kumar V, Das AK, Dixit AR (2019) Surface modification of Ti-alloy by micro-electrical discharge process using tungsten disulphide powder suspension. J of Manuf Processes 37:28–41

    Article  Google Scholar 

  10. Hourmand M, Sarhan AA, Farahany S, Sayuti M (2018) Microstructure characterization and maximization of the material removal rate in nano-powder mixed EDM of Al-Mg2Si metal matrix composite—ANFIS and RSM approaches. The Int J of Adv Manuf Tech 101:2723–2737

    Article  Google Scholar 

  11. Jahan MP, Rahman M, San Wong Y (2011) Study on the nano-powder-mixed sinking and milling micro-EDM of WC-Co. The Int J Adv Manuf Tech 53(1–4):167–180

    Article  Google Scholar 

  12. Nguyen TD, Nguyen PH, Banh LT (2018) Die steel surface layer quality improvement in titanium μ-powder mixed die sinking electrical discharge machining. The Int J of Adv Manuf Tech 100(9–12):2637–2651

    Article  Google Scholar 

  13. Prihandana GS, Sriani T, Mahardika M, Hamdi M, Miki N, Wong YS, Mitsui K (2014) Application of powder suspended in dielectric fluid for fine finish micro-EDM of Inconel 718. The Int J Adv Manuf Tech 75(1–4):599–613

    Article  Google Scholar 

  14. Furutani K, Shimizu Y (2003) Experimental analysis of deposition process of lubricant surface by electrical discharge machining with molybdenum disulfide powder suspended in working oil. Proc 18th Ann Meet Am Soc Precis Eng, Portland, pp 547–550

    Google Scholar 

  15. Furutani K, Shiraki K. (2002) Deposition of lubricant layer during finishing process by electrical discharge machining with molybdenum disulfide powder suspended in working fluid. In the proceedings of the JSME Mater Process Conf (M&P), the Japan Society of Mechanical Engineers 67(12):2042–2047

  16. Renevier NM, Oosterling H, König U, Dautzenberg H, Kim BJ, Geppert L, Koopmans FG, Leopold J (2003) Performance and limitations of MoS2/Ti composite coated inserts. Surface and Coatings Tech 172(1):13–23

    Article  Google Scholar 

  17. Amaro RI, Martins RC, Seabra JO, Renevier NM, Teer DG (2005) Molybdenum disulphide/titanium low friction coating for gears application. Tribology Int 38(4):423–434

    Article  Google Scholar 

  18. Tyagi R, Das AK, Mandal A (2018) Electrical discharge coating using WS2 and Cu powder mixture for solid lubrication and enhanced tribological performance. Tribology Int 120:80–92

    Article  Google Scholar 

  19. Murray JW, Cook RB, Senin N, Algodi SJ, Clare AT (2018) Defect-free TiC/Si multi-layer electrical discharge coatings. Mater Des 155:352–365

    Article  Google Scholar 

  20. Chu X, Feng W, Wang C, Hong Y (2017) Analysis of mechanism based on two types of pulse generators in micro-EDM using single pulse discharge. The Int J of Adv Manuf Tech 89(9–12):3217–3230

    Article  Google Scholar 

  21. Khosrozadeh B, Shabgard M (2017) Effects of hybrid electrical discharge machining processes on surface integrity and residual stresses of Ti-6Al-4V titanium alloy. The Int J of Adv Manuf Tech 93(5–8):1999–2011

    Article  Google Scholar 

  22. Prihandana GS, Mahardika M, Hamdi M, Wong YS, Mitsui K (2009) Effect of micro-powder suspension and ultrasonic vibration of dielectric fluid in micro-EDM processes—Taguchi approach. Int J of Mach Tools and Manuf 49(12–13):1035–1041

    Article  Google Scholar 

  23. Rahang M, Patowari PK (2016) Parametric optimization for selective surface modification in EDM using Taguchi analysis. Mater and Manuf Processes 31(4):422–431

    Article  Google Scholar 

  24. Öpöz TT, Yaşar H, Ekmekci N, Ekmekci B (2018) Particle migration and surface modification on Ti6Al4V in SiC powder mixed electrical discharge machining. J Manuf Process 31:744–758

    Article  Google Scholar 

  25. Upadhyay C, Datta S, Masanta M, Mahapatra SS (2017) An experimental investigation emphasizing surface characteristics of electro-discharge-machined Inconel 601. J Braz Soc of Mech Sci and Engg 39(8):3051–3066

    Article  Google Scholar 

  26. Gill AS, Kumar S (2018) Investigation of micro-hardness in electrical discharge alloying of En31 tool steel with Cu–W powder metallurgy electrode. Arab J Sci Engg 43(3):1499–1510

    Article  Google Scholar 

  27. McDonnell S, Smyth C, Hinkle CL, Wallace RM (2016) MoS2–titanium contact interface reactions. ACS Appl Mater Interf 8(12):8289–8294

    Article  Google Scholar 

  28. Algodi SJ, Murray JW, Brown PD, Clare AT (2018) Wear performance of TiC/Fe cermet electrical discharge coatings. Wear 402:109–123

    Article  Google Scholar 

  29. Fellah M, Aissani L, Abdul Samad M, Purnama A, Djebaili H, Montagne A, Iost A, Nouveau C (2018) Effect of Zr content on friction and wear behavior of Cr-Zr-N coating system. Int J of Appl Ceramic Tech 15(3):701–715

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology (IIT-ISM), Dhanbad, Jharkhand, 826004, India

    Shalini Mohanty, Brij Bhushan, Alok Kumar Das & Amit Rai Dixit

Authors
  1. Shalini Mohanty
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Brij Bhushan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Alok Kumar Das
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Amit Rai Dixit
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Alok Kumar Das.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mohanty, S., Bhushan, B., Das, A.K. et al. Production of hard and lubricating surfaces on miniature components through micro-EDM process. Int J Adv Manuf Technol 105, 1983–2000 (2019). https://doi.org/10.1007/s00170-019-04380-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04380-z

Keywords

Search

Navigation