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Effect of Powder-Mixed Electric Discharge Alloying Using WS2 on the Tribological Performance of Ti6Al4V

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Abstract

Powder-mixed electric discharge machining (PMEDM) of Ti6Al4V is performed in the current study using tungsten disulphide (WS2) powder as the additive in dielectric media. PMEDM at different levels of pulse on time (Ton) at three levels of powder concentrations was conducted, and it was observed that MRR improved with the PMEDM process. The surface roughness analysis of the PMEDM samples showed that there was not any direct relation with Ton time; however, with an increase in powder concentration, TWR was reduced. The PMEDM-prepared specimens were further used to analyse the tribological performance of surface-modified Ti6Al4V using pin-on-disc experimentation. PMEDM samples exhibited improved tribological performance in terms of coefficient of friction and specific wear rate (SWR). The lowest SWR was 2.8623E−05 at 2 gm/L, 40 µs Ton. During the dry condition sliding wear test, oxides of Ti (TiO) and Al (Al2O3) were formed due to the frictional heating, creating a protective tribofilm that helped to reduce wear. WS2 and its oxides were also identified during XRD analysis of the worn surface, which had lubricating properties bringing down the friction at the interface for the PMEDM samples. Abrasive and delamination wear were the predominant wear mechanisms identified on the worn surface.

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Abbreviations

CoF:

Coefficient of friction

EDM:

Electrical discharge machining

EDX:

Energy-dispersive X-ray spectroscopy

LVDT:

Linear variable displacement transducer

MRR:

Material removal rate

PMEDM:

Powder-mixed electrical discharge machining

PMEDA:

Powder-mixed electrical discharge alloying

PoD:

Pin-on-disc

SEM:

Scanning electron microscopy

SR:

Surface roughness

SWR:

Specific wear rate

Ti64:

Ti6Al4v

TWR:

Tool wear rate

XRD:

X-ray diffraction spectroscopy

Al:

Aluminium

Al2O3 :

Aluminium oxide

EN31:

Case hardened steel

Fe:

Iron

gm/L:

Gram per litre

gm/min:

Gram per minute

Sa:

Average surface roughness

Ti:

Titanium

TiO:

Titanium oxide

T on :

Pulse on time

WO3 :

Tungsten trioxide

WS2 :

Tungsten disulphide

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Acknowledgements

The authors would like to thank the Department of Science and Technology (DST) sincerely, Govt. of India, for carrying out this project under the FIST (FIST – No. SR/FST/ETI-388/2015) scheme. Also, the authors thank the UGC DAE Consortium for Scientific Research for the partial financial support to complete this project under CRS/2021-22/04/636. The assistance extended by Mr. Renumala Sudheer, M.Tech Scholar, Department of Mechanical Engineering, National Institute of Technology Calicut, to complete the experimenters is also acknowledged.

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  1. Advanced Manufacturing Centre, Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut, Kerala, 673601, India

    Jino Joshy, M. Venkata Krishna Reddy, Basil Kuriachen & M. L. Joy

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  1. Jino Joshy
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  2. M. Venkata Krishna Reddy
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  3. Basil Kuriachen
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Correspondence to Basil Kuriachen.

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Joshy, J., Venkata Krishna Reddy, M., Kuriachen, B. et al. Effect of Powder-Mixed Electric Discharge Alloying Using WS2 on the Tribological Performance of Ti6Al4V. Trans Indian Inst Met 76, 2413–2424 (2023). https://doi.org/10.1007/s12666-022-02817-w

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