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Morphological studies and wear behavior of electro discharge coated steel
Materials Today: Proceedings xxx (xxxx) xxx
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Morphological studies and wear behavior of electro discharge coated steel P.D. Machkale ⇑, B.M. Dabade Department of Production Engineering, SGGSIE&T, Nanded 431606, India
a r t i c l e
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Article history: Received 27 August 2019 Received in revised form 4 January 2020 Accepted 14 January 2020 Available online xxxx Keywords: Powder metallurgy (PM) Wear EDC Electric discharge machining (EDM) W-Cu SEM EDS
a b s t r a c t This paper elaborates on the deposition of tungsten and copper (W-Cu) material on the AISI 1020 steel substrate and the method used for deposition with its surface and wear characteristics. The tool electrode used is of tungsten copper (W-Cu) manufactured by powder metallurgy (PM) route with different ratios of tungsten and copper metal powders. The process carried out for deposition is by electro-discharge coating (EDC). In this, the tool electrode material is melted and deposited on the substrate by the application of heat energy due to sparking between the electrode and the substrate. Then a thick layer of W-Cu coating is formed on the substrate material. The substrate material of AISI 1020 steel was cut in cylindrical shapes of 10 mm diameter and height 10 mm by wire cut EDM machine and was then surface grinded for the accuracy and polished surface. The cylindrical size was considered for holding the specimen in the clamping device of wear testing machine easily during wear testing. The wear behavior of the coated samples is assessed by the pin on disc method. The effect of mixing ratio, micro hardness, Scanning Electron Microscope (SEM), Energy Disperse Spectroscopy (EDS) analysis, Coefficient of friction (COF) etc., for different composition coated samples has been investigated. The results show that the micro hardness achieved in the range 51-84HV for coated specimens of W-Cu of different composite substrates. The COF was achieved in the range of 0.16 to 0.31 after wear experimentation. The microstructures of the coated samples are analyzed before and after wear by using SEM and EDS. Ó 2020 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the scientific committee of the First International Conference on Recent Advances in Materials and Manufacturing 2019.
1. Introduction This paper mainly focuses on the morphological studies and wear behaviour of the coated layer processed by electrodischarge coating on the AISI 1020 steel as substrate material. The Electro discharge coating (EDC) process is adopted as it is one of the emerging coating technology nowadays due to its simplicity and ease in operation compared to CVD, PVD and related coating processes [1–4]. As this process does not require complicated equipment like vacuum chamber by using Electro Discharge Machine (EDM) coating can be obtained easily on different substrate materials [1,3–7]. The Process of EDC is opposite to that of EDM in which the spark is generated and deposited on the substrate material by varying the parameters at different levels [8,9]. The high spark temperatures associated with the EDM exploited to deposit the useful material on the substrate which produces ⇑ Corresponding author. E-mail address: [email protected] (P.D. Machkale).
higher wearing properties and high melting points [10]. The electrodes used for electro discharge coating has some specific properties than conventional electrodes like low density [11], wear resistance [4,12,13], corrosion resistance [14–19], abrasive resistance [20–22], high temperature resistance [17,23], high hardness [24–26] etc. The polarity used in this process is in reverse condition i.e. tool electrode as anode and work piece as cathode [10,27–29]. This process is widely used in surface modifications of die and moulds or to make wear or corrosion resistance components used in adverse environmental conditions [4,30].Many researches have analysed the EDC process by using various electrode materials such as W, Cu, Ti ,Graphite etc. for surface modification in recent years [14,31]. Similar study was carried out by author for surface modification of steel having 90% copper(Cu) and 10% tin(Sn) and the layer obtained is of Cu and Sn on steel surface [28].Some electrodes are used as a feed-stock material, in an effort to produce significant work piece surface alloying on the surface and enhance the wear resistance of the machined surface[32–34]. EDC process can be used for many industrial applications such as for treatment of a
https://doi.org/10.1016/j.matpr.2020.01.292 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the scientific committee of the First International Conference on Recent Advances in Materials and Manufacturing 2019.
Please cite this article as: P. D. Machkale and B. M. Dabade, Morphological studies and wear behavior of electro discharge coated steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.292
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film required to strengthen and lubricate under high temperature environmental conditions such as a turbine blade for gas turbine and a film used for building up in repair of a component etc. [9,15]. This paper describes about the morphological study and property observations of the coated samples of different compositions. The wear test was carried out on pin on disc wear testing machine to find out the effects of different compositions coated samples by considering the coefficient of friction (COF) as response variable. The input parameters were considered as time, speed and track diameter. This investigation was carried out from the observation of the literature that as few researchers have focused on the wear behaviour of the coated samples of different compositions and sintering temperatures which are manufactured by powder metallurgy (PM) route.
Fig. 1. Tool holder.
2. Methodology adopted for the research work In the present research work tool electrodes of W-Cu of different compositions (i.e 50:50 wt%, 60:40 wt%, 75:25 wt%, 70:30 wt %) are manufactured by Powder metallurgy process. A micro hardness and wear characteristic of the coated specimens was investigated. The Electro discharge coating was adopted for the coating process. The Micro hardness analysis was carried out on Vickers Micro hardness tester. Coating process was done on the AISI 1020 steel substrate material (Specimen was cut into 10 mm 10 mm using Wire Cut EDM machine). Tool holder and substrate holder are manufactured separately for the coating process. The investigation of coated samples of different compositions are done by Scanning Electron Microscope (SEM) and Energy Disperse Spectroscopy (EDS).
Fig. 2. Substrate material holder.
Table 1 EDC Parameters.
2.1. Methods and manufacturing process 2.1.1. Experimental procedure for W-Cu coating. The power metallurgy route was used for manufacturing of the tool electrodes of W-Cu composite. The electrodes are manufactured in different compositions of W-Cu (i.e 50:50 wt%, 60:40 wt %, 75:25 wt%, 70:30 wt%). The diameter of the electrode is same as that of substrate material. For experimental work sparkonix 35A EDM machine was considered for all the coating samples. The substrate material used was low carbon steel of AISI 1020 steel grade for all compositions of the electrode material for coatings on the substrates. The polarity considered as negative (tool electrode as anode and substrate material as cathode). Before experimentation, the substrate material was surface grinded on both sides of surface before coating. Then the surface of the samples were the EDC process is to be carried out was polished by emery paper and acetone was applied on the surface to remove any contamination on the surfaces. The weight of the samples and electrodes were measured before and after coating by electronic weighing machine (Make: CONTECT). Fig. 1 shows the tool holder for holding the electrode on EDM. Fig. 2 shows the work piece holder for the coating process fabricated specifically to fix the substrate of required size and shape considered for experimentation. The experiment was done by using Commercial EDM oil as dielectric and flushing was done on the surface of the samples for constant coating. The parameters taken for EDC coating are shown in Table.1.After experimentation also each sample was cleaned buy acetone for removal of any contamination on the surface. Fig. 3 indicates the magnified view of the coated sample after coating of W-Cu composition. Fig. 4 indicates the coated samples of different compositions of W-Cu.
Parameters
Values
Electrode material Composition Substrate Polarity Current (A) On time Gap Voltage(V) Time Compacting pressure Sintering temperature
W-Cu 50:50 wt%,60:40 wt%,75:25 wt%,70:30 wt% AISI 1020 Negative 6 100 40 5 min 188 MPa 770 °C
2.1.2. Micro hardness The micro hardness analysis was carried out by using MVH-1 Vickers hardness testing machine (Make: Metatech). Before hardness testing, the surface of the coated samples were polished by using polishing machine (Make: CENSICO). The hardness was carried out at 1 kg load and at 25 dwell time from the observations. Initially, the plain surface of AISI 1020 steel was considered at five different points for indentation point’s observation. Further, similar measurements are taken at five different locations on the coated surface of AISI 1020 steel of different composition specimens. The micro hardness was calculated by using Vickers hardness number (Hv) formula [35] as
Hv ¼ 1:8544 P=d2 kg=mm2 where, P = applied load in Kg, d = diagonal length of the indentation in mm
Please cite this article as: P. D. Machkale and B. M. Dabade, Morphological studies and wear behavior of electro discharge coated steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.292
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2.1.3. Wear and COF analysis The wear behaviour of the coated samples prepared by EDC of different ratios are characterized by pin on disc wear testing machine (Make. DUCOM). The W-Cu metal powder mixture of different weight ratios (i.e. 50:50 wt%,60:40 wt%,75:25 wt%,70:30 wt %) under compacting pressure (CT) 188 MPa and sintering temperature (ST) 770 °C. The weight loss of the coated samples are measured by precision weighing machine with the accuracy of 0.1 mg. The input parameters were considered as speed at 200 rpm, time 1000 sec, load 40 N and track diameter was taken as 80 for all the compositions. These parameters are examined on the basis of preliminary experiments. The comparison of the result was done by using winducom software. The test was carried out by considering pure copper (100%) coated sample also for comparative study. The response was considered as coefficient of friction (COF).
Fig. 3. Magnified view of the coated substrate.
2.1.4. Morphology and wear behaviour analysis Microstructure of the coated samples are analysed by Scanning Electron Microscope (SEM) and the elements present on the coated surface of different compositions were analysed at different points by using Energy dispersive spectroscopy (EDS). The analyses was done to find out the effect of current, pulse on time and mixing ratios of W-Cu electrodes considering compacting and sintering temperature. Before SEM and EDS analysis, the coated substrates
Fig. 4. Coated samples of different compositions.
Fig. 5. Hardness of coated specimens at different locations.
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were polished by polishing machine for removal of contamination in microns on specimen surfaces. Acetone was applied on the surface of specimen for removal of impurities after polishing. The process was done for all the specimens. The bonding between the tungsten and the copper is clearly observed from the SEM images. The elements present in the coated surface specimen are clearly observed from the EDS. The morphological study was also carried out after wear testing of the specimens.
3.2. Morphological analysis of coated samples The compositions of W-Cu in different proportions are studied using SEM and EDS. The results of observations of different compositions are discussed below.
The hardness value was calculated at various points on the coated specimens. The average hardness value of different compositions is calculated at five different locations. From the analysis, the micro hardness was achieved in the range between 51 and 84 Hv respectively. The higher Hv was achieved for the 60:40 wt % composition and lower for 75:25 wt% from the analysis as shown in Fig. 5.
3.2.1. 50:50 wt% composition Fig.6(a) indicates the bonding of W-Cu of 50:50 wt% composition on the surface of specimen. Uniform proportions of thin layer of W-Cu deposition appeared on the surface of the specimen. This was occurred due to sparking during EDC process and flow of material from electrode to the substrate material. The EDS analysis was processed on the top surface of the specimen at distinct points after polishing. The polishing process was done for smooth surface. The EDS plots show the presence of various elements as shown in Fig.6(b). Fig.6(b) shows the presence of tungsten and copper deposition on the surface of the substrate from the peaks obtained during EDS process. From the observation, the intensity of copper peak is higher for 50:50 wt% composition than tungsten on the surface of the substrate. This indicates that the percentage of copper is higher at top surface of specimen and at the inner portion contains the presence of tungsten is higher. This is desirable for obtaining
Fig. 6a. SEM images for 50:50 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
Fig. 7a. SEM images for 60:40 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
3. Results and discussion 3.1. Micro hardness
Fig. 6b. EDS images for 50:50 wt% composition.
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Fig. 7b. EDS images for 60:40 wt% composition.
Fig. 8a. SEM images for 75:25 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
Fig. 9a. SEM images for 75:25 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
Fig. 8b. EDS images for 75:25 wt% composition.
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the hardness on the surface of the specimens. The polishing process gives the results for smooth and harder surface can be achieved. 3.2.2. 60:40 wt% composition The result from the SEM morphology and EDS graphs shows that the deposition of tungsten was more than that of copper at distinct points for 60:40 wt% along with other elements as shown in Fig. 7(a) (Fig. 7(b)). 3.2.3. 75:25 wt% composition From the Fig.8(a) the 75:25 wt% composition shows the percentage of tungsten and copper deposition was more proportionate
to other elements. The SEM image indicates that the coated sample of this composition consists of thick and thin layer of deposition. Surface roughness was higher for the coated specimen of this composition (Fig 8(b)).
3.2.4. 70:30 wt% composition The SEM and EDS images for the 70:30 wt% composition as shown in Fig 9a. From the SEM image, it was observed that the deposition of W-Cu was not uniform. Thick and thin layers of coated materials appears on the surface of the substrate. In the EDS analysis, the peak of deposition of Cu appears to be high than W at distinct points. This is occurred due to the melting point, as Cu melting point is lower than W. The deposition of Cu is at faster
Fig. 9b. EDS images for 70:30 wt% composition.
Fig. 10. Wear analysis for pure copper (100%).
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Fig. 11. COF verses Composition.
rate than W. The surface of the coated sample is non-uniform due to higher percentage of W. The elements of carbon and oxides appear in the Fig.9(b) due to influence of dielectric fluid in the coating process.
(i.e.0.48). The COF for different compositions of coated specimens (i.e 50:50 wt% ,60:40 wt% ,75:25 wt%,70:30 wt%) are shown in Fig. 11.The results shows that among different compositions the COF is higher in composition of 70:30 wt% and was lower in 60:40 wt% with respect to time. Fig 12.
4. Wear test and COF analysis 5. Analysis of wear substrates by SEM The test was carried out by considering pure copper (100%) coated sample for comparative study as shown in Fig. 10. The result of COF of copper was higher compared to coated specimens
The morphological study was also carried out after wear testing of the specimens. The SEM images as shown in Fig. 13 indicates
Fig. 12. COF verses Time comparison for different coated specimens with respect to mixing ratio of 6A and 100 ls.
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Fig. 13. SEM image of different coated specimens after wear test.
that when the wear of coated samples. The coating material was peel out more at 70.30 wt% than that of other compositions. Fig. 13 also indicates that the wear is peeled out lesser at some surface and stronger at remaining surface due to bonding of the coating compositions. At higher speed the coating material is removed at some points for different composition.
6. Conclusions Specially prepared powder metallurgy electrodes were used for electro discharge coating on AISI 1020 steel substrate. Different compositions of tungsten and copper metal powders in the proportion of (50:50 wt%, 60:40 wt%, 75:25 wt%, 70:30 wt%) were considered for the investigation. The compacting pressure and sintering temperature were considered as 188 MPa and sintering temperature as 770 °C based on preliminary experiments. The micro hardness analysis was done for the base material and the coated samples of various portions for finding the hardness value of the coated substrates. The values obtained in the range between 51
and 84 Hv based on Vickers micro hardness tester MVH1 considering applied load as 1kgf and for dwell time 30sec. The tungsten and copper coated layer is obtained on the surface of the coated substrates of different compositions. The hardness values are checked for best suitable composition for EDC. From the experimental investigation, it is observed that by varying the process parameters on the EDM machine, the machining and surface modifications can be achieved easily by powder metallurgy electrodes. The SEM and EDS analysis was done the on selected samples to analyse the effect of mixing ratios of tungsten and copper metal powders in different proportions on the surface of the substrate. The investigation was carried out to help in further research work in this area and for industrial applications in various fields.
CRediT authorship contribution statement P.D. Machkale: Conceptualization, Formal analysis, Investigation, Writing - original draft, Visualization, Writing - review & editing. B.M. Dabade: Methodology, Resources, Supervision.
Please cite this article as: P. D. Machkale and B. M. Dabade, Morphological studies and wear behavior of electro discharge coated steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.01.292
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Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Acknowledgements This work was carried out at the SGGSIE&T, Nanded and the author express their sincere thanks to AICTE NEW DELHI for grant of funds under RPS project(8-18/RIFD/RPS/POLICY-1/2015-16) for EDM Machine. The Author also thankful to VNIT Nagpur for SEM and EDS analysis.
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Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Morphological studies and wear behavior of electro discharge coated steel P.D. Machkale ⇑, B.M. Dabade Department of Production Engineering, SGGSIE&T, Nanded 431606, India
a r t i c l e
i n f o
Article history: Received 27 August 2019 Received in revised form 4 January 2020 Accepted 14 January 2020 Available online xxxx Keywords: Powder metallurgy (PM) Wear EDC Electric discharge machining (EDM) W-Cu SEM EDS
a b s t r a c t This paper elaborates on the deposition of tungsten and copper (W-Cu) material on the AISI 1020 steel substrate and the method used for deposition with its surface and wear characteristics. The tool electrode used is of tungsten copper (W-Cu) manufactured by powder metallurgy (PM) route with different ratios of tungsten and copper metal powders. The process carried out for deposition is by electro-discharge coating (EDC). In this, the tool electrode material is melted and deposited on the substrate by the application of heat energy due to sparking between the electrode and the substrate. Then a thick layer of W-Cu coating is formed on the substrate material. The substrate material of AISI 1020 steel was cut in cylindrical shapes of 10 mm diameter and height 10 mm by wire cut EDM machine and was then surface grinded for the accuracy and polished surface. The cylindrical size was considered for holding the specimen in the clamping device of wear testing machine easily during wear testing. The wear behavior of the coated samples is assessed by the pin on disc method. The effect of mixing ratio, micro hardness, Scanning Electron Microscope (SEM), Energy Disperse Spectroscopy (EDS) analysis, Coefficient of friction (COF) etc., for different composition coated samples has been investigated. The results show that the micro hardness achieved in the range 51-84HV for coated specimens of W-Cu of different composite substrates. The COF was achieved in the range of 0.16 to 0.31 after wear experimentation. The microstructures of the coated samples are analyzed before and after wear by using SEM and EDS. Ó 2020 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the scientific committee of the First International Conference on Recent Advances in Materials and Manufacturing 2019.
1. Introduction This paper mainly focuses on the morphological studies and wear behaviour of the coated layer processed by electrodischarge coating on the AISI 1020 steel as substrate material. The Electro discharge coating (EDC) process is adopted as it is one of the emerging coating technology nowadays due to its simplicity and ease in operation compared to CVD, PVD and related coating processes [1–4]. As this process does not require complicated equipment like vacuum chamber by using Electro Discharge Machine (EDM) coating can be obtained easily on different substrate materials [1,3–7]. The Process of EDC is opposite to that of EDM in which the spark is generated and deposited on the substrate material by varying the parameters at different levels [8,9]. The high spark temperatures associated with the EDM exploited to deposit the useful material on the substrate which produces ⇑ Corresponding author. E-mail address: [email protected] (P.D. Machkale).
higher wearing properties and high melting points [10]. The electrodes used for electro discharge coating has some specific properties than conventional electrodes like low density [11], wear resistance [4,12,13], corrosion resistance [14–19], abrasive resistance [20–22], high temperature resistance [17,23], high hardness [24–26] etc. The polarity used in this process is in reverse condition i.e. tool electrode as anode and work piece as cathode [10,27–29]. This process is widely used in surface modifications of die and moulds or to make wear or corrosion resistance components used in adverse environmental conditions [4,30].Many researches have analysed the EDC process by using various electrode materials such as W, Cu, Ti ,Graphite etc. for surface modification in recent years [14,31]. Similar study was carried out by author for surface modification of steel having 90% copper(Cu) and 10% tin(Sn) and the layer obtained is of Cu and Sn on steel surface [28].Some electrodes are used as a feed-stock material, in an effort to produce significant work piece surface alloying on the surface and enhance the wear resistance of the machined surface[32–34]. EDC process can be used for many industrial applications such as for treatment of a
https://doi.org/10.1016/j.matpr.2020.01.292 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the scientific committee of the First International Conference on Recent Advances in Materials and Manufacturing 2019.
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film required to strengthen and lubricate under high temperature environmental conditions such as a turbine blade for gas turbine and a film used for building up in repair of a component etc. [9,15]. This paper describes about the morphological study and property observations of the coated samples of different compositions. The wear test was carried out on pin on disc wear testing machine to find out the effects of different compositions coated samples by considering the coefficient of friction (COF) as response variable. The input parameters were considered as time, speed and track diameter. This investigation was carried out from the observation of the literature that as few researchers have focused on the wear behaviour of the coated samples of different compositions and sintering temperatures which are manufactured by powder metallurgy (PM) route.
Fig. 1. Tool holder.
2. Methodology adopted for the research work In the present research work tool electrodes of W-Cu of different compositions (i.e 50:50 wt%, 60:40 wt%, 75:25 wt%, 70:30 wt %) are manufactured by Powder metallurgy process. A micro hardness and wear characteristic of the coated specimens was investigated. The Electro discharge coating was adopted for the coating process. The Micro hardness analysis was carried out on Vickers Micro hardness tester. Coating process was done on the AISI 1020 steel substrate material (Specimen was cut into 10 mm 10 mm using Wire Cut EDM machine). Tool holder and substrate holder are manufactured separately for the coating process. The investigation of coated samples of different compositions are done by Scanning Electron Microscope (SEM) and Energy Disperse Spectroscopy (EDS).
Fig. 2. Substrate material holder.
Table 1 EDC Parameters.
2.1. Methods and manufacturing process 2.1.1. Experimental procedure for W-Cu coating. The power metallurgy route was used for manufacturing of the tool electrodes of W-Cu composite. The electrodes are manufactured in different compositions of W-Cu (i.e 50:50 wt%, 60:40 wt %, 75:25 wt%, 70:30 wt%). The diameter of the electrode is same as that of substrate material. For experimental work sparkonix 35A EDM machine was considered for all the coating samples. The substrate material used was low carbon steel of AISI 1020 steel grade for all compositions of the electrode material for coatings on the substrates. The polarity considered as negative (tool electrode as anode and substrate material as cathode). Before experimentation, the substrate material was surface grinded on both sides of surface before coating. Then the surface of the samples were the EDC process is to be carried out was polished by emery paper and acetone was applied on the surface to remove any contamination on the surfaces. The weight of the samples and electrodes were measured before and after coating by electronic weighing machine (Make: CONTECT). Fig. 1 shows the tool holder for holding the electrode on EDM. Fig. 2 shows the work piece holder for the coating process fabricated specifically to fix the substrate of required size and shape considered for experimentation. The experiment was done by using Commercial EDM oil as dielectric and flushing was done on the surface of the samples for constant coating. The parameters taken for EDC coating are shown in Table.1.After experimentation also each sample was cleaned buy acetone for removal of any contamination on the surface. Fig. 3 indicates the magnified view of the coated sample after coating of W-Cu composition. Fig. 4 indicates the coated samples of different compositions of W-Cu.
Parameters
Values
Electrode material Composition Substrate Polarity Current (A) On time Gap Voltage(V) Time Compacting pressure Sintering temperature
W-Cu 50:50 wt%,60:40 wt%,75:25 wt%,70:30 wt% AISI 1020 Negative 6 100 40 5 min 188 MPa 770 °C
2.1.2. Micro hardness The micro hardness analysis was carried out by using MVH-1 Vickers hardness testing machine (Make: Metatech). Before hardness testing, the surface of the coated samples were polished by using polishing machine (Make: CENSICO). The hardness was carried out at 1 kg load and at 25 dwell time from the observations. Initially, the plain surface of AISI 1020 steel was considered at five different points for indentation point’s observation. Further, similar measurements are taken at five different locations on the coated surface of AISI 1020 steel of different composition specimens. The micro hardness was calculated by using Vickers hardness number (Hv) formula [35] as
Hv ¼ 1:8544 P=d2 kg=mm2 where, P = applied load in Kg, d = diagonal length of the indentation in mm
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2.1.3. Wear and COF analysis The wear behaviour of the coated samples prepared by EDC of different ratios are characterized by pin on disc wear testing machine (Make. DUCOM). The W-Cu metal powder mixture of different weight ratios (i.e. 50:50 wt%,60:40 wt%,75:25 wt%,70:30 wt %) under compacting pressure (CT) 188 MPa and sintering temperature (ST) 770 °C. The weight loss of the coated samples are measured by precision weighing machine with the accuracy of 0.1 mg. The input parameters were considered as speed at 200 rpm, time 1000 sec, load 40 N and track diameter was taken as 80 for all the compositions. These parameters are examined on the basis of preliminary experiments. The comparison of the result was done by using winducom software. The test was carried out by considering pure copper (100%) coated sample also for comparative study. The response was considered as coefficient of friction (COF).
Fig. 3. Magnified view of the coated substrate.
2.1.4. Morphology and wear behaviour analysis Microstructure of the coated samples are analysed by Scanning Electron Microscope (SEM) and the elements present on the coated surface of different compositions were analysed at different points by using Energy dispersive spectroscopy (EDS). The analyses was done to find out the effect of current, pulse on time and mixing ratios of W-Cu electrodes considering compacting and sintering temperature. Before SEM and EDS analysis, the coated substrates
Fig. 4. Coated samples of different compositions.
Fig. 5. Hardness of coated specimens at different locations.
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were polished by polishing machine for removal of contamination in microns on specimen surfaces. Acetone was applied on the surface of specimen for removal of impurities after polishing. The process was done for all the specimens. The bonding between the tungsten and the copper is clearly observed from the SEM images. The elements present in the coated surface specimen are clearly observed from the EDS. The morphological study was also carried out after wear testing of the specimens.
3.2. Morphological analysis of coated samples The compositions of W-Cu in different proportions are studied using SEM and EDS. The results of observations of different compositions are discussed below.
The hardness value was calculated at various points on the coated specimens. The average hardness value of different compositions is calculated at five different locations. From the analysis, the micro hardness was achieved in the range between 51 and 84 Hv respectively. The higher Hv was achieved for the 60:40 wt % composition and lower for 75:25 wt% from the analysis as shown in Fig. 5.
3.2.1. 50:50 wt% composition Fig.6(a) indicates the bonding of W-Cu of 50:50 wt% composition on the surface of specimen. Uniform proportions of thin layer of W-Cu deposition appeared on the surface of the specimen. This was occurred due to sparking during EDC process and flow of material from electrode to the substrate material. The EDS analysis was processed on the top surface of the specimen at distinct points after polishing. The polishing process was done for smooth surface. The EDS plots show the presence of various elements as shown in Fig.6(b). Fig.6(b) shows the presence of tungsten and copper deposition on the surface of the substrate from the peaks obtained during EDS process. From the observation, the intensity of copper peak is higher for 50:50 wt% composition than tungsten on the surface of the substrate. This indicates that the percentage of copper is higher at top surface of specimen and at the inner portion contains the presence of tungsten is higher. This is desirable for obtaining
Fig. 6a. SEM images for 50:50 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
Fig. 7a. SEM images for 60:40 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
3. Results and discussion 3.1. Micro hardness
Fig. 6b. EDS images for 50:50 wt% composition.
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Fig. 7b. EDS images for 60:40 wt% composition.
Fig. 8a. SEM images for 75:25 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
Fig. 9a. SEM images for 75:25 wt%. Ip:6A, CP: 188 MPa, ST: 770 °C.
Fig. 8b. EDS images for 75:25 wt% composition.
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the hardness on the surface of the specimens. The polishing process gives the results for smooth and harder surface can be achieved. 3.2.2. 60:40 wt% composition The result from the SEM morphology and EDS graphs shows that the deposition of tungsten was more than that of copper at distinct points for 60:40 wt% along with other elements as shown in Fig. 7(a) (Fig. 7(b)). 3.2.3. 75:25 wt% composition From the Fig.8(a) the 75:25 wt% composition shows the percentage of tungsten and copper deposition was more proportionate
to other elements. The SEM image indicates that the coated sample of this composition consists of thick and thin layer of deposition. Surface roughness was higher for the coated specimen of this composition (Fig 8(b)).
3.2.4. 70:30 wt% composition The SEM and EDS images for the 70:30 wt% composition as shown in Fig 9a. From the SEM image, it was observed that the deposition of W-Cu was not uniform. Thick and thin layers of coated materials appears on the surface of the substrate. In the EDS analysis, the peak of deposition of Cu appears to be high than W at distinct points. This is occurred due to the melting point, as Cu melting point is lower than W. The deposition of Cu is at faster
Fig. 9b. EDS images for 70:30 wt% composition.
Fig. 10. Wear analysis for pure copper (100%).
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Fig. 11. COF verses Composition.
rate than W. The surface of the coated sample is non-uniform due to higher percentage of W. The elements of carbon and oxides appear in the Fig.9(b) due to influence of dielectric fluid in the coating process.
(i.e.0.48). The COF for different compositions of coated specimens (i.e 50:50 wt% ,60:40 wt% ,75:25 wt%,70:30 wt%) are shown in Fig. 11.The results shows that among different compositions the COF is higher in composition of 70:30 wt% and was lower in 60:40 wt% with respect to time. Fig 12.
4. Wear test and COF analysis 5. Analysis of wear substrates by SEM The test was carried out by considering pure copper (100%) coated sample for comparative study as shown in Fig. 10. The result of COF of copper was higher compared to coated specimens
The morphological study was also carried out after wear testing of the specimens. The SEM images as shown in Fig. 13 indicates
Fig. 12. COF verses Time comparison for different coated specimens with respect to mixing ratio of 6A and 100 ls.
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Fig. 13. SEM image of different coated specimens after wear test.
that when the wear of coated samples. The coating material was peel out more at 70.30 wt% than that of other compositions. Fig. 13 also indicates that the wear is peeled out lesser at some surface and stronger at remaining surface due to bonding of the coating compositions. At higher speed the coating material is removed at some points for different composition.
6. Conclusions Specially prepared powder metallurgy electrodes were used for electro discharge coating on AISI 1020 steel substrate. Different compositions of tungsten and copper metal powders in the proportion of (50:50 wt%, 60:40 wt%, 75:25 wt%, 70:30 wt%) were considered for the investigation. The compacting pressure and sintering temperature were considered as 188 MPa and sintering temperature as 770 °C based on preliminary experiments. The micro hardness analysis was done for the base material and the coated samples of various portions for finding the hardness value of the coated substrates. The values obtained in the range between 51
and 84 Hv based on Vickers micro hardness tester MVH1 considering applied load as 1kgf and for dwell time 30sec. The tungsten and copper coated layer is obtained on the surface of the coated substrates of different compositions. The hardness values are checked for best suitable composition for EDC. From the experimental investigation, it is observed that by varying the process parameters on the EDM machine, the machining and surface modifications can be achieved easily by powder metallurgy electrodes. The SEM and EDS analysis was done the on selected samples to analyse the effect of mixing ratios of tungsten and copper metal powders in different proportions on the surface of the substrate. The investigation was carried out to help in further research work in this area and for industrial applications in various fields.
CRediT authorship contribution statement P.D. Machkale: Conceptualization, Formal analysis, Investigation, Writing - original draft, Visualization, Writing - review & editing. B.M. Dabade: Methodology, Resources, Supervision.
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Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Acknowledgements This work was carried out at the SGGSIE&T, Nanded and the author express their sincere thanks to AICTE NEW DELHI for grant of funds under RPS project(8-18/RIFD/RPS/POLICY-1/2015-16) for EDM Machine. The Author also thankful to VNIT Nagpur for SEM and EDS analysis.
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