Evaluation of Bronze Electrode in Electrical Discharge Coating Process for Copper Coating

Area of Science:

• Materials Science
• Manufacturing Engineering
• Surface Engineering

Background:

• Electrical discharge machining (EDM) is a non-traditional method for complex shapes.
• EDM is increasingly utilized for material deposition by controlling parameters.
• Bronze electrodes offer a readily available option for deposition processes.

Purpose of the Study:

• To evaluate bronze electrodes for copper deposition on titanium alloy using EDM.
• To investigate the effect of preheating and quenching on titanium alloy substrate properties.
• To optimize EDM parameters for enhanced deposition characteristics.

Main Methods:

• Taguchi experimental design for parameter selection (current, Ton, Toff, preheating temperature).
• Titanium alloy substrate hardening via preheating and quenching in various media.
• Material characterization using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDX).
• Optimization of output parameters (MDR, EWR, CT, SCD) using the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS).

Main Results:

• Preheating and quenching treatments altered titanium alloy hardness and microstructure.
• Optimized EDM parameters yielded a material deposition rate (MDR) of 0.00506 g/m.
• Optimal conditions resulted in a coating thickness (CT) of 40.2 µm and electrode wear rate (EWR) of 0.00462 g/m.
• The optimal parameter set included Ton of 440 µs, Toff of 200 µs, 300 °C preheating, and castor oil quenching.

Conclusions:

• Bronze electrodes are viable for copper deposition on titanium alloy via EDM.
• Pretreatment of titanium alloy is crucial for successful deposition and to prevent workpiece erosion.
• The TOPSIS method effectively identified optimal EDM parameters for material deposition.