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Experimental investigation and parametric optimization of electro-discharge coated aluminum alloy by desirability based technique

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Abstract

In today's industrial practice, automobilesectors,aviation,military and missile applications aluminium alloys are being widely used material instead of steel because of its light weight and high strength to weight ratio, but it possesses very low wear resistance. To enhance thewear resistance ofaluminumalloysurface modification required.Electrical discharge coating (EDC)one of the surface modification process carried out in the existing electrical discharge machining (EDM) with reverse polarity and powder metallurgy electrode. Hence in the present work, coating of 7075aluminium alloy has been coated with WC/Ni semi-sintered electrode to improve surface properties due to its lower wear resistance during higher load applications. Experiments are percformed based on DOE the study effect of the individual parametersparameters (compaction load, current and pulse on time) on the responses such as micro hardness and surface roughness. The experimental results are verified and justified using ANOVA and revealed that pulse on time has most significant parameter followed by current and compaction laod. However the coating performance are conflict in nature hence there is a need to identify the optimal coating parameters to achieve the desired coating characteristics. Finally, RSM method is adopted for optimization of EDCto identified the optimal coating parameters. Confirmation tests are performed on at predicted optimum process parameters and results are verified. Further, SEM was used to determine the surface morphologyand EDS is used to validate the confirm the alloying of electrode materials on the surface of Al alloy.

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Acknowledgements

The author acknowledges Department of Manufacturing Engineering, Annamalai University, for the support and facilities provided to conduct the research.

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Authors and Affiliations

  1. Department of Manufacturing Engineering, Annamalai University, Chidambaram, 608002, India

    S. Srikanth & C. Senthilkumar

  2. Department of Automobile Engineering, Easwari Engineering College, Chennai, 600089, India

    U. Elaiyarasan

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  1. S. Srikanth
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  2. C. Senthilkumar
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  3. U. Elaiyarasan
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Srikanth, S., Senthilkumar, C. & Elaiyarasan, U. Experimental investigation and parametric optimization of electro-discharge coated aluminum alloy by desirability based technique. Int J Interact Des Manuf 17, 667–677 (2023). https://doi.org/10.1007/s12008-022-00983-1

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