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    of 4

    Journal of Materials Processing Technology 129 (2002) 139±142

    Surface modi®cation process by electrical discharge machining


    with a Ti powder green compact electrode
    Z.L. Wanga,*, Y. Fanga, P.N. Wua, W.S. Zhaoa, K. Chengb
    a
    Department of Mechanical Engineering, Harbin Institute of Technology, P.O. Box 421,
    West Dazhi Street 92, Harbin 150001, PR China
    b
    School of Engineering, Leeds Metropolitan University, Calverley Street, Leeds LSI 3HE, UK

    Abstract

    This paper describes a new method of surface modi®cation by electrical discharge machining (EDM). By using an ordinary EDM machine
    tool and kerosene ¯uid, a hard ceramic layer can be created on the workpiece surface with a Ti or other compressed powder electrode in a
    certain condition. This revolutionary new method is called electrical discharge coating (EDC). The process of EDC begins with electrode wear
    during EDM, then a kind of hard carbide is created through the chemical reaction between the worn electrode material and the carbon particles
    decomposed from kerosene ¯uid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic
    of about 20 mm thickness in several minutes. This paper studies the principle and process of EDC systemically by using a Ti powder green
    compact electrode. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of the metal workpiece.
    The hardness of the ceramic layer is more than three times higher than that of the base body, and the hardness changes gradually from the
    surface to the base body. This method can ®nd wide application in the ®elds of surface modi®cation, such as the surface repairing and
    strengthening of cutting tools and molds.
    # 2002 Elsevier Science B.V. All rights reserved.

    Keywords: Electrical discharge machining; Electrical discharge coating; Ti powder green compact electrode; Surface modi®cation

    1. Introduction Saito in the Mitsubishi Electric Corporation have coated the


    surface of mental molds in kerosene by using a Ti powder
    Electrical discharge coating (EDC) is a coating method green compact or a TiC semi-sintered electrode successfully.
    developed in recent years to form a hard layer on metallic Experiments show that the hardness of the surface is very
    material using an electrical discharge in a dielectric ¯uid [1]. high, and the mold's adherence is three times greater and is
    There are many surface modi®cation methods through twice as strong as that of molds without being coated or
    which a ceramic layer is created on the surface of material, those coated by titanium nitride (TiN) with PVD. The life is
    such as physical vapor deposition (PVD), chemical vapor lengthened by three to seven times [3,4].
    deposition (CVD) and so on. They all can improve the whole In China, the Research Institute of Nontraditional Man-
    performance, and reduce the manufacturing cost of products ufacturing and Mechatronics, Harbin Institute of Technol-
    by using a few materials instead of many expensive materi- ogy, began this research ®rst. By using an ordinary electrical
    als [2], but these methods need special apparatus, and the discharge machining (EDM) machine tool and kerosene, a
    machining area and the coating thickness cannot be con- layer of TiC ceramic about 20 mm thickness is created on the
    trolled well, so they do not ®nd wide application in ordinary workpiece successfully with a Ti powder green compact
    tool and mold workshops. For example, as for PVD, it needs electrode in a very short time.
    special vacuum apparatus, and pre-processing such as the
    elaborate cleaning of the workpiece is indispensable [1].
    The method of EDC does not have these defects. Japan 2. Principle of EDC
    and other developed countries began this research a few
    years ago. Mohri at the University of Tokyo and Moro and Fig. 1 shows the principle of EDC. With the EDM
    machine tool and kerosene, Ti, W or other metallic materials
    *
    Corresponding author. are used as the electrode. In the process of EDC, a kind of
    E-mail address: [email protected] (Z.L. Wang). hard carbide (such as TiC or WC) is created through

    0924-0136/02/$ ± see front matter # 2002 Elsevier Science B.V. All rights reserved.
    PII: S 0 9 2 4 - 0 1 3 6 ( 0 2 ) 0 0 5 9 7 - 6
    140 Z.L. Wang et al. / Journal of Materials Processing Technology 129 (2002) 139±142

    Table 1
    EDC conditions

    Discharge current (A) ie ˆ 2:2 10


    Discharge duration (ms) te ˆ 2 12
    Duty factor (%) t ˆ 5:88
    Machining time (min) 18
    Machining area (mm2) 12
    Polarity Electrode (±)
    Electrode f 12Titanium
    Workpiece Carbon steel

    Fig. 1. Principle of EDC. Table 2


    Electrodes

    Electrode type Green compact


    chemical reaction between the worn electrode material and Material Ti powders
    the carbon particles decomposed from the kerosene ¯uid Diameter of powders (mm) 80
    Forming pressure (t/cm2) 10
    under high temperature. The carbide is piled up on a work- Size (mm2) 12
    piece quickly and becomes a hard layer of ceramic in several
    minutes. Since the hard layer is created on the workpiece in
    the process of EDC, then EDC is indeed the contrary process
    of EDM. It requires that the cutting speed of the workpiece Table 1 shows the EDC conditions, whilst Table 2 shows
    be lower than the wearing speed of the electrode. A theory of the material of the electrode and its forming conditions.
    deposition has been advanced.
    In general, the forms of electrodes are green powder
    compressed, or sintered, and so on. The powder green 4. Characteristics of a layer by EDC
    compact electrode has some characteristics that are good
    for deposition, e.g.: heat conduction is not very good, 4.1. Characteristics of a layer by EDC
    resistance is great, the wearing speed is comparatively rapid,
    and so on. When the powder green compact electrode is Fig. 2 shows a photograph of a cross-section of the layer
    used, in order to reduce the combining intensity of mole- coated by EDC. This photograph was taken with an electron
    cules, the less the pressure of molding, the better will be the microscope after EDC, cutting, polishing and etching. The
    effects of EDC. In contrast to the powder green compact electrical conditions under which the layer is formed are as
    electrode, the sintered electrode has many merits. At the follows: discharge current ie ˆ 10 A; discharge duration
    same time the sintered materials can be made into all kinds te ˆ 4 ms; pulse interval time t0 ˆ 64 ms; machining time
    of shaped electrodes easily, so that it can be used to ®nish 18 min; and workpiece carbon steel.
    random shape machining. The smaller the diameter of the From Fig. 2 it can be seen that the ratio of Fe is reduced
    powder, the better the surface roughness of the hard layer. gradually from the base metal to the surface, and almost to
    The method of EDC has many merits compared with zero at the end, while the ratio of Ti is increased gradually
    some conventional methods.

    (1) It does not require complicate equipment such as


    vacuum apparatus. With only an ordinary EDM
    machine tool, a ceramic layer can be created easily
    on the workpiece.
    (2) The ceramic layer can be created in different places of
    the workpiece with different areas, and the coating
    speed is fast, the thickness being well controlled also.
    (3) The range of materials used by the EDC method is
    wide, and the operation is very simple, so this method
    has better application prospects.

    3. Experimental conditions

    With the ordinary EDM machine tool and dielectric ¯uid,


    the authors ®nished the test of EDC on the workpiece. Fig. 2. Cross-section of EDC layer.
    Z.L. Wang et al. / Journal of Materials Processing Technology 129 (2002) 139±142 141

    Fig. 3. X-ray diffraction of hard layer by EDC.

    with grads, and the surface of the layer is rich in Ti. It can
    also be seen that there is no clear boundary between the layer
    and the base metal. It can be considered that is why the EDC Fig. 5. Relation between average hardness and discharge duration.
    layer has strong adherence to the base metal.
    5. Future views
    4.2. Composition of a layer by EDC
    The method of EDC will have a great future because many
    Fig. 3 shows the result of X-ray diffraction of a hard layer materials can be easily added to the electrode and then be
    by EDC, the electrical conditions being the same as above. coated on the workpiece surface. Adjusting the parameters,
    From the ®gure the diffraction apex of TiC and Fe can be ceramic can create ceramic layers with different thickness.
    seen clearly, which means that there are TiC and Fe com- Then, by changing the electrode or using a special sintered
    ponents in the surface. The ®rst diffraction apex of TiC (2y) electrode, a ceramic layer with another composition is
    is 36.228, and the ®rst diffraction apex of Fe (2y) is 44.408. created on the former layer, thus the composite ceramic
    In the surface texture of the layer, TiC is 51%, Fe is 48%, and layer will have special characteristics. The switch between
    the rest is impurity. the deposition process and the removal process is carried out
    easily by changing the polarity and the parameters of
    4.3. Hardness machining, thus the alteration of the thickness and shape
    of the composite ceramic layer is carried out easily. This kind
    Fig. 4 shows the relationship between the average of composite ceramic layer will possibly be used to deal with
    hardness of the surface by EDC and the discharge current. the surface of the cutting tools or molds, in order to lengthen
    Fig. 5 shows the relationship between the average hardness their life. It also can ®nd wide application in the ®elds of the
    of the surface by EDC and the discharge duration. From surface repairing and strengthening of ships or aircraft.
    the above ®gures, it can be seen that even the lowest
    hardness of the surface layer is also four or ®ve times
    higher than that of the base material. The instrument used 6. Conclusions
    in measuring is an MN-3 Vickers hardness meter produced
    by the former Soviet Union. The load of measurement is This paper describes a new surface modi®cation method
    200 gf. with EDM technology, the following conclusions being
    drawn:
    1. The method of EDC is a very practical technology, and
    it will find good prospects of application in ordinary tool
    or mold workshops.
    2. The EDC process is very simple and does not need special
    equipment, compared with other conventional methods.
    3. There is an evident grad variety in the EDC surface layer
    component. The surface of the layer is rich in Ti but
    gradually the Ti decreases. This is very important to the
    surface modification.

    Acknowledgements

    This study is funded by China national ``863'' project


    (2001AA421240). Special thanks are expressed for the
    Fig. 4. Relation between average hardness and discharge current. support of HIT CKSP Group development funding.
    142 Z.L. Wang et al. / Journal of Materials Processing Technology 129 (2002) 139±142

    References [3] H. Miyake, A. Imai, A. Goto, N. Saito, N. Mohri, Improvement of tool


    life through surface modification by electrical discharge machining,
    Proc. ISEM 12 (1998) 261±270.
    [1] A. Goto, T. Moro, K. Matsukawa, M. Akiyoshi, N. Saito, N. Mohri,
    [4] T. Moro, A. Goto, N. Mohri, N. Saito, K. Matsukawa, H. Miyake,
    Development of electrical discharge coating method, in: Proceedings
    Surface modification process by electrical discharge machining with
    of the 13th International Symposium for Electromaching ISEM XIII,
    TiC semi-sintered electrode, J. Jpn. Soc. Prec. Eng. 67 (1) (2001) 114±
    vol. 1, no. 5, 2000.
    119.
    [2] C. Weixi, Developing status and views for tool coating technology,
    Tool Eng. 34 (3) (2000).

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