Abstract
Electrical discharge coating (EDC) is performed to deposit the mixture of tungsten disulfide (WS2) and copper (Cu) powder onto the mild steel surface for solid lubrication. The material deposition process takes place through green compact tool by using EDC setup inside the die-sink electrical discharge machine (EDM). The powder compact tool has been prepared in the hot mounting press for different values of powder mixing ratio, i.e., WS2: Cu/40:60, WS2: Cu/50:50, and WS2: Cu/60:40. The coating material deposits due to series of chemical reactions between the tool and workpiece in the presence of hydrocarbon oil when reverse polarity has been used in die-sinking electrical discharge machine (EDM). Response surface methodology has been utilized for optimization by varying the molding press and machining input parameters such as mixing ratio, duty factor, and peak current. Reduction in micro-hardness value as a result of solid lubricant deposition has been revealed with the help of Vickers hardness testing machine. Field emission scanning electron microscope (FESEM) analysis has been performed to examine the presence of pores, voids, and gaps on the mild steel surface. X-ray diffraction study along with the energy-dispersive X-ray spectroscopy (EDX) results also confirms the presence of WS2, W, S, Cu, and Cu2S compounds in the coating. The effect of duty factor and peak current on different output parameters (mass transfer rate, tool wear rate, and micro-hardness) has been evaluated.
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Tyagi, R., Pandey, K., Mohanty, S., Kumar, S., Das, A.K., Mandal, A. (2019). Optimization of Electrical Discharge Coating of WS2 and Cu Powder Mixture Deposited Through Green Compact Electrode. In: Shanker, K., Shankar, R., Sindhwani, R. (eds) Advances in Industrial and Production Engineering . Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-13-6412-9_25
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DOI: https://doi.org/10.1007/978-981-13-6412-9_25
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