Modares Mechanical Engineering

Modares Mechanical Engineering

Improving the surface properties of pure aluminum using Monel 400 by Electrical Discharge Alloying (EDA)

Authors
Hadi Eivazi bagheri 1
Hamid Gorji 2
salman nourouzi 3
Shabghard Mohammad reza 4
1 Student
2 Advance metal forming research center, Department of Mechanical Engineering, Babol University of Technology, Babol, iran.
3 Babol University of Technology
4 Tabriz Un.
Abstract
Surface engineering in many manufacturing industries plays an important role in improving product performance and increasing the operating time of parts. Pure aluminum has a very high electrical conductivity, good corrosion resistance and strength to weight ratio. However, due to very low hardness and wear resistance, its application is limited. Therefore, this paper is studied may improve the surface properties of pure aluminum using copper and nickel as alloying elements using electric discharge process. The pulse on time and pulse current as input parameters and surface hardness, alloyed layer texture and surface roughness as output parameters have been considered. According to the microhardness testing results, in this alloying method, the average hardness of the aluminum parts is about more than 8 times and in some parts of the 38.5 Vickers reached up to 450 Vickers, Based on the results of XRD analysis, the formation of intermetallic compounds Al3Ni2, ALCu, and Al4C3 increased surface hardness. The results show that by increasing the pulse on time surface hardness increased and surface roughness becomes greater. Also, Increasing pulse current the surface roughness increasing trend.
Keywords
Monel
Aluminum
Electrical Discharge
Microhardness
[1] Y. Ab. Alwafi, N. Bidin, R. Hussin, M. Shkhawat, D. Gustiono,
Michrohardness evaluation of pure aluminum substrate after laser surface
alloying with iron and copper, Journal of Materials Science Engineering,
Vol. B 1, No. 1, pp. 200-205, 2011.
[2] A. P. I. Popoola, S. L. Pityana, T. Fedotova, O. M. Popoola, Quantitative
study of the hardness property of laser surface alloyed aluminium AA1200,
The Journal of The Southern African Institute of Mining and Metallurgy,
Vol. 111, No. 1, pp. 335-344, 2011.
[3] T. G. Rambau, A. P. I. Popoola, C. A. Loto, T. Mathebula, M. Theron,
Tribological and corrosion characterization of Al/(Stellite- 6+Zirconium)
laser alloyed composites, International Journal of Electrochemical Science,
Vol. 8, No. 1, pp. 5515-5528, 2013.
[4] W. G. Jiru, M. R. Sankar, U. S. Dixit, Surface alloying of aluminum with
copper using Co2 laser, Proceedings of The 5th International and 26th All
India Manufacturing Technology, Design and Research Conference, India,
December 12-14, 2014.
[5] J. Simao, H. G. Lee, D. K. Aspinwall, R. C. Dewes, E. M. Aspinwall,
Workpiece surface modification using electrical discharge machining,
International Journal of Machine Tools and Manufacture, Vol. 43, No. 2, pp.
121-128, 2003.
[6] S. Kumar, R. Singh, T. P. Singh, B. L. Sethi, Surface modification by
electrical discharge machining: A review, Journal of Materials Processing
Technology, Vol. 209, No. 8, pp. 3675-3687, 2009.
[7] Ph. Bleys, J. P. Kruth, B. Lauwers, B. Schacht, Surface and sub-surface
quality of steel after EDM, Advanced Engineering Materials, Vol. 8, No. 1,
pp.15-25, 2006.
[8] W. Jiru, M. R. Sankar, U. S. Dixit, Laser Surface alloying of copper,
manganese and magnesium with pure aluminum substrate, Journal of
Materials Engineering and performance, DOI:10.1007/s1166-016-1922-x,
2016.
[9] L. A. Mabahali, S. L. Pitiyana, N. Sacks, Laser surface alloying of Aluminum
with Ni and SiC powders, Materials and Manufacturing Processes,Vol. 25,
No. 12, pp. 1397-1403, 2010.
[10] S. Kumar, U. Batra, Surface modification of die steel materials by EDM
method using tungsten powder-mixed dielectric, Journal of Manufacturing
Processes, Vol. 14, No. 1, pp. 35-40, 2012.
[11] M. J. Mir, Kh. Sheikh, B. Singh, N. Malhotra, Modeling and analysis of
machining parameters for surface roughness in powder mixed EDM using
RSM approach, International Journal of Engineering, Science and
Technology, Vol. 4, No. 3, pp. 45-52, 2012.
[12] N. K. Khedkar, T. P. Singh, V. S. Jatti, Material migration and surface
improvement of OHNS die steel material by EDM method using tungsten
powder-mixed dielectric, WSEAS Transactions on Applied and Theoretical
Mechanics, Vol. 9, No. 1, pp. 161-166, 2014.
[13] Ph. T. Eubank, M. R. Patel, M. A. Barrufet, Theoretical models of the
electrical discharge machining process, I. A simple cathode erosion model,
Journal of Applied Physics, Vol. 66, No. 9, pp. 4095-4103, 1989.
[14] M. R. Shabgard, H. Eivazi Bagheri, A. Afsari, R. Rhamani, The study of the
input parameters on the depth of heat affected zone (HAZ) of AISI H13 steel
in electrical discharge machining process (EDM), Journal of New Materials,
Vol. 2, No. 1, pp. 23-34, 2011. (in Persian )فارسی
[15] D. Pradhan, S. C. Jayswal, Behaviour of copper and aluminium electrodes
on EDM of EN-8 alloy steel, International Journal of Engineering Science
and Technology, Vol. 3, No. 7, pp. 5492-5499, 2011.
[16] A. Descoeudres, Characterization of Electrical Discharge Machining
Plasmas, PhD Thesis, University of Lausanne, India, 2006.
[17] B. H. Yan, Y. Ch. Lin, F. Y. Huang, Ch. Wang, Surface modification of SKD
61 during EDM with metal powder in dielctric, Materials Transactions, Vol.
42, No. 12, pp. 2597-2604, 2011.
[18] H. T. Lee, F. Ch. Hsu, T. Y. Tai, Study of surface integrity using the small
area EDM process with a copper-tungesten electrode, Material Science and
Engineering, Vol. 364, No. 1, pp. 346-356, 2004.
[19] J. P. Davim, Surface Integrity In Machining, Springer, pp. 55-56, 2010
Modares Mechanical Engineering
Volume 18, Issue 1
March 2018
Pages 69-74