Title: Experimental study of surface modification of aluminium 7075 alloy by reverse EDM process using SiC-Cu powder metallurgy green compact electrode and Taguchi experimental design

Authors: Lokesh Kumar Ranjan; Sujoy Chakraborty; Uttam Kumar Mandal

Addresses: Department of Production Engineering, NIT Agartala, Tripura, 799046, India ' Department of Production Engineering, NIT Agartala, Tripura, 799046, India ' Department of Production Engineering, NIT Agartala, Tripura, 799046, India

Abstract: In this work, an attempt has been made to alter the surface of Al-7075 substrate using SiC and Cu powder mixed electrodes in Die sink EDM. Experiments have been carried out using Taguchi L-9 orthogonal array. There are three input parameters in this experiment like compaction load, peak current, and tool composition. Analysis of variance (ANOVA) and main effect analysis have also been performed for the output responses like material deposition rate (MDR), tool wear rate (TWR) and surface roughness (SR) respectively. Material deposition rate of 0.385 (mg/min), tool wear rate of 4.37 (mg/min), average surface roughness of 2.101 (μm) and average layer thickness of 25.01 μm have been successfully achieved. Furthermore, examining the nature of surface geology; scanning electron microscope (SEM), energy dispersive spectrometer (EDS) and X-Ray diffraction (XRD) analysis have also been performed which supports the transfer of tool ingredients over work piece samples with enhanced surface characteristics.

Keywords: electro-discharge coating; EDC; powder metallurgy; P/M; green compact electrode; Taguchi design; surface geology.

DOI: 10.1504/IJMMM.2023.136026

International Journal of Machining and Machinability of Materials, 2023 Vol.25 No.3/4, pp.315 - 328

Received: 10 Feb 2023
Accepted: 09 May 2023
Published online: 12 Jan 2024 *

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