<p>The present research investigates the performance of mild steel (MS), copper (Cu), and tungsten copper (WCu) form tools in fabricating large-area micro-textured surfaces, alongside the optimization of EDM parameters for surface texturing. The WCu tool electrode achieved the highest form accuracy, producing uniform, sharp-edged micro-pillars, followed by Cu and MS electrodes. The lower form accuracy of the MS tool leads to a higher overcut in the MS-textured surface and reduced interspacing, resulting in increased textured density. The overcut in the cavities is <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="11665_2025_11997_Article_IEq1.gif" Format="GIF" Height="6" Rendition="HTML" Resolution="72" Type="Linedraw" Width="17" /> </InlineMediaObject> <EquationSource Format="TEX">$\sim$</EquationSource> <EquationSource Format="MATHML"><math> <mo>∼</mo> </math></EquationSource> </InlineEquation> 50 ± 15, <InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="11665_2025_11997_Article_IEq1.gif" Format="GIF" Height="6" Rendition="HTML" Resolution="72" Type="Linedraw" Width="17" /> </InlineMediaObject> <EquationSource Format="TEX">$\sim$</EquationSource> <EquationSource Format="MATHML"><math> <mo>∼</mo> </math></EquationSource> </InlineEquation> 75 ± 20, and <InlineEquation ID="IEq3"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="11665_2025_11997_Article_IEq1.gif" Format="GIF" Height="6" Rendition="HTML" Resolution="72" Type="Linedraw" Width="17" /> </InlineMediaObject> <EquationSource Format="TEX">$\sim$</EquationSource> <EquationSource Format="MATHML"><math> <mo>∼</mo> </math></EquationSource> </InlineEquation> 110 ± 20 µm for WCu, Cu, and MS tools, respectively. MS-textured surfaces exhibited the roughest morphology, with uneven recast material deposition with high frequency, micro-cracks, pockmarks, and voids, further reducing the patterned surfaces' hydrophobicity. XRD analysis indicates tensile residual stress, microstrain, crystallite size reduction, stable oxide layer, and carbide formation on patterned surfaces. The MS-textured surface exhibited the highest corrosion resistance, with a corrosion rate (CR) of 0.00918 mm/year, compared to the Cu- and WCu-textured surfaces, which showed CR values of 0.01994 and 0.02773 mm/year, respectively. Additionally, the MS-textured surface demonstrated the lowest wear rate and coefficient of friction (COF), recording a wear rate of 0.001138 mm<sup>3</sup>/m and a COF of 0.433.</p>

Performance Evaluation of Various Tool Materials and Electrical Discharge Machining Parameters for Fabrication of Large-Area Micro-textured Surfaces

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发表日期：

2025年9月5日

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Ranajit Mahanti,
Rahul Singh,
Manas Das

摘要

The present research investigates the performance of mild steel (MS), copper (Cu), and tungsten copper (WCu) form tools in fabricating large-area micro-textured surfaces, alongside the optimization of EDM parameters for surface texturing. The WCu tool electrode achieved the highest form accuracy, producing uniform, sharp-edged micro-pillars, followed by Cu and MS electrodes. The lower form accuracy of the MS tool leads to a higher overcut in the MS-textured surface and reduced interspacing, resulting in increased textured density. The overcut in the cavities is $\sim$ $\sim$ 50 ± 15, $\sim$ $\sim$ 75 ± 20, and $\sim$ $\sim$ 110 ± 20 µm for WCu, Cu, and MS tools, respectively. MS-textured surfaces exhibited the roughest morphology, with uneven recast material deposition with high frequency, micro-cracks, pockmarks, and voids, further reducing the patterned surfaces' hydrophobicity. XRD analysis indicates tensile residual stress, microstrain, crystallite size reduction, stable oxide layer, and carbide formation on patterned surfaces. The MS-textured surface exhibited the highest corrosion resistance, with a corrosion rate (CR) of 0.00918 mm/year, compared to the Cu- and WCu-textured surfaces, which showed CR values of 0.01994 and 0.02773 mm/year, respectively. Additionally, the MS-textured surface demonstrated the lowest wear rate and coefficient of friction (COF), recording a wear rate of 0.001138 mm³/m and a COF of 0.433.