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<p>This study explores Dry Electro Discharge Coating (DEDC) on Al-6061 alloy using a zirconia–copper green compact electrode in nitrogen, argon, and air environments. Material Deposition Rate (MDR), surface roughness (SR), and surface morphology were evaluated to assess coating performance. Key process parameters—compaction load, peak current pulse-on time (Ton), and Cu:Zr composition—were systematically varied. MDR and SR quantified coating efficiency and surface quality, while SEM analysis revealed microstructural features and adhesion characteristics. Nitrogen showed the most consistent results, delivering superior MDR and surface finish at moderate compaction loads with a balanced T<sub>on</sub>–T<sub>off</sub> ratio. Argon improved wear resistance through better energy dispersion, whereas air yielded the lowest MDR but enhanced microstructural properties due to rapid cooling. The findings demonstrate DEDC’s adaptability for optimizing coating adhesion, uniformity, and mechanical performance, with promising applications in automotive, aerospace, and industrial components requiring tailored surface properties.</p>

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Influence of Gaseous Dielectric Environments on Dry Electro Discharge Coating of Al 6061 Alloy with Zirconia–Copper Electrodes

  • 期刊论文

  • 发表日期：

    2026年1月27日

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  • Panna Goswami,
  • Sujoy Chakraborty,
  • Vidyut Dey,
  • Debashis Podder

摘要

This study explores Dry Electro Discharge Coating (DEDC) on Al-6061 alloy using a zirconia–copper green compact electrode in nitrogen, argon, and air environments. Material Deposition Rate (MDR), surface roughness (SR), and surface morphology were evaluated to assess coating performance. Key process parameters—compaction load, peak current pulse-on time (Ton), and Cu:Zr composition—were systematically varied. MDR and SR quantified coating efficiency and surface quality, while SEM analysis revealed microstructural features and adhesion characteristics. Nitrogen showed the most consistent results, delivering superior MDR and surface finish at moderate compaction loads with a balanced Ton–Toff ratio. Argon improved wear resistance through better energy dispersion, whereas air yielded the lowest MDR but enhanced microstructural properties due to rapid cooling. The findings demonstrate DEDC’s adaptability for optimizing coating adhesion, uniformity, and mechanical performance, with promising applications in automotive, aerospace, and industrial components requiring tailored surface properties.