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<p>This study explores the feasibility of applying a wear-resistant chromium–copper (Cr–Cu) coating onto AISI 4340 steel, a high-strength alloy widely used in automotive and aerospace industries for its fatigue resistance and toughness. The coating process employed is electrical discharge coating (EDC) using a green compact electrode fabricated from blended Cr and Cu powders. The effects of electrode composition and process parameters on material deposition rate (MDR), coating hardness, thickness, and wear resistance were systematically evaluated. X-ray diffraction (XRD) analysis confirmed the formation of intermetallic phases such as Cr₇C₃ and Fe₃C, which increased coating hardness from 250 HV (uncoated substrate) to 1230.9 HV with the 80/20 Cr–Cu electrode. The highest MDR (1.020 mm<sup>3</sup>/min) was obtained at 8 A with the same electrode composition, whereas the maximum material removal rate ( – 1.690 mm<sup>3</sup>/min) was observed at 16 A using the 60/40 Cr–Cu electrode, indicating a transition from deposition to erosion at high discharge energy. Coating thickness in experiments ranged from 29&#xa0;µm to 148&#xa0;µm, increasing with current intensity. Wear tests revealed that greater hardness did not necessarily lead to lower wear rate. The 80/20 Cr–Cu electrode at 16 A exhibited the highest wear rate (0.35&#xa0;mg/min), while the 60/40 Cr–Cu electrode resulted in the lowest wear rate (0.07&#xa0;mg/min). These results emphasize the need for optimizing the Cr–Cu ratio to achieve a balanced combination of mechanical properties and tribological behaviour. The EDC technique demonstrated also significant potential for enhancing the surface properties of AISI 4340 steel components for demanding industrial applications.</p>

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Feasibility study of printing chromium on the surface of AISI 4340 steel using the electrical discharge process

  • 期刊论文

  • 发表日期：

    2025年9月9日

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  • Saeed Oskueyan,
  • Alireza Hajialimohammadi,
  • Vahid Abedini,
  • Rashi Tyagi

摘要

This study explores the feasibility of applying a wear-resistant chromium–copper (Cr–Cu) coating onto AISI 4340 steel, a high-strength alloy widely used in automotive and aerospace industries for its fatigue resistance and toughness. The coating process employed is electrical discharge coating (EDC) using a green compact electrode fabricated from blended Cr and Cu powders. The effects of electrode composition and process parameters on material deposition rate (MDR), coating hardness, thickness, and wear resistance were systematically evaluated. X-ray diffraction (XRD) analysis confirmed the formation of intermetallic phases such as Cr₇C₃ and Fe₃C, which increased coating hardness from 250 HV (uncoated substrate) to 1230.9 HV with the 80/20 Cr–Cu electrode. The highest MDR (1.020 mm3/min) was obtained at 8 A with the same electrode composition, whereas the maximum material removal rate ( – 1.690 mm3/min) was observed at 16 A using the 60/40 Cr–Cu electrode, indicating a transition from deposition to erosion at high discharge energy. Coating thickness in experiments ranged from 29 µm to 148 µm, increasing with current intensity. Wear tests revealed that greater hardness did not necessarily lead to lower wear rate. The 80/20 Cr–Cu electrode at 16 A exhibited the highest wear rate (0.35 mg/min), while the 60/40 Cr–Cu electrode resulted in the lowest wear rate (0.07 mg/min). These results emphasize the need for optimizing the Cr–Cu ratio to achieve a balanced combination of mechanical properties and tribological behaviour. The EDC technique demonstrated also significant potential for enhancing the surface properties of AISI 4340 steel components for demanding industrial applications.