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<p>Electrical Discharge Coating (EDC) is a promising technique for enhancing surface properties such as hardness, wear resistance, and corrosion resistance. In this study, green compact electrodes composed of chromium (Cr) and copper (Cu) powders in 60/40, 70/30, and 80/20 wt% ratios were used to coat AISI 4340 steel. The effects of electrode composition and peak current (4–16&#xa0;A) on Material Deposition Rate (MDR), coating thickness, and surface hardness were systematically investigated using a factorial experimental design. Statistical analysis through ANOVA and regression modeling revealed that the combination of 70% Cr and 30% Cu with a peak current of 8&#xa0;A achieved optimal performance, yielding a high MDR (0.70&#xa0;mm³/min), uniform coating thickness (46.25&#xa0;μm), and enhanced hardness (1008 HV). The strong predictive capability of the developed regression models was further confirmed through external validation experiments, which showed less than 5% deviation between predicted and measured values under the optimized conditions. X-ray Diffraction (XRD) analysis confirmed the formation of Cr₇C₃ and Fe₃C phases, while morphological studies showed dense and uniform microstructures without noticeable void formation. The coatings demonstrated significantly enhanced hardness (up to 1008 HV), formation of carbide phases (Cr₇C and Fe₃C), and dense microstructures, all of which are established indicators of improved wear protection. This approach offers a sustainable and scalable surface treatment method for components in automotive, aerospace, and tooling industries.</p>

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Statistical optimization of Cr–Cu green compact electrode parameters in the electrical discharge coating of AISI 4340 steel

  • 期刊论文

  • 发表日期：

    2026年2月5日

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

摘要

Electrical Discharge Coating (EDC) is a promising technique for enhancing surface properties such as hardness, wear resistance, and corrosion resistance. In this study, green compact electrodes composed of chromium (Cr) and copper (Cu) powders in 60/40, 70/30, and 80/20 wt% ratios were used to coat AISI 4340 steel. The effects of electrode composition and peak current (4–16 A) on Material Deposition Rate (MDR), coating thickness, and surface hardness were systematically investigated using a factorial experimental design. Statistical analysis through ANOVA and regression modeling revealed that the combination of 70% Cr and 30% Cu with a peak current of 8 A achieved optimal performance, yielding a high MDR (0.70 mm³/min), uniform coating thickness (46.25 μm), and enhanced hardness (1008 HV). The strong predictive capability of the developed regression models was further confirmed through external validation experiments, which showed less than 5% deviation between predicted and measured values under the optimized conditions. X-ray Diffraction (XRD) analysis confirmed the formation of Cr₇C₃ and Fe₃C phases, while morphological studies showed dense and uniform microstructures without noticeable void formation. The coatings demonstrated significantly enhanced hardness (up to 1008 HV), formation of carbide phases (Cr₇C and Fe₃C), and dense microstructures, all of which are established indicators of improved wear protection. This approach offers a sustainable and scalable surface treatment method for components in automotive, aerospace, and tooling industries.