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Electro Discharge Machining (EDM) is a widely used non-traditional machining process for manufacturing complex geometries in hard-to-machine materials such as Ti-6Al-4V, Inconel, and tungsten carbide. However, challenges such as high tool wear, poor surface finish, and low material removal efficiency limit its effectiveness. The Implementing thin-film coatings on EDM tool electrodes has emerged as a promising solution to enhance machining performance. This review examines the effects of several thin-film coatings on important performance metrics such as surface integrity, tool wear rate (TWR), and material removal rate (MRR). These coatings include titanium nitride (TiN), aluminum chromium nitride (AlCrN), diamond-like carbon (DLC), graphene, and carbon nanotubes (CNT). Furthermore, the impact physical vapor deposition (PVD) and chemical vapor deposition (CVD), two types of deposition techniques on coating efficacy and uniformity is examined. The review also discusses recent advancements in multilayer and nanocomposite coatings, highlighting their potential to further optimize EDM processes. Finally, future research directions are identified, emphasizing the need for advanced coating materials and deposition technologies to enhance electrode durability and EDM efficiency.

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A Comprehensive Review on Thin-Film Coated Tool Electrodes for Enhanced Electrical Discharge Machining (EDM) Performance

  • 会议论文

  • 发表日期：

    2026年

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  • Shailesh Shirguppikar,
  • Vinay Choudhari,
  • Phan Nguyen Huu,
  • Vaibhav Ganachari,
  • Pankaj Gavali,
  • Amol S. Todkar

摘要

Electro Discharge Machining (EDM) is a widely used non-traditional machining process for manufacturing complex geometries in hard-to-machine materials such as Ti-6Al-4V, Inconel, and tungsten carbide. However, challenges such as high tool wear, poor surface finish, and low material removal efficiency limit its effectiveness. The Implementing thin-film coatings on EDM tool electrodes has emerged as a promising solution to enhance machining performance. This review examines the effects of several thin-film coatings on important performance metrics such as surface integrity, tool wear rate (TWR), and material removal rate (MRR). These coatings include titanium nitride (TiN), aluminum chromium nitride (AlCrN), diamond-like carbon (DLC), graphene, and carbon nanotubes (CNT). Furthermore, the impact physical vapor deposition (PVD) and chemical vapor deposition (CVD), two types of deposition techniques on coating efficacy and uniformity is examined. The review also discusses recent advancements in multilayer and nanocomposite coatings, highlighting their potential to further optimize EDM processes. Finally, future research directions are identified, emphasizing the need for advanced coating materials and deposition technologies to enhance electrode durability and EDM efficiency.