A Comparative Study of Copper and Copper-Coated WC Electrodes Using Electrical Discharge Machining for the Surface Alloying of Ti-Alloy
摘要
A non-traditional machining method that is frequently used for precise cutting and surface modification of advanced materials is electro discharge machining (EDM). A comparison of pure copper and WC (tungsten carbide) copper-coated electrodes in EDM for titanium (Ti) alloy surface alloying is presented in this work. Under the same machining settings, the study examines how various electrodes affect surface properties, material transfer, and alloying efficiency. According to experimental findings, Cu-WC electrodes greatly increase alloying depth, wear resistance, and surface hardness because they provide better material transfer and the development of a reinforced surface layer. The coated electrode's tungsten carbide particles help tungsten diffuse into the titanium alloy, which encourages the creation of hard intermetallic compounds. On the other hand, pure copper electrodes show little improvement in surface characteristics and a poorer alloying efficiency. EDS and SEM microstructural investigation validates the development of a modified surface layer enriched with carbon, copper, and tungsten. When compared to pure copper electrodes, Cu-WC electrodes yield a more consistent and polished surface finish, according to surface roughness measurements. The study concludes that Cu-WC electrodes offer superior performance in EDM surface alloying of Ti alloys, making them a promising choice for enhancing the wear and mechanical properties of titanium-based components in aerospace, biomedical, and automotive applications.