This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface wi...This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.展开更多
A new process was used for producing FeAl alloy pow de rs with double consumable rotating electrodes and the powders made in this appar atus were analyzed. In this new technology, tungsten rod serves as a cathode ele ...A new process was used for producing FeAl alloy pow de rs with double consumable rotating electrodes and the powders made in this appar atus were analyzed. In this new technology, tungsten rod serves as a cathode ele ctrode, while the alloy rod as an anode electrode. The conventional rotating ele ctrode process must have an anode with pre-melting alloys; however, in this new process, using pure iron as cathode electrode and pure aluminum as anode electr ode can eliminate the step of pre-melting. The effects of process variables, which include electrode rotational speed, a nd electrode diameter of the mean particle diameter were determined. Results showed that both the rotational speed and diameter of electrodes would a ffect the mean diameter of particles. There are three kinds of powders with diff erent composition produced in this study and the possible mechanisms are discuss ed. The process parameters and volume mean diameter of the powders have been cor related to find an experimental equation. The results show that when the rotational speed and the diameter of the anode el ectrode are increased, the powders size will decrease. However, the powders size will increase with cathode electrode.展开更多
文摘This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.
文摘A new process was used for producing FeAl alloy pow de rs with double consumable rotating electrodes and the powders made in this appar atus were analyzed. In this new technology, tungsten rod serves as a cathode ele ctrode, while the alloy rod as an anode electrode. The conventional rotating ele ctrode process must have an anode with pre-melting alloys; however, in this new process, using pure iron as cathode electrode and pure aluminum as anode electr ode can eliminate the step of pre-melting. The effects of process variables, which include electrode rotational speed, a nd electrode diameter of the mean particle diameter were determined. Results showed that both the rotational speed and diameter of electrodes would a ffect the mean diameter of particles. There are three kinds of powders with diff erent composition produced in this study and the possible mechanisms are discuss ed. The process parameters and volume mean diameter of the powders have been cor related to find an experimental equation. The results show that when the rotational speed and the diameter of the anode el ectrode are increased, the powders size will decrease. However, the powders size will increase with cathode electrode.
