Through hole making by electro-discharge machining on Inconel 625 super alloy using hollow copper tool electrode

2018 ◽  
Vol 233 (2) ◽  
pp. 348-370 ◽  
Author(s):  
Dileep Kumar Mishra ◽  
▪ Rahul ◽  
Saurav Datta ◽  
Manoj Masanta ◽  
Siba Sankar Mahapatra
Keyword(s):  
Matrix Material ◽  
Inconel 625 ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
X Ray ◽  
Work Surface ◽  
Electro Discharge Machining ◽  
Hole Making ◽  
Through Hole ◽  
Super Alloy

A case experimental research on through hole making process on Inconel 625 super alloy by using hollow (tubular) copper tool electrode in electro-discharge machining has been delineated herein. Based on three controllable process variables namely peak discharge current, pulse-on duration, and gap voltage, experiments on through hole making have been carried out following the electro-discharge machining route (die-sinking electro-discharge machining without flushing). In addition to surface morphology, topographical features of the electro-discharge machined work surface have been examined for both internal cylindrical surface of the hole produced and also the external peripheral surface of the removed cylindrical part. The influence of the process parameters have been analyzed on various process performance features like material removal rate, surface roughness, surface crack density, white layer thickness, circularity, radial overcut, and hole taper. An optimal parameter setting has been identified for sound hole making and thereby to improve electro-discharge machining performance. Additionally, energy-dispersive X-ray spectroscopic analysis has been carried out to investigate the extent of carbon enrichment onto the electro-discharge machined work surface of Inconel 625 as affected by the pyrolysis of the dielectric fluid whilst executing electro-discharge machining operation. X-ray diffraction tests have been carried out to compare metallurgy of the electro-discharge machined work surface (various phases/precipitates present in bulk of the matrix material, extent of grain refinement, crystallite size, strain, and dislocation density) with respect to that of “as received” Inconel 625. Results, thus obtained, have also been compared to that of the micro-hardness test data.

Micro-EDM Deposition Alloying Process

2004 ◽  
Author(s):  
Ricardo I. Ori ◽  
Fumihiro Itoigawa ◽  
Shinya Hayakawa ◽  
Takashi Nakamura ◽  
Shun-ichiro Tanaka
Keyword(s):  
Electrical Discharge ◽  
Metal Electrode ◽  
Medium Carbon Steel ◽  
Tool Electrode ◽  
Micro Edm ◽  
Cross Sectional ◽  
Medium Carbon ◽  
X Ray ◽  
Work Surface ◽  
Eds Analysis

A new deposition alloying process using Micro-EDM was developed. Using the energy released by the electrical discharge, material from the tool electrode is melted and deposited over the work surface. When a rotating bi-metal tool electrode is fed towards the work surface, the alloying between its elements occurs during process. The obtained results of the alloying between nickel and iron are presented in the present paper, when the components of the bi-metal tool electrode are made of YNi-1 (nickel alloy used in TIG welding — JIS standard) and medium carbon steel (S45C — JIS standard). X-ray and EDS analysis have shown that the chemical composition of the obtained deposit can be controlled and is proportional to the cross sectional area of each element present in the bi-metal electrode. With this process, a material with the same composition of Invar was successfully deposited.

EDM with USM Combination Process of Sintered NdFeB Permanent Magnet

2010 ◽  
Vol 44-47 ◽  
pp. 1066-1069
Author(s):  
Li Li ◽  
Li Ling Qi ◽  
Zong Wei Niu
Keyword(s):  
Permanent Magnet ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Dielectric Fluid ◽  
Machined Surface ◽  
Combination Process ◽  
Electro Discharge Machining ◽  
Ndfeb Permanent Magnet ◽  
Machining Characteristics

This paper presents an experimental investigation of the machining characteristics of sintered NdFeB permanent magnet using a combination process of electro-discharge machining (EDM) with ultrasonic machining (USM). Concentration of abrasive in the dielectric fluid is changed to explore its effect on the material removal rate (MRR). MRR of EDM /USM, conventional EDM are compared, machined surface characteristics are also compared between them. It is concluded that the combination EDM/USM process can increase the MRR and decrease the thickness of the recast layer. In the combination process, an appropriate abrasive concentration can improve its machining efficiency.

Electrical Discharge Coating by Copper-Tungsten Composite Electrode Prepared by Powder Metallurgy Route

2018 ◽  
pp. 195-224 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Harmony Search ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Weight Percentage ◽  
Material Deposition ◽  
Edm Process ◽  
Powder Metallurgy Route

Electrical discharge machining (EDM), a thermo-mechanical machining process, is used in producing complicated intrinsic cavity in difficult-to- machine materials with excellent surface finish. One of the major disadvantage of EDM process is the tool wear, which can be used advantageously for coating purpose. Coating is a unique method of EDM process by the use of electrode prepared via powder metallurgy route. Copper and tungsten powders in weight percentage of 30 and 70 respectively are used for the preparation of the tool electrode by varying the PM process parameters like compaction pressure and sintering temperature. The substrate on which coating is made is chosen as AISI 1040 stainless steel with EDM oil as the dielectric fluid. During coating, influence of parameters like discharge current, duty cycle and pulse-on-time on material deposition rate, tool wear rate and radial under deposition are studied. To find out the best parametric combination Grey Relational Analysis method combined with Harmony Search algorithm has been employed.

scholarly journals Material Characterization of Magnetorheological Elastomers with Corroded Carbonyl Iron Particles: Morphological Images and Field-dependent Viscoelastic Properties

2019 ◽  
Vol 20 (13) ◽  
pp. 3311 ◽  
Author(s):  
Siti Aishah Binti Abdul Aziz ◽  
Saiful Amri Mazlan ◽  
Nur Azmah Nordin ◽  
Nor Azlin Nazira Abd Rahman ◽  
U Ubaidillah ◽  
...  
Keyword(s):  
Carbonyl Iron ◽  
Matrix Material ◽  
Rheological Characteristics ◽  
Iron Particles ◽  
Ambient Conditions ◽  
X Ray ◽  
Field Dependent ◽  
Mr Effect

High temperatures and humidity could alter the field-dependent rheological properties of MR materials. These environmental phenomena may accelerate the deterioration processes that will affect the long-term rheological reliability of MR materials such as MR elastomer (MRE). This study therefore attempts to investigate the field-dependent rheological characteristics of MRE with corroded carbonyl iron particles (CIPs). The corroded CIPs were treated with hydrochloric acid (HCl) as a way of providing realistic environments in gauging the CIPs reaction towards the ambient conditions. The corroded CIPs along with silicone rubber as a matrix material were used in the fabrication of the MRE samples. To observe the effect of HCl treatment on the CIPs, the morphological observations of MREs with non-corroded and corroded CIPs were investigated via field emission scanning electron microscopy (FESEM), energy-dispersive x-ray spectroscopy (EDX) and x-ray diffractometer (XRD). In addition, the magnetic properties were examined through the vibrating sample magnetometer (VSM), while the field-dependent rheological characteristics such as the storage modulus of MRE with the corroded CIPs were also tested and compared with the non-corroded CIPs. The results showed that the corroded CIPs possessed hydrangea-like structures. In the meantime, it was identified that a sudden reduction of up to 114% of the field-dependent MR effect of MRE with the corroded CIPs was observed as a result of the weakened interfacial bonding between the CIPs and the silicon in the outer layers of the CIPs structure.

Employing X-ray scattering to characterize materials with grain sizes in the nano-regime

2008 ◽  
Vol 23 (2) ◽  
pp. 96-100 ◽  
Author(s):  
E. A. Laitila ◽  
D. E. Mikkola
Keyword(s):  
Crystallite Size ◽  
Large Fraction ◽  
Matrix Material ◽  
Background Intensity ◽  
X Ray ◽  
Volume Fractions ◽  
X Ray Scattering ◽  
The Matrix ◽  
Diffraction Peaks ◽  
Ray Scattering

This study focuses on characterization of an (Al,Cr)3Ti alloy processed together with titanium powder by reactive mechanical milling (RMM) to produce an ultrafine grained intermetallic alloy matrix with in situ carbide and hydride phases formed during processing. Observations of X-ray scattering as RMM processing time increases show severe broadening of matrix diffraction peaks, accompanied by the appearance of diffraction peaks resulting from the formation of very small crystallites of TiC and TiH1.92 phases with increasing volume fractions, and finally, increasing background intensity as the crystallite size of the matrix phase decreases to ∼2 nm. Estimates of phase volume fractions were made by the direct comparison method, along with crystallite sizes by Warren–Averbach peak profile analysis. The general increase in background intensities has been attributed to random static displacements of the large fraction of atoms located within the grain boundary regions. Further, it has been concluded that the matrix material with a crystallite size of a few nanometers has about half the atoms in statically displaced positions defining the boundary regions. The results argue that background intensity changes should not be ignored and are useful in interpreting scattering from these nano-scale materials.

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