Fundamental Research on the Structure and Properties of Electroerosion-Resistant Coatings on Copper

The electroerosion-resistant coatings of CuO–Ag and ZnO–Ag systems were obtained on the Cu surface. The formation of the coating was caused by the processing of copper surface with a plasma formed in the electrical explosion of silver foil with a weighed sample of copper oxide or zinc oxide. After electroexplosion spraying, the electron-beam treatment of coatings was performed. The nanohardness, Young modulus, wear resistance, friction coefficient, and electrical erosion resistance of the formed coatings were studied. All studied properties exceed those of copper. Electrical erosion coatings were studied by the methods of scanning electron microscopy, transmission electron microscopy, and atomic force microscopy. It became possible to achieve the high level of operational properties of electrical erosion coatings due to their nanostructurization. Structure of coating is formed by cells of high-speed crystallization. The size of cells varies within the range from 150 nm to 400 nm. The cells are separated by interlayers of the second phase whose thickness varies as 15–50 nm. By method of atomic force microscopy, the separate particles of ZnO or CuO of different shapes and 10–15 nm in size chaotically located in silver matrix were revealed as well as spherical particles of ZnO or CuO in size of 2–5 nm. The total thickness of coatings is 60 μm. The complex of studies we have carried out permits to recommend the integrated processing for strengthening the switch copper contacts of powerful electrical networks.

Elemental and Thermochemical Analyses of Materials after Electrical Discharge Machining in Water: Focus on Ni and Zn

The mechanism of the material destruction under discharge pulses and material removal mechanism based on the thermochemical nature of the electrical erosion during electrical discharge machining of conductive materials were researched. The experiments were conducted for two structural materials used in the aerospace industry, namely austenite anticorrosion X10CrNiTi18-10 (12kH18N10T) steel and 2024 (D16) duralumin, machined by a brass tool of 0.25 mm in diameter in a deionized water medium. The optimized wire electrical discharge machining factors, measured discharge gaps (recommended offset is 170–175 µm and 195–199 µm, respectively), X-ray photoelectron spectroscopy for both types of materials are reported. Elemental analysis showed the presence of metallic Zn, CuO, iron oxides, chromium oxides, and 58.07% carbides (precipitation and normal atmospheric contamination) for steel and the presence of metallic Zn, CuO, ZnO, aluminum oxide, and 40.37% carbides (contamination) for duralumin. For the first time, calculating the thermochemistry parameters for reactions of Zn(OH)2, ZnO, and NiO formation was produced. The ability of Ni of chrome–nickel steel to interact with Zn of brass electrode was thermochemically proved. The standard enthalpy of the Ni5Zn21 intermetallic compound formation (erosion dust) ΔH0298 is −225.96 kJ/mol; the entropy of the crystalline phase Scint is 424.64 J/(mol·K).

Wire Tool Electrode Behavior and Wear under Discharge Pulses

This work is devoted to researching the tool electrode behavior and wear under discharge pulses at electrical discharge machining. The experiments were conducted on the workpieces of 12Kh18N10T (AISI 321) chrome-nickel anti-corrosion steel and D16 (AA 2024) duralumin by a 0.25-mm-diameter CuZn35 brass tool in a deionized water medium. The developed diagnostic and monitoring mean based on acoustic emission registered the oscillations accompanying machining at 4–8 kHz. The obtained workpiece and non-profiled tool surfaces were investigated by optical and scanning electron microscopy. Calculated volumetric and mass removal rates showed the difference in the character of wear at roughing and finishing. It was shown that interaction between material components in anti-corrosion steel machining had an explosive character between Zn of brass and Ni of steel at a micron level and formed multiple craters of 30–100 µm. The secondary structure and topology of worn tool surfaces were caused by material sublimation, chemical interaction between material components at high heat (10,000 °C), explosive deposition of the secondary structure. Acoustic diagnostics adequately registered the character of interaction. The observed phenomena at the submicron level and microstructure of the obtained surfaces provide grounding on the nature of material interactions and electrical erosion wear fundamentals.

Machining Characteristics of IN718 by EDM with Cooled Electrode and Vibration of the Workpiece

Inconel718 has been widely used in various fields for its good performance, but it is difficult to machine with traditional machining methods. Electrical discharge machining is an alternative competitive process to machine Nickel-based alloys by electrical erosion. In order to improve reduce the electrode loss and improve the machining efficiency, the horizontal ultrasonic vibration of the workpiece and the cryogenic cooling of the tool electrode were applied into the EDM process. Material removal efficiency, surface roughness, surface topography, and microhardness have been characterized.