Mazarbhuiya, Rashed Mustafa, Kar, Siddhartha, Mohanty, Shalini and Rahang, Maneswar (2026) Altering the surface properties of Al 6061 by depositing tungsten-copper through the spark discharge process. Canadian Metallurgical Quarterly (CMQ). pp. 1-17. ISSN 0008-4433 (Print), 1879-1395 (Online) (doi:10.1080/00084433.2026.2717670)

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Abstract

This study explores the surface modification of Al 6061 using electrical discharge coating method using a tungsten-copper (W-Cu) tool (75:25 weight%) fabricated through powder metallurgy. The effect of compact load, peak current and pulse on-time on material deposition rate (MDR), tool wear rate (TWR) and surface roughness (Ra) are evaluated using Taguchi L16 orthogonal design of experiments. Desirability analysis is employed for the simultaneous optimization of MDR, TWR and Ra, wherein absolute errors of <5% are obtained for all responses at the optimum parametric conditions. The coated surfaces exhibited redeposited layers due to repeated quenching of the workpiece, which is more pronounced at higher energy discharge due to enhanced deposition. Furthermore, globules, voids, pores and cracks are observed by Field Emission Scanning Electron Microscope (FESEM) analysis on the coated surfaces, which are undesirable. Energy dispersive spectroscopy (EDS) analysis confirmed the transfer of W and Cu from the tool and carbon from the dielectric due to pyrolysis. The modified surface exhibited a 381.4% increase in microhardness compared to the base material. Wettability analysis demonstrated enhanced hydrophobic behaviour after coating with a contact angle of 129.4° and 126° for experiments 4 and 16, respectively compared to 99º of the base material.

Item Type:	Article
Additional Information:	The authors express heartfelt gratitude to NIT Meghalaya for providing the experimental facilities and to IIT Guwahati for characterisation facilities.
Uncontrolled Keywords:	coating, aluminium, electric discharge coating, EDM, Tungsten, copper, TWR, MDR
Subjects:	T Technology > T Technology (General) T Technology > TJ Mechanical engineering and machinery T Technology > TS Manufactures
Faculty / School / Research Centre / Research Group:	Faculty of Engineering & Science Faculty of Engineering & Science > School of Engineering (ENG)
Last Modified:	02 Sep 2026 14:44
URI:	https://gala.gre.ac.uk/id/eprint/54324

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