AN ENHANCEMENT IN THE COPPER ELECTRODE WEAR CHARACTERISTIC ELECTRICAL DISCHARGE MACHINED INCONEL 718 THROUGH ION NITRIDING, LASER SURFACE HARDENING AND HYBRID PROCESS

S. Dhanabalan (), D. Raj Kumar (), N. Jeyaprakash, M. Satheesh Kumar () and Hitesh Vasudev ()
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S. Dhanabalan: Department of Mechanical Engineering, M. Kumarasamy College of Engineering, Karur 639113, Tamil Nadu, India
D. Raj Kumar: ��Department of Mechanical Engineering, Sri Ramakrishna College Of Engineering, Perambalur 621113, Tamil Nadu, India
N. Jeyaprakash: ��School of Mechanical and Electrical Engineering, China University of Mining and Technology, Xuzhou 221116, P. R. China
M. Satheesh Kumar: Department of Mechanical Engineering, M. Kumarasamy College of Engineering, Karur 639113, Tamil Nadu, India
Hitesh Vasudev: �School of Mechanical Engineering, Lovely Professional University, Phagwara 144411, Punjab, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 06, 1-12

Abstract: The virgin copper electrode has limited application due to its wear and mechanical properties using Electrical Discharge Machined (EDMed) on Inconel 718 superalloys. In order to enhance the performance of copper electrodes, in this work, Ion Nitriding (IN), Surface Hardening by Laser (LSH) and Hybrid Process (IN+LSH) are performed on copper electrodes to reduce the electrode wear in frontal and lateral. The electrode wear in the frontal and lateral of virgin copper electrode is processed and studied using EDM with varying pulse durations, current and Silicon Carbide (SiC) mixed EDM oil. The surface hardness in virgin and processed electrodes is also investigated. Overall analysis found that the hybrid technique produced a 59% higher hardness than that of virgin copper. The hardness in the EDMed surface was higher than that of the processed copper surface. A 1000μs pulse duration, 2 A current and 15 g/l SiC powder mixing EDM oil produced a low frontal wear in both virgin and processed copper electrodes. The electrode wear was reduced by 30% for frontal and 76% for lateral using a hybrid method.

Keywords: EDM; Â copper; ion nitriding; surface hardening by laser; hybrid process (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X24400018

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