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<p>Powder-mixed electric discharge machining is the most widely used nonconventional machining process for simultaneous machining and surface property improvement of hard to machine substances. This work made an attempt on the surface modification of the work horse of titanium alloy Ti-6Al-4V, which possesses low wear resistance and high wettability, by the use of Ti<sub>2</sub>CN powder-mixed reverse polarity EDM called as&#xa0;electric discharge coating (EDC). EDC makes use of the inherent property of EDM, the recast layer (RCL) formation and electrophoresis deposition (cataphoresis). An average RCL thickness of 35&#xa0;µm (Max. 60&#xa0;µm) is observed by the cross-sectional analysis with SEM. Surfaces with lower defects, crack density (68&#xa0;×&#xa0;10<sup>−4</sup>&#xa0;μm/μm<sup>2</sup>) and little/lower residual stress compared to EDM-processed parts are formed. The presence of TiO, TiC, TiN and TiC<sub>0.3</sub>N<sub>0.7</sub> are revealed with XRD and XPS analysis. A reduction in SR (<i>S</i><sub>a</sub> approximately 1.3&#xa0;μm) compared to conventionally processed parts and EDM-processed parts is observed. Variation in wettability of the processed parts with the variation in roughness factor is also analyzed and hydrophilic to hydrophobic transformation (50°-100° CA) with reduction in SR and with the presence of oxides is observed. Reduction in specific wear rate (~in the order of 10<sup>−5</sup> mm<sup>3</sup>/Nm), COF (0.2-0.3) and friction factor (6-9&#xa0;N) with the presence of titanium carbides, protective oxides and increased HAZ were observed for the substrate processed under specified parametric conditions.</p> Graphical Abstract <p></p>

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Surface Modification of Ti-6Al-4V with Surface Roughness, Wettability and Wear Analysis Using Titanium Carbonitride Powder-Mixed Electric Discharge Process

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • N. V. Prajina,
  • J. Mathew,
  • B. Kuriachen

摘要

Powder-mixed electric discharge machining is the most widely used nonconventional machining process for simultaneous machining and surface property improvement of hard to machine substances. This work made an attempt on the surface modification of the work horse of titanium alloy Ti-6Al-4V, which possesses low wear resistance and high wettability, by the use of Ti2CN powder-mixed reverse polarity EDM called as electric discharge coating (EDC). EDC makes use of the inherent property of EDM, the recast layer (RCL) formation and electrophoresis deposition (cataphoresis). An average RCL thickness of 35 µm (Max. 60 µm) is observed by the cross-sectional analysis with SEM. Surfaces with lower defects, crack density (68 × 10−4 μm/μm2) and little/lower residual stress compared to EDM-processed parts are formed. The presence of TiO, TiC, TiN and TiC0.3N0.7 are revealed with XRD and XPS analysis. A reduction in SR (Sa approximately 1.3 μm) compared to conventionally processed parts and EDM-processed parts is observed. Variation in wettability of the processed parts with the variation in roughness factor is also analyzed and hydrophilic to hydrophobic transformation (50°-100° CA) with reduction in SR and with the presence of oxides is observed. Reduction in specific wear rate (~in the order of 10−5 mm3/Nm), COF (0.2-0.3) and friction factor (6-9 N) with the presence of titanium carbides, protective oxides and increased HAZ were observed for the substrate processed under specified parametric conditions.

Graphical Abstract