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<p>AISI H13 tool steel is used in mold and die applications where surface integrity and corrosion resistance are critical. This study evaluates electrical discharge machining (EDM) to enhance these properties by analyzing the effects of peak current and duty factor. The MRR increased from 0.15 to 0.18&#xa0;g/h at 3 A to nearly 0.50&#xa0;g/h at 9 A, while the EWR showed the opposite trend, demonstrating the balance between productivity and tool preservation. At 6 A, surface hardness reached 580-590 HV, with minimal variation across the tested range. Areal surface roughness (Sa) increased by about one-third across the current settings, providing a more accurate representation of surface topography than Ra. After EDM, corrosion resistance improved significantly, with corrosion current and corrosion rate decreasing by up to&#xa0;98%, indicating enhanced electrochemical stability. EDS revealed modified elemental distribution in the recast layer due to melting and rapid solidification, while XRD showed thermally influenced phases linked to improved corrosion performance. Response surface methodology identified a global optimum at 7.24 A and 15% duty factor. Overall, EDM improved hardness, corrosion resistance, and surface integrity, showing predictable response trends suitable for mold applications.</p>

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Corrosion and Surface Integrity Enhancement of AISI H13 Tool Steel via Electrical Discharge Machining

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • B. Karthik,
  • Basil Kuriachen,
  • Vikash Kumar

摘要

AISI H13 tool steel is used in mold and die applications where surface integrity and corrosion resistance are critical. This study evaluates electrical discharge machining (EDM) to enhance these properties by analyzing the effects of peak current and duty factor. The MRR increased from 0.15 to 0.18 g/h at 3 A to nearly 0.50 g/h at 9 A, while the EWR showed the opposite trend, demonstrating the balance between productivity and tool preservation. At 6 A, surface hardness reached 580-590 HV, with minimal variation across the tested range. Areal surface roughness (Sa) increased by about one-third across the current settings, providing a more accurate representation of surface topography than Ra. After EDM, corrosion resistance improved significantly, with corrosion current and corrosion rate decreasing by up to 98%, indicating enhanced electrochemical stability. EDS revealed modified elemental distribution in the recast layer due to melting and rapid solidification, while XRD showed thermally influenced phases linked to improved corrosion performance. Response surface methodology identified a global optimum at 7.24 A and 15% duty factor. Overall, EDM improved hardness, corrosion resistance, and surface integrity, showing predictable response trends suitable for mold applications.