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<p>This study investigates the dry electro-discharge coating (DEDC) process on Al6061 alloy using a copper-graphene green compact electrode in an argon dielectric medium. The process parameters considered include discharge current (Ip) ranging from 4 to 10&#xa0;A, pulse-on time (Ton) ranging from 50 to 200&#xa0;µs, and compaction load for electrode fabrication ranging from 5 to 20&#xa0;ton, composition Cu:Gr. Gray relational analysis (GRA) was employed to optimize the process parameters, aiming to enhance MDR, minimize tool wear rate (TWR), and achieve improved surface roughness (SR) and microhardness (HV). The results indicate that discharge current has the most substantial influence on MDR and SR, while compaction load predominantly affects TWR. The optimal process parameters identified through gray relational analysis (GRA) are a discharge current of 8&#xa0;A, a pulse-on time of 150&#xa0;µs, and a compaction load 20&#xa0;ton. Under these conditions, MDR improved by 12.5%, TWR was reduced by 15.3%, and SR decreased by 18.9% compared to the initial settings. This work contributes to advancing the way for industrial applications requiring enhanced surface properties.</p>

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Gray Relational Optimization of Dry Electrical Discharge Coating Parameters for Copper-Graphene Coating on Al6061 Alloy in Argon Atmosphere

  • 期刊论文

  • 发表日期：

    2026年5月5日

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  • Panna Goswami,
  • Sujoy Chakraborty,
  • Vidyut Dey,
  • Debashis Podder

摘要

This study investigates the dry electro-discharge coating (DEDC) process on Al6061 alloy using a copper-graphene green compact electrode in an argon dielectric medium. The process parameters considered include discharge current (Ip) ranging from 4 to 10 A, pulse-on time (Ton) ranging from 50 to 200 µs, and compaction load for electrode fabrication ranging from 5 to 20 ton, composition Cu:Gr. Gray relational analysis (GRA) was employed to optimize the process parameters, aiming to enhance MDR, minimize tool wear rate (TWR), and achieve improved surface roughness (SR) and microhardness (HV). The results indicate that discharge current has the most substantial influence on MDR and SR, while compaction load predominantly affects TWR. The optimal process parameters identified through gray relational analysis (GRA) are a discharge current of 8 A, a pulse-on time of 150 µs, and a compaction load 20 ton. Under these conditions, MDR improved by 12.5%, TWR was reduced by 15.3%, and SR decreased by 18.9% compared to the initial settings. This work contributes to advancing the way for industrial applications requiring enhanced surface properties.