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<p>Electro-discharge alloying (EDA) is a new surface modification technique that has been used to improve the surface properties of Aluminum 7075 (Al 7075) through alloying with tungsten reinforced. A high-temperature plasma channel is created between the dielectric and the workpiece to transfer the tungsten particles in the dielectric to the substrate, resulting in a hard alloyed substrate. The influence of process parameters such as peak current (<i>I</i>), pulse-on time (<i>P</i><sub>on</sub>), and pulse-off time (<i>P</i><sub>off</sub>) on key tribological responses—specific wear rate (SWR), coefficient of friction (CoF), and surface roughness (SR) - was experimentally evaluated using the Taguchi design of experiments. Also, multi-objective optimization was conducted on the basis of objective pairwise adjusted ratio analysis (OPARA), which is used to evaluate the best parameter setting to minimize both wear and surface irregularities simultaneously. Optical microscope, scanning electron microscope (SEM), energy-dispersive spectroscopy (EDS), and tribological testing were utilized in characterizing the alloyed layer. The results supported the effective insertion of tungsten into the Al&#xa0;7075 surface leading to a homogeneous crack-free alloyed zone that is more resistant to wear. Optimized procedure of Taguchi-OPARA optimization and EDA process is efficient to have a strong base in creating superior improvement of composite surfaces as applied to the engineering processes in automobiles and aerospace industry. OPARA resulting the best solution from the combination of 6 I, the <i>P</i><sub>on</sub> is at 100&#xa0;µs. and the <i>P</i><sub>off</sub> is 100&#xa0;µs.</p>

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Taguchi–Opara-Based Multi-attribute Optimization of Electro-Discharge Alloying Parameters for Tungsten-Reinforced Al 7075 Alloy

  • 期刊论文

  • 发表日期：

    2026年7月1日

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  • A. Haja Maideen,
  • Muthukannan Duraiselvam,
  • M. Varatharajulu,
  • A. Balaji

摘要

Electro-discharge alloying (EDA) is a new surface modification technique that has been used to improve the surface properties of Aluminum 7075 (Al 7075) through alloying with tungsten reinforced. A high-temperature plasma channel is created between the dielectric and the workpiece to transfer the tungsten particles in the dielectric to the substrate, resulting in a hard alloyed substrate. The influence of process parameters such as peak current (I), pulse-on time (Pon), and pulse-off time (Poff) on key tribological responses—specific wear rate (SWR), coefficient of friction (CoF), and surface roughness (SR) - was experimentally evaluated using the Taguchi design of experiments. Also, multi-objective optimization was conducted on the basis of objective pairwise adjusted ratio analysis (OPARA), which is used to evaluate the best parameter setting to minimize both wear and surface irregularities simultaneously. Optical microscope, scanning electron microscope (SEM), energy-dispersive spectroscopy (EDS), and tribological testing were utilized in characterizing the alloyed layer. The results supported the effective insertion of tungsten into the Al 7075 surface leading to a homogeneous crack-free alloyed zone that is more resistant to wear. Optimized procedure of Taguchi-OPARA optimization and EDA process is efficient to have a strong base in creating superior improvement of composite surfaces as applied to the engineering processes in automobiles and aerospace industry. OPARA resulting the best solution from the combination of 6 I, the Pon is at 100 µs. and the Poff is 100 µs.