Abstract
The present research provides a rigid, wear-resistant lubricating localized layer on Hastelloy C276 (HC 276) surface at meso level by tungsten disulphide (WS2) powder suspended electrical discharge alloying (EDA) process through micro-electrical discharge machining (μ-EDM) setup. The performance characteristics of the coated surface were evaluated in terms of material deposition rate (MDR), surface morphology, surface roughness (Ra, Rz and Rq), recast layer thickness (RLT), compositional analysis, micro-hardness & indentation depth, wear test and water contact angle analysis. Maximum MDR has been achieved at 15 g/L WS2 concentration and 80 V of gap voltage whereas The RLT varies from 6.87 μm to 18.91 μm and is enhanced with the increase in WS2 concentration. The critical surface characterization confirms higher WS2 concentration reduces the crater dimensions and the presence of micro-cracks and micro-voids on the coated surface. The surface roughness has been increased with the gap voltage and capacitance, whereas higher WS2 concentration provides lower surface roughness. X-Ray diffraction analysis (XRD) confirms the presence of hard and wear resistance phases like WC, WO3, ZnO, and MoO2 on the coated surface. Energy-Dispersive X-Ray Spectroscopy (EDS) analysis along with elemental mapping justifies tool, dielectric materials, and powder particles migration on the coated surface. The micro-hardness of the coated surface (402 HV to 1166 HV) is enhanced by 3–4 times compared to the base material (299 HV) whereas the indentation depth has been reduced with the rise in WS2 concentration and lies within the RLT of the coated surface. The wear rate of the WS2 coated surface is drastically reduced compared to the base material with a lower value of coefficient of friction (COF). The coated surface became hydrophobic in nature with a contact angle of 109.6° compared to the hydrophilic base HC 276.
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