Abstract
ElectroSpark Deposition (ESD) is a pulsed micro-welding process that is capable of depositing wear and corrosion resistance deposit to repair, improve, and to extend the service life of the components and tools. Major new applications have taken place in gas turbine blades and steam turbine blade protection and repair, and in military, medical, metal-working, and recreational equipment applications. In this study, the ESD technique was exploited to fabricate 2024 aluminum alloy deposit on a similar substrate. The deposits were deposited using different process parameters. Heat input was varied on three levels. The outcoming microstructure was analyzed by optical and scanning electron microscopies. The deposit was characterized by the overlapping of layers with a mixed microstructure. The average hardness was independent from the process parameters. Both porosity inside the deposits and cracks at the deposit/substrate interface were detected. The porosity lowered with the heat input and increased the average length of cracks.
Highlights
In recent years the deposition processes [1,2] and the repair method [3,4] of some high value components have become more prominent in the aeronautics industry
Long processing time, and pollution are just some of the disadvantages of the traditional surface treatment processes (such as physical vapor deposition (PVD), chemical vapor deposition (CVD), electro plating, thermal diffusion (TD)) that are widely used to improve anti-wear, anti-corrosion and anti-softening of component material [5]
ElectroSpark Deposition (ESD) technique consists of a capacitor-based power supply, a consumable electrode, and an applicator
Summary
In recent years the deposition processes [1,2] and the repair method [3,4] of some high value components have become more prominent in the aeronautics industry. The physical and microstructural characteristics of the alloy limit the fusion welding repair techniques [6]. The fusion welding repair process of AA20204 is not suitable because the alloy is susceptible to hot cracking, both in the welding (solidification cracking) and in the base metal (liquation cracking) [7,8,9,10,11,12,13]. ElectroSpark Deposition (ESD) technique consists of a capacitor-based power supply, a consumable electrode, and an applicator (electrode holder). The high cooling-rates during ESD, on the order of 105 –106 ◦ C/s, can produce nano-structured deposits [17], characterized by increased hardness and tribological benefits [16,18]
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