Electrical Discharge Machining of Alumina Using Cu-Ag and Cu Mono- and Multi-Layer Coatings and ZnO Powder-Mixed Water Medium

Abstract

The paper aims to extend the current knowledge on electrical discharge machining of insulating materials, such as cutting ceramics used to produce cutting inserts to machine nickel-based alloys in the aviation and aerospace industries. Aluminum-based ceramics such as Al2O3, AlN, and SiAlON are in the most demand in the industry but present a scientific and technical problem in obtaining sophisticated shapes. One of the existing solutions is electrical discharge machining using assisting techniques. Using assisting Cu-Ag and Cu mono- and multi-layer coatings of 40–120 µm and ZnO powder-mixed deionized water-based medium was proposed for the first time. The developed coatings were subjected to tempering and testing. It was noticed that Ag-adhesive reduced the performance when tempering had a slight effect. The unveiled relationship between the material removal rate, powder concentration, and pulse frequency showed that performance was significantly improved by adding assisting powder up to 0.0032–0.0053 mm3/s for a concentration of 14 g/L and pulse frequency of 2–7 kHz. Further increase in concentration leads to the opposite trend. The most remarkable results corresponded to the pulse duration of 1 µs. The obtained data enlarged the knowledge of texturing insulating cutting ceramics using various powder-mixed deionized water-based mediums.