Enhancing surface properties of electric discharge coating using a Ti6Al4V powder 3DPE method on tungsten substrate.

This research evaluates the use of novel 3D-printed titanium alloy electrodes (3DPEs) as electrical discharge coating (EDC) on tungsten surfaces. Characterization through experimental analyses revealed that 3DPEs provide significant improvements in coating thickness and titanium content when compared to conventional EDC techniques. At suitable parameters, the 3DPE coatings achieved a thickness of 119.61 μm, surpassing conventional coatings at 15.18 μm. Additionally, the 3DPE coatings exhibited higher titanium concentrations, reaching 74.93%, indicating enhanced performance. A statistical analysis highlights the balance between surface roughness and material transfer rate (MTR), with conventional coatings exhibiting a more favorable balance. Optimal pulse on/off times maximize MTR and minimize surface roughness, respectively, with 3DPE coatings offering a more straightforward optimization path. Therefore, 3DPEs present a transformative approach to EDC, offering thicker, more uniform coatings with customizable electrical properties for diverse applications. • Incorporating 3D-printed electrodes (3DPE) for Electric Discharge Coating (EDC). • 3D-printed Ti alloy electrodes in EDC enhance coating thickness and increase Titanium content on tungsten surfaces. • 3DPE coatings achieved 119.61 μm thickness, surpassing conventional coatings by a considerable margin. • Optimal pulse on/off times of 1000 μs and 400 μs maximize MTR and minimize surface roughness, respectively. • Statistical analysis reveals a balance between surface roughness and MTR, favouring conventional coatings over 3DPEs. [ABSTRACT FROM AUTHOR]