Research on the Ultrasonic Electro-Spark Deposition Process and the Properties of the Deposition Layer
Abstract
1. Introduction
2. Materials and Methods
2.1. Materials
2.2. Sample Treatment
2.3. Preparation Process and Parameters
2.4. Characteristic Analysis
3. Analysis of the Ultrasonic Electro-Spark Deposition Process
3.1. Deposition Process
3.2. Effect of Ultrasonics on Deposition Process
4. Analysis of Deposition Layer Properties
4.1. Surface Morphologies of Deposition Layer
4.2. Cross-Sectional Morphologys of Deposition Layer
4.3. Composition Analysis of Deposition Layer
4.4. Microhardness of Deposition Layer
5. Conclusions
- (1)
- The results show that the charge–discharge frequency of the ultrasonic electro-spark deposition process was commensurate with the discharge frequency of the ultrasonic electro-spark deposition power source, and the voltage waveform was stable. During a single charging and discharging phase, the electrode and substrate made roughly 15 mechanical contacts, 1 of which was discharging, and the remaining 14 were mechanically contacted reinforcement. The addition of ultrasonics successfully directs the molten droplet spray trajectory, preventing haphazard splashing and causing the spark spray trajectory to exhibit notable directional concentration features.
- (2)
- The addition of ultrasonics improves the spread ability of the molten droplets on the substrate surface by decreasing their size and quickening their motion toward the surface. Real-time compression of semi-solid metal by the mechanical contact strengthening produced by ultrasonics helps to lessen the shrinkage stress brought on by fast cooling, which prevents cracks from starting and spreading in the deposition layer. The ultrasonic electro-spark deposition layer’s surface exhibited sputtering morphology, with no surface cracks and a surface roughness of 2.554 μm, which was around 61.4% less than that of the electro-spark deposition layer.
- (3)
- By increasing the fluidity of the molten metal, the introduction of ultrasonics reduces microporosity defects brought on by incomplete local melting, relieves the concentration of thermal stress, lessens the occurrence of cracks in the deposited layer, lowers its porosity, and prevents the aberrant growth of WC particles. The cross-section porosity of the ultrasonic electro-spark deposition layer was 1.3%, or 57.5% less than that of the electro-spark deposition layer. Phase structures such as Co3W3C, Fe3W3C, Fe6W6C, WC, and W2C constituted the majority of the ultrasonic electro-spark deposition layer’s microstructure and showed strong metallurgical bonds with the substrate.
- (4)
- Simultaneously, the semi-solid deposition layer’s surface experiences plastic deformation due to the mechanical contact strengthening produced by ultrasonics, creating a work-hardened layer that raises the deposition layer’s microhardness. At a maximum of 1038.8 HV0.025, the microhardness of the ultrasonic electro-spark deposition layer was roughly 15.5% more than that of the electro-spark deposition layer.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
- Liu, X.; Zhang, W. Selection and application of cold work die steel. Forg. Stamp. Technol. 2007, 6, 13–17. [Google Scholar]
- Deng, C. A brief analysis of the selection of modern cold work die materials. Mech. Electr. Inf. 2011, 21, 200–201. [Google Scholar]
- Zhang, S.; Wang, D.; Cheng, P.; Shao, C. Experimental and numerical analysis of the wear mechanism in spring coil forming die and the effects of die geometry on wear. Proc. Inst. Mech. Eng. Part J J. Eng. Tribol. 2021, 236, 2087–2094. [Google Scholar] [CrossRef]
- Cwikla, A.; Tofil, A. Analysis of wear of cold forging dies using the technique of focal differentiation microscopy. In Proceedings of the 2019 IEEE 5th International Workshop on Metrology for AeroSpace (MetroAeroSpace), Turin, Italy, 19–21 June 2019; pp. 629–632. [Google Scholar]
- Lu, Y.; Guan, W.; Ye, Y.; Wang, L. Wear characteristics of PVD coated carbide tools in milling of TA15 titanium alloy. Mater. Today Commun. 2024, 38, 108058. [Google Scholar] [CrossRef]
- Senin, P.V.; Velichko, S.A.; Martynov, A.V.; Martynova, E.G. Increasing the wear resistance of forged tools by electrospark deposition. Russ. Eng. Res. 2020, 40, 427–430. [Google Scholar] [CrossRef]
- Liu, H.; Huang, L.; Wang, D.; Chen, C.; Cui, A.; Dong, S.; Duan, Z. Preparation Process of WC Wear-Resistant Coating on Titanium Alloys Using Electro-Spark Deposition. Arch. Metall. Mater. 2025, 509–514. [Google Scholar] [CrossRef]
- Burkov, A.A.; Pyachin, S.A. Formation of WC–Co coating by a novel technique of electrospark granules deposition. Mater. Des. 2015, 80, 109–115. [Google Scholar] [CrossRef]
- Pliszka, I.; Radek, N.; Gądek-Moszczak, A. Properties of WC-Cu electro spark coatings subjected to laser modification. Tribologia 2017, 5, 73–79. [Google Scholar] [CrossRef]
- Brezinová, J.; Džupon, M.; Puchý, V.; Brezina, J.; Maruschak, P.; Guzanová, A.; Sobotová, L.; Badida, M. Research on the tribological properties of a new generation of multi-layer nanostructured PVD coatings for increasing the technological lifetime of moulds. Metals 2024, 14, 131. [Google Scholar] [CrossRef]
- D’Avico, L.; Beltrami, R.; Lecis, N.; Trasatti, S. Corrosion Behavior and Surface Properties of PVD Coatings for Mold Technology Applications. Coatings 2018, 9, 7. [Google Scholar] [CrossRef]
- Liu, X.; Zhang, Y.; Wang, X.; Wang, Z.; He, P. Microstructure and corrosion properties of AlCrxNiCu0.5Mo (X = 0, 0.5, 1.0, 1.5, 2.0) high entropy alloy coatings on Q235 steel by electrospark—Computer numerical control deposition. Mater. Lett. 2021, 292, 129642. [Google Scholar] [CrossRef]
- Liang, H.; Liu, Z.; Lin, N.; Chen, D.; Gao, Z.; Chen, H. Research progress of electrospark deposition technology and its surface properties. Hot Work. Technol. 2021, 50, 1–7. [Google Scholar]
- Shafyei, H.; Salehi, M.; Bahrami, A. Fabrication, Microstructural characterization and mechanical properties evaluation of Ti/TiB/TiB2 composite coatings deposited on Ti6Al4V alloy by electro-spark deposition method. Ceram. Int. 2020, 46, 15276–15284. [Google Scholar] [CrossRef]
- Salmaliyan, M.; Malek Ghaeni, F.; Ebrahimnia, M. Effect of electro spark deposition process parameters on WC-Co coating on H13 steel. Surf. Coat. Technol. 2017, 321, 81–89. [Google Scholar] [CrossRef]
- Zhang, J.; Zhu, C. Progress in research and application of electro-spark deposition technology. Mater. Rep. 2023, 37, 221–234. [Google Scholar]
- Burkov, A.A. Improvement of Ti6Al4V-alloy wear resistance by electric-spark hafnium carbide coatings. J. Frict. Wear 2020, 41, 543–548. [Google Scholar] [CrossRef]
- Bhaskar, M.; Anand, G.; Nalluswamy, T.; Suresh, P. Die Life in aluminium high-pressure die casting industries. J. Inst. Eng. (India) Ser. D 2022, 103, 1–7. [Google Scholar] [CrossRef]
- Holubets, V.M.; Pashechko, M.I.; Borc, J.; Tisov, O.V.; Shpuliar, Y.S. Wear resistance of electrospark-deposited coatings in dry sliding friction conditions. Powder Met. Met. Ceram. 2021, 60, 90–96. [Google Scholar] [CrossRef]
- Luan, C.; Wang, W.; Kuang, L. Microstructures and properties of niobium coating on H13 steel substrate by electrospark deposition. Surf. Technol. 2019, 48, 285–290. [Google Scholar]
- Geng, M.; Wang, W.; Zhang, X. Microstructures and properties of Ni/Ti(C,N) composite cermet coating prepared by electrospark deposition. Surf. Technol. 2020, 49, 222–229. [Google Scholar]
- Habibi, F.; Samadi, A. In-situ formation of ultra-hard titanium-based composite coatings on carbon steel through electro-spark deposition in different gas media. Surf. Coat. Technol. 2024, 478, 130472. [Google Scholar] [CrossRef]
- Abdi, F.; Aghajani, H.; Asl, S.K. Evaluation of the corrosion resistance of AlCoCrFeMnNi high entropy alloy hard coating applied by electro spark deposition. Surf. Coat. Technol. 2023, 454, 129156. [Google Scholar] [CrossRef]
- Liu, Y.; Wang, D.; Deng, C.; Huo, L.; Wang, L.; Fang, R. Novel method to fabricate Ti–al intermetallic compound coatings on Ti–6Al–4V alloy by combined ultrasonic impact treatment and electrospark deposition. J. Alloys Compd. 2015, 628, 208–212. [Google Scholar] [CrossRef]
- Liu, Y.; Wang, D.; Deng, C.; Huo, L.; Wang, L.; Fang, R. Study on fabrication of ceramic coatings on Ti–6Al–4V alloy by combined ultrasonic impact treatment and electrospark. Surf. Eng. 2014, 31, 892–897. [Google Scholar] [CrossRef]
- Shang, J.; Cao, W.; Chen, Y. Effect of surface-treatment of ultrasonic impact combined with electrospark deposition on corrosion resistance of TC4 titanium alloy. Corros. Prot. 2021, 42, 22–25, 33. [Google Scholar]
- Wang, D.; Gao, J.; Deng, S.; Wang, W. A novel particle planting process based on electrospark deposition. Mater. Lett. 2022, 306, 130872. [Google Scholar] [CrossRef]
- Zhao, H.; Gao, C.; Guo, C.; Xu, B.; Wu, X.-Y.; Lei, J.-G. In-Situ TiC-reinforced Ni-based composite coatings fabricated by ultrasonic-assisted electrospark powder deposition. J. Asian Ceram. Soc. 2022, 11, 26–38. [Google Scholar] [CrossRef]
- Zhang, L.; Long, W.; Du, D.; Fan, Z.; Jiang, C.; Jin, X. A novel Diamond/AlSi composite coating on Ti-6Al-4V substrate made by ultrasonic-assisted brazing. Coatings 2023, 13, 1596. [Google Scholar] [CrossRef]
- Chen, J.; He, Z.; Zheng, S.; Gao, W.; Wang, Y. Ultrasonic-assisted electrodeposition of Cu-TiO2 nanocomposite coatings with long-term antibacterial activity. ACS Appl. Mater. Interfaces 2024, 16, 66695–66705. [Google Scholar] [CrossRef]
- Cao, M.; Tian, D.; Guo, X.; Li, W. Optimization of plating parameters and properties of ultrasonic-assisted jet-electrodeposited Ni-W-Al2O3 nanocomposite coatings. Int. J. Mol. Sci. 2025, 26, 2404. [Google Scholar] [CrossRef]
- Zhou, S.; Zeng, X.; Hu, Q.; Huang, Y. Analysis of crack behavior for Ni-based WC composite coatings by laser cladding and crack-free realization. Appl. Surf. Sci. 2008, 255, 1646–1653. [Google Scholar] [CrossRef]
- Zhao, H.; Gao, C.; Wu, X.; Xu, B.; Lu, Y.; Zhu, L. A novel method to fabricate composite coatings via ultrasonic-assisted electro-spark powder deposition. Ceram. Int. 2019, 45, 22528–22537. [Google Scholar] [CrossRef]
- Duan, H.; Dong, X.; Ma, Z.; Guo, S.; Xia, F.; Yang, Z. Morphology and growth behavior of Si phases in an Al-Si piston alloy under ultrasonic vibration. JOM 2025, 77, 6260–6268. [Google Scholar] [CrossRef]
- Wang, B.; Tan, D.; Lee, T.L.; Khong, J.C.; Wang, F.; Eskin, D.; Connolley, T.; Fezzaa, K.; Mi, J. Ultrafast synchrotron X-ray imaging studies of microstructure fragmentation in solidification under ultrasound. Acta Mater. 2018, 144, 505–515. [Google Scholar] [CrossRef]
- Farahmand, P.; Liu, S.; Zhang, Z.; Kovacevic, R. Laser cladding assisted by induction heating of Ni–WC composite enhanced by nano-WC and La2O3. Ceram. Int. 2014, 40, 15421–15438. [Google Scholar] [CrossRef]
- Wang, Z.; Jiang, F.; Guo, C.; Xing, X.; Dou, X.; Li, H.; Liu, C.; Xu, D.; Jiang, G.; Konovalov, S. Effects of ultrasonic vibration on microstructure and mechanical properties of 1Cr12Ni3MoVN alloy fabricated by directed energy deposition. Ultrasonics 2023, 132, 106989. [Google Scholar] [CrossRef] [PubMed]
- Yang, X.; Li, X.; Yang, Q.; Wei, H.; Fu, X.; Li, W. Effects of WC on microstructure and corrosion resistance of directional structure Ni60 coatings. Surf. Coat. Technol. 2020, 385, 125359. [Google Scholar] [CrossRef]
- Wang, Q.; Chen, X.; Zhu, L.; Yan, J.; Lai, Z.; Zhao, P.; Bao, J.; Lv, G.; You, C.; Zhou, X.; et al. Rapid ultrasound-induced transient-liquid-phase bonding of Al-50Si alloys with Zn interlayer in air for electrical packaging application. Ultrason. Sonochemistry 2016, 34, 947–952. [Google Scholar] [CrossRef] [PubMed]
- Kesavan, D.; Kamaraj, M. The Microstructure and High Temperature Wear Performance of a Nickel Base Hardfaced Coating. Surf. Coat. Technol. 2010, 204, 4034–4043. [Google Scholar] [CrossRef]
C | Mn | Si | S | Cr | Fe |
---|---|---|---|---|---|
0.95–1.05 | 0.20–0.40 | 0.15–0.35 | ≤0.020 | 1.30–1.65 | Bal. |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2025 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Li, B.; Ma, X.; Liu, Y.; Wang, H.; Bao, M.; Wang, R. Research on the Ultrasonic Electro-Spark Deposition Process and the Properties of the Deposition Layer. Coatings 2025, 15, 1038. https://doi.org/10.3390/coatings15091038
Li B, Ma X, Liu Y, Wang H, Bao M, Wang R. Research on the Ultrasonic Electro-Spark Deposition Process and the Properties of the Deposition Layer. Coatings. 2025; 15(9):1038. https://doi.org/10.3390/coatings15091038
Chicago/Turabian StyleLi, Bihan, Xiaobin Ma, Yongwei Liu, Hanqi Wang, Manyu Bao, and Ruijun Wang. 2025. "Research on the Ultrasonic Electro-Spark Deposition Process and the Properties of the Deposition Layer" Coatings 15, no. 9: 1038. https://doi.org/10.3390/coatings15091038
APA StyleLi, B., Ma, X., Liu, Y., Wang, H., Bao, M., & Wang, R. (2025). Research on the Ultrasonic Electro-Spark Deposition Process and the Properties of the Deposition Layer. Coatings, 15(9), 1038. https://doi.org/10.3390/coatings15091038