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Electrical discharge alloying was performed on AISI-D2 steel using Ni–W powder mixed dielectric in order to improve the hardness and to reduce the specific wear rate. The alloyed layer was characterized using optical microscopy, scanning electron microscopy, X-ray diffraction analysis and energy-dispersive spectroscopy. Wear tests were conducted based on L9 orthogonal array in a pin-on-disc tribometer and the alloying parameters were optimized using Taguchi's technique. Hard intermetallics based on Fe 7 C 3 , Cr 3 C 2  and Ni 2 W 4 C were formed by electric discharge alloying, which primarily contributed to the improvement in hardness up to 600 HV 0.5 . The specific wear rate of the alloyed layer was subsequently reduced by around a factor of eight compared to that of the base material. The pulse off-time was found to be predominant in obtaining higher hardness and lower specific wear rate among the alloying parameters, peak current, pulse on-time and off-time.

Development of carbide intermetallic layer by electric discharge alloying on AISI-D2 tool steel and its wear resistance