Effect of different currents and compositions of Cu, MoS2 and HBN on the coating thickness of mild steel substrate using electric discharge coating

The substrate deposited on the workpiece is used by surface coating for the achievement of various properties in terms of hardness, smoothness, tear or wear etc. But various methods such as electro-plating, conversion coating or several, are less effective because of costly machine involvement, complexity during operation, complexity during work-surface installation, specific (high/low) temperatures and thick coating. To achieve better coating among all, a layer of the modified composite coated surface using Copper (Cu), Molybdenum disulfide (MoS2) and Hexagonal Boron Nitride (HBN) with the help of an Electrical Discharge Machine (EDM) with reverse polarity is formed. In this process, the effect of two variable parameters current and composition (powder mixing ratio) of Cu, MoS2 and HBN with a 50% duty factor on the thickness of the deposited layer is observed. During the deposition process, each green compact electrode is formed by mixing the powdered material in a mortar for approximately 2.5 hours and after processing in a hot press moulding machine. The deposited layer of the coating has also been analyzed using FESEM, XRD and tribological properties, where the highest deposition or thickness of the coating has been achieved at a powder mixing ratio of 20/40/40 to Cu/HBN/MoS2 with a current of 10 A at the same duty factor. Overall, better coating with controllable thickness can be achieved by using EDC, which can be helpful in automobiles or other industries where metal-to-metal friction causes performance loss.