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Arabian Journal for Science and Engineering

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06-10-2020 | Research Article-Mechanical Engineering

Influence of Electrical Discharge Machining on Thermal Barrier Coating in a Two-Step Drilling of Nickel-Based Superalloy

Authors: Changshui Gao, Zhuang Liu, Tianhai Xie, Chao Guo

Published in: Arabian Journal for Science and Engineering | Issue 3/2021

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Abstract

The influence of electrical discharge machining (EDM) on thermal barrier coating (TBC) in a two-step drilling of nickel-based superalloy has been studied. The TBC was coated on the superalloy using electron beam physical vapor deposition (EB-PVD). Simulation result shows that the temperature at TBC/metal interface increases with pulse-on time and peak current. The temperature will exceed the melting point of the coating material when using relatively large pulse energy. Experimental result reveals that large pulse-on time or high peak current caused defect such as cracking at coating sidewall and delamination at the TBC/metal interface. For EDM drilling holes with inclined angle, the leading edge had worse condition of debris evacuation, and consequently caused secondary discharge which resulted in melt and spalling of the coating material. In addition, relatively larger pulse-on time and greater peak current might result in greater thermal stress gradient at the interface and subsequently lead to cracking or spalling at the coating layer. Therefore, process conditions of short pulse-on time, longer pulse-off time, and small peak current are recommended for EDM drilling of the EB-PVD coated nickel-based superalloy.

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Title: Influence of Electrical Discharge Machining on Thermal Barrier Coating in a Two-Step Drilling of Nickel-Based Superalloy
Authors: Changshui Gao
Zhuang Liu
Tianhai Xie
Chao Guo
Publication date: 06-10-2020
Publisher: Springer Berlin Heidelberg
Published in: Arabian Journal for Science and Engineering / Issue 3/2021
Print ISSN: 2193-567X
Electronic ISSN: 2191-4281
DOI: https://doi.org/10.1007/s13369-020-04987-5

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