The paper initially reviews the concept and technology of EDM surface alloying using either metallic powders added to the dielectric or partially sintered powder metallurgy (PM) tool electrodes. Experimental results are presented when EDM surface alloying titanium, T1-6Al-4V using WC/Co PM tool electrodes and a hydrocarbon dielectric. The effect of different operating parameters such as electrode polarity, generator open circuit voltage, peak current and pulse on/off times on workpiece recast layer thickness, microstructure/microhardness and chemical composition are highlighted. Changes in workpiece metallurgy were measured up to a depth of ~50 micron with hardness values at the workpiece surface of up to 2100 HK(0.025) (bulk material 360-390 HR(0.025)). GDOES analysis showed that tungsten together with pyrolytic carbon from the hydrocarbon dielectric were transferred to the workpiece.


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