Improving the Surface Wear Resistance of Aluminum by Electrical Discharge Process

In this study, electrical discharge process was used to increase surface wear resistance of pure aluminum. Pulse-on-time and pulse current were considered as the input parameters of the electrical discharge process. Experimental results revealed that the electrical discharge process is a successful method for improving the surface wear resistance of aluminum, to the effect that it has greatly increased the surface wear resistance of aluminum parts. The results indicate that with increasing the input parameters (pulse-on-time and pulse current), weight loss of the aluminum specimens is reduced and wear resistance increases. The XRD analysis demonstrated that Al3Ni2 and AlCu intermetallic compound and Al4C3 were formed on the alloyed surface. The presence of these compounds and hard particles on the surface increases the wear resistance. Also, friction coefficient measurements showed that after electrical discharge process and improving surface wear resistance, the friction coefficient slightly increased due to the presence of hard particles on the alloyed surface.