Multi Response Optimization and Experimental Investigations into the Impact of Wire EDM on the Tribological Properties of Ti-6Al-4V

Titanium (Ti) alloy, Ti-6Al-4V (commonly known as Ti64), is employed in numerous applications due to their superior strength to weight ratio, low cost to performance ratio, tensile strength, and corrosion resistance properties. However, due to its poor tribological (friction and wear) properties and difficult-to-machine material, its implementation in the intended applications is limited. Nevertheless, Ti64 can be accurately machined using wire electrical discharge machining (WEDM) and further, this process develops a recast layer on the surface of Ti64, which posses larger percentage of oxygen. Therefore, in the present work, it is hypothesized that, the presence of the recast layer on the surface of Ti64 may enhance its tribological properties. To validate the proposed hypothesis, pins of (1) pure Ti64 and (2) WEDMed Ti64 were slided against EN32 steel disc on a pin on disc experimental setup for load of 50 N, rotational speed of 200 rpm and sliding distance of 500 m. In-situ analysis (scanning electron microscope and energy dispersive spectroscopy) and mechanical properties (nano-hardness and elastic modulus) were performed on the pin's surface, to identify the change in properties. Obtained results indicated significant increase in the oxide layer formation, consequently enhanced the tribological properties of WEDMed Ti64 compared to pure Ti64. To understand the tribological behavior of WEDMed Ti64 at other rotational speed and load, second set of experiments was performed by varying load (50, 70 and 90 N) and rotational speed of (200, 400 and 600 rpm). It was observed that wear values were not proportional to increase in load and speed. To identify the condition favoring the tribological behavior, multi-response optimization technique was performed and the identified load and speed values for the optimum tribological behavior were estimated.