ADVANCING SUSTAINABLE ENGINEERING THROUGH TI-CU ELECTRICAL DISCHARGE COATING OF AA6062 ALUMINUM ALLOY

Electrical discharge coating (EDC) is a reverse polarity process that uses strategic deposition of electrode materials such as Titanium (Ti) and Copper (Cu) onto AA6062 aluminum, providing advanced surface modification in microfluidic and thermal applications. Using a Face-Centered Central Composite Design, this study illustrates that although peak current and pulse-on time are the most important factors to maximize the Deposition Rate (DR), the optimal pulse-off times are highly important to ensure stability in the discharge. In addition to checking elemental diffusion through SEM, Electron Backscatter Diffraction (EBSD) enables a more detailed understanding of the development of the coating microstructure and ensures that both electrical calibration and a more uniform grain distribution with better continuity of the matrix result in a more uniform distribution of the coating. Through crystallographic orientations, the research confirms the efficacy of EDC as a promising technique to fill the gap between the traditional machining and the innovative functional coating, making sure that the deposited layers have the structural integrity required to produce high-performance industrial components.