Study of the Direct Metal Deposition of AA2024 by ElectroSpark for Coating and Reparation Scopes

ElectroSpark Deposition (ESD) is a pulsed micro-welding process that is capable of depositing wear and corrosion resistance deposit to repair, improve, and to extend the service life of the components and tools. Major new applications have taken place in gas turbine blades and steam turbine blade protection and repair, and in military, medical, metal-working, and recreational equipment applications. In this study, the ESD technique was exploited to fabricate 2024 aluminum alloy deposit on a similar substrate. The deposits were deposited using different process parameters. Heat input was varied on three levels. The outcoming microstructure was analyzed by optical and scanning electron microscopies. The deposit was characterized by the overlapping of layers with a mixed microstructure. The average hardness was independent from the process parameters. Both porosity inside the deposits and cracks at the deposit/substrate interface were detected. The porosity lowered with the heat input and increased the average length of cracks