Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating

Cemented tungsten carbide (WC-Co) cutting tools are widely used in metal cutting industry. These tools wear rapidly when machining abrasive alloys and glass-epoxy composites. In order to enhance the overall machining effectiveness of WC-Co, the coating of diamond on WC-Co has been attractive by virt...

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Main Author:	Ahrari, Ayoob
Format:	Thesis
Language:	English
Published:	2010
Subjects:	TJ Mechanical engineering and machinery TS Manufactures
Online Access:	http://eprints.utm.my/id/eprint/12288/4/AyoobAhrariMFKM2010.pdf
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spelling	my-utm-ep.122882017-09-20T04:11:24Z Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating 2010-11 Ahrari, Ayoob TJ Mechanical engineering and machinery TS Manufactures Cemented tungsten carbide (WC-Co) cutting tools are widely used in metal cutting industry. These tools wear rapidly when machining abrasive alloys and glass-epoxy composites. In order to enhance the overall machining effectiveness of WC-Co, the coating of diamond on WC-Co has been attractive by virtue of its excellent hardness and low coefficient of friction. Poor adhesion of diamond coating to WC-Co is however observed because of the weak interface bonding resulting from graphite film formation during low-pressure diamond deposition due to presence of the cobalt binder. The use of interlayer between WC-Co and diamond coating has proved to overcome and reduce the negative effect of cobalt binder. In the current study, the coating of nickel-chromium on the cemented carbide (WC-Co) substrate via electroplating process has been investigated in order to obtain a thin layer with a good adhesion. Nickel was first coated on WC-Co substrate in experiments/trials involving three variable parameters; bath temperature, current density and plating time. Subsequently, chromium was coated on the nickel surface in experiments/trials involving two variable parameters; bath temperature and current density. Two levels factorial design of experiments involving nickel and chromium coatings on WC-Co substrates enabled the identification of current density and plating time as the two important variable parameters affecting the thickness of nickel and chromium coating. Temperature did not appear to have a significant influence on the thickness of coating. However, it had notable effects on the adhesion of nickel and chromium coatings. The current density had a slight effect on the adhesion in comparison with the temperature. A current density of 4 Amp/dm2, bath temperature of 58 ºC, and plating time of 26.31 minutes were identified as suitable electroplating parameter conditions for producing a thin, 6.3 µm, nickel layer with good adhesion on the WC-Co substrate whilst a current density of 12 Amp/dm2 , bath temperature of 42 ºC, and plating time of 15 minutes were identified as suitable electroplating parameter conditions for producing a thin, 2.4µm, chromium layer with good adhesion on the nickel coated WC-Co substrate. 2010-11 Thesis http://eprints.utm.my/id/eprint/12288/ http://eprints.utm.my/id/eprint/12288/4/AyoobAhrariMFKM2010.pdf application/pdf en public masters Universiti Teknologi Malaysia, Faculty of Mechanical Engineering Faculty of Mechanical Engineering
institution	Universiti Teknologi Malaysia
collection	UTM Institutional Repository
language	English
topic	TJ Mechanical engineering and machinery TS Manufactures
spellingShingle	TJ Mechanical engineering and machinery TS Manufactures Ahrari, Ayoob Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating
description	Cemented tungsten carbide (WC-Co) cutting tools are widely used in metal cutting industry. These tools wear rapidly when machining abrasive alloys and glass-epoxy composites. In order to enhance the overall machining effectiveness of WC-Co, the coating of diamond on WC-Co has been attractive by virtue of its excellent hardness and low coefficient of friction. Poor adhesion of diamond coating to WC-Co is however observed because of the weak interface bonding resulting from graphite film formation during low-pressure diamond deposition due to presence of the cobalt binder. The use of interlayer between WC-Co and diamond coating has proved to overcome and reduce the negative effect of cobalt binder. In the current study, the coating of nickel-chromium on the cemented carbide (WC-Co) substrate via electroplating process has been investigated in order to obtain a thin layer with a good adhesion. Nickel was first coated on WC-Co substrate in experiments/trials involving three variable parameters; bath temperature, current density and plating time. Subsequently, chromium was coated on the nickel surface in experiments/trials involving two variable parameters; bath temperature and current density. Two levels factorial design of experiments involving nickel and chromium coatings on WC-Co substrates enabled the identification of current density and plating time as the two important variable parameters affecting the thickness of nickel and chromium coating. Temperature did not appear to have a significant influence on the thickness of coating. However, it had notable effects on the adhesion of nickel and chromium coatings. The current density had a slight effect on the adhesion in comparison with the temperature. A current density of 4 Amp/dm2, bath temperature of 58 ºC, and plating time of 26.31 minutes were identified as suitable electroplating parameter conditions for producing a thin, 6.3 µm, nickel layer with good adhesion on the WC-Co substrate whilst a current density of 12 Amp/dm2 , bath temperature of 42 ºC, and plating time of 15 minutes were identified as suitable electroplating parameter conditions for producing a thin, 2.4µm, chromium layer with good adhesion on the nickel coated WC-Co substrate.
format	Thesis
qualification_level	Master's degree
author	Ahrari, Ayoob
author_facet	Ahrari, Ayoob
author_sort	Ahrari, Ayoob
title	Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating
title_short	Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating
title_full	Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating
title_fullStr	Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating
title_full_unstemmed	Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating
title_sort	application of design of experiment technique in the nickel-chromium electroplating process on wc-co substrate prior hfcvd diamond coating
granting_institution	Universiti Teknologi Malaysia, Faculty of Mechanical Engineering
granting_department	Faculty of Mechanical Engineering
publishDate	2010
url	http://eprints.utm.my/id/eprint/12288/4/AyoobAhrariMFKM2010.pdf
_version_	1747814915033268224

Application of design of experiment technique in the nickel-chromium electroplating process on WC-Co substrate prior HFCVD diamond coating

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