Electrospark deposition (ESD) is a micro-arc and micro-scale additive welding processes that:
- Produces a true metallurgical bond with substrate
- Keeps the substrate near ambient temperature; eliminating distortion, stress, and either reducing or preventing a HAZ
- Allows for dissimilar materials to be joined
- Produces consistent, thin layers
- Can be used for surface modification for hardness, wear resistance, corrosion resistance, friction, etc.
- Can be used an overlay for repair of worn, corroded, or defective components
Electrospark Deposition (ESD) is a direct current electrode positive (DCEP) micro-arc welding process, where high current, short duration pulses facilitate the flow of electrons from the substrate to the electrode. The flow of electrons interacts with gaseous ions in the intermediate distance forming a plasma arc. Material is deposited as molten material from the electrode, impinging on the substrate forming a metallurgical bond. The material is deposited via a moving applicator and ground, which transfers the electrical signals and facilitates relative motion through the use of rotation, linear motion or vibration to prevent the electrode sticking to the surface.
Huys’ Low Energy Welding (LEW) equipment is the latest evolution of electrospark deposition. Some of its advantages are:
- Available with or without shielding gas (to eliminate oxidation in the process)
- Portability for field operation
- Integration into an automated system
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Example Application 1: Surface Modification of Stainless Steel with Molybdenum Coating for Corrosion Resistance
Mo coated 304 stainless exhibits excellent corrosion resistance to 5% NaCl solution. It corrodes 350 times slower than 304 SS, and four times slower than DSS 2205.
Example Application 2: Repair of 6061 Aluminum Alloy 6061