Int J Adv Manuf Technol (2015) 76:69–82
DOI 10.1007/s00170-014-5943-z
ORIGINAL ARTICLE
Experimental analysis of electro-discharge deposition process
B. Muralidharan & H. Chelladurai
Received: 10 October 2013 / Accepted: 8 May 2014 / Published online: 27 May 2014
# Springer-Verlag London 2014
Abstract The application of miniaturized products is slowly
increasing due to their demand in micro feature-based sys-
tems, which needs multitude of functions to be integrated.
Several lithographic-based technologies are used to manufac-
ture high-aspect ratio micro features, which has limitations to
produce 3D features. Electro-discharge deposition (EDD) is a
newly developing nonlithographic additive manufacturing
process to produce micro products. The potential of this
process is that any material which is conductive in nature
can be made to deposit over the substrate. In the present paper,
the use of magnetic field in EDD process has been investigat-
ed. It is observed from the results that height and weight of
deposition are increased significantly by using magnetic field
and at the same time width is reduced due to plasma confine-
ment by magnetic field effects. From the scanning electronic
microscope (SEM) images it is observed that there is unifor-
mity in deposition of the tool material over the substrate. It is
concluded from the experimental results that, magnetic field is
also a one of the significant contributing parameter assisting in
electro-discharge deposition process.
Keywords Electro-discharge deposition process . Magnetic
field . SEM . Design of experiments
1 Introduction
The demand for micro products and its components are grow-
ing significantly, owing to wide applications in many fields
like, electronics, MEMS, medical, automobile and
B. Muralidharan (*) : H. Chelladurai
Discipline of Mechanical Engineering, PDPM IIITDM Jabalpur,
Jabalpur, MP, India
e-mail: b.murlidharan@gmail.com
biotechnology etc., reported in Alting et al. [1]. In the present
trend, micro products are designed and produced with more
functionalities and compactness. To meet the above con-
straints and need for reduced size of products, various
micro-fabrication techniques are developed. Research find-
ings of micro-nanofabrication technologies like, lithography,
FIB, etching technology and replication technology with their
advantages, limitations (manufacturability, material, econom-
ic feasibility and dimensions like 1D, 2D, 2.5D, and 3D) are
discussed in Cui [2] and Brousseau et al. [3]. Micro products
prone to aggressive environments and enhanced force actua-
tion are 3D in nature, which is reported in Brousseau et al. [3].
Dimov et al. [4] discussed that lithographic technologies can
extend their hands only upto 2D and 2.5D features with
limited material usage. So, complex 3D micro features with
high aspect ratios, suitable to unstable environments can be
produced by nonlithographic based technologies whether by
adding or by removing the material to get the final product,
reported by Rajurkar et al. [5]. The micro manufacturing can
be done both by additive and subtractive process. Subtractive
process in micro scale especially in case of micro machines, it
is very difficult to handle micro tools, workpiece position,
normally all those positions and its conditions of fittings are
monitored by using sensors, which consumes huge investment
cost. So, additive process is preferred to subtractive process in
micro scale. EDD process is one of the innovative deposition
methods in which reverse electrical discharge machining
(EDM) principle is used. In reverse EDM, electrodes are
connected in reverse polarity, i.e., tool is connected to positive
polarity and substrate is connected to negative polarity. The
advantage of EDD is that any conductive material irrespective
of hardness can be used. Gangadhar et al. [6] initially inves-
tigated the transfer of material from tool to work piece during
reverse EDM process. Simao et al. [7] and Goto et al. [8]
reported that EDD process can be used for modifying the
surface of the material and it is extended to form anti wear
70 Int J Adv Manuf Technol (2015) 76:69–82

Table 1 Factors and their levels

S.No Factors Levels

−2 −1 0 1 2

1. Current (I), A 3 9 14 19 25
2. Pulse on time (Ton), μs 7.5 20 30 40 50
3. Duty factor (t) 2 5 7 9 12
4. voltage (v),V 2 30 50 70 98
5. Magnetic flux (F), Tesla 0.04 0.07 0.16 0.20 0.40

pulse duration having less spatial current density. EDD pro-

Fig. 1 Schematic diagram of deposition process
coating of hard materials by using reverse EDM principle.
This idea is developed further and used for metal layer depo-
sition, which leads to fabrication of 3D micro parts. In EDD,
thin wire is selected as a tool so that tool is melted and
deposited over the substrate. Mohri et al. [9] noted that the
wear of a thin electrode is greater than that of a thick electrode
because of the difference in thermal resistivity. Mohri et al.
[10] observed that higher tool wear occurs in shorter pulse
having more spatial current density comparatively with longer
cess is advantageous to any additive process such that, com-
plex 3D microstructures with free form surface can be
manufactured at optimum cost which is observed by
Rajurkar et al. [5]. Chi et al. [11] fabricated 3D spiral structure
with brass electrode as a tool, steel as workpiece and air as a
dielectric medium. From spectrum analysis it is observed that
the composition of deposited material is almost same as tool
material. Wang et al. [12] fabricated brass micro cylinders
with approximately 200 μm in diameter and 1.2 mm in height
which is deposited on high-speed steel. Jain et al. [13] have
attempted for micro-fabrication of parts by using conventional
EDM machine and factors (current, duty cycle, and pulse on
time) are varied, in order to find the significant factors con-
tributing to the EDD process. It is realized that the presence of
magnetic field in EDD may enhance the deposition process by
forming uniform layer, increasing height, weight, and reduc-
ing the width of deposition. Heinz [14] reported that magnetic
field when used around plasma, discharge plasma channel will
be altered and the plasma particles will behave according to
electromagnetic field interaction and Lorentz force. Kazufumi
et al. [15, 16] observed plasma arc shape can be controlled by
the permanent magnet to get sound weld beads in a magne-
tized tungsten inert gas (TIG) arc welding process. Many
researches have been carried out in the area of welding using
magnetic field to confine the discharge of plasmas by Tayler
[17], Keidar et al. [18], Beilis et al. [19] and Rondanini et al.
[20] in order to improve the quality of welding. Still
now, limited literatures are available in the area of EDD
process, particularly using magnetic field to improve the
quality of deposition.

Fig. 2 Schematic diagram of EDD setup Fig. 3 EDD deposited layer