Metrological and Technological Quality Assurance in Electrospark Alloying of Automotive Engine Parts Surfaces

Abstract

The article is devoted to the study of the influence of electrospark alloying energy parameters on the formation of surface layer quality indicators of machine parts. The technological scheme of forming a strengthened surface layer by electrospark alloying is substantiated taking into account the physical mechanisms of electrode material transfer, thermal processes in the discharge zone, and the stochastic nature of surface microrelief formation.

It is established that the energy parameters of the process significantly influence the formation of surface microgeometry, microhardness, thickness of the strengthened layer, and wear intensity. With increasing discharge energy, the thickness of the strengthened layer and surface microhardness increase due to intensification of thermal and diffusion processes, while surface roughness also grows as a result of a more developed microrelief formation.

The analysis of experimental results showed that the minimum wear rate is achieved at a medium electrospark alloying режим, which provides an optimal combination of microhardness, strengthened layer thickness, and surface microgeometry. It is proved that wear resistance is determined by the complex interaction of surface roughness, microhardness, and strengthened layer thickness rather than by a single parameter.

A metrologically substantiated approach to quality evaluation is proposed, which includes the use of calibrated measuring instruments, statistical processing of results, and estimation of measurement uncertainty. The obtained analytical relationships make it possible to predict surface quality parameters and wear intensity depending on the energy режим of electrospark alloying and to ensure controlled formation of эксплуатационных свойств strengthened surfaces.