Enhanced plasma arc machining performance for improved surface characteristics of SS304 using nickel nano-coated copper nozzle

This study examines the use of nickel Nano-coating on copper nozzles in plasma arc machining (PAM) to improve performance in demanding industrial settings. PAM is a thermal cutting technique that employs ionized gas to create a high-temperature plasma arc, allowing for the accurate machining of challenging materials such as SS304 stainless steel, all while reducing heat-affected zones (HAZ). The effectiveness and caliber of PAM are significantly influenced by various process parameters, including arc current, cutting speed, and gas pressure. This study utilizes an L27 orthogonal array to methodically examine the impact of these parameters on surface roughness, contrasting nickel Nano-coated and uncoated 130A copper nozzles. The application of nickel Nano-coating through thin-film deposition technique results in a consistent and robust layer that improves the nozzle's resistance to wear, thermal conductivity, and stability during arcing. Experimental results indicate that Nano-coated nozzles yield smoother surfaces, exhibit decreased erosion, and sustain stable arc behavior, resulting in cleaner and more accurate cuts on SS304. The comparative analysis demonstrated that uncoated nozzles experience heightened wear and arc instability, which adversely affects machining accuracy. The evaluation conducted after machining, utilizing Scanning Electron Microscopy (SEM), revealed a notable reduction in wear and erosion on coated nozzles, thereby affirming their superior durability and prolonged service life. The enhanced coating significantly decreases surface deterioration, lowers the need for maintenance, and boosts overall machining performance. This study emphasizes the effectiveness of nickel Nano-coating in enhancing nozzle longevity and cutting performance through the refinement of critical PAM parameters. The findings indicate notable progress in materials engineering, providing a viable solution to improve PAM's reliability and cost-effectiveness for industrial applications. The study highlights the promise of Nano-coating in enhancing precision machining, minimizing downtime, and maximizing productivity in challenging manufacturing settings.