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Surface & Coatings Technology 202 (2008) 2765 – 2774

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A study on the characteristics of electrical discharge

textured skin pass mill work roll
Oktay Elkoca ⁎
Research and Development Department, Eregli Iron and Steel Works Inc., 67330 Eregli, Zonguldak, Turkey
Received 24 April 2007; accepted in revised form 8 October 2007
Available online 16 October 2007

Abstract

Electrical discharge texturing induces a recast white layer on the skin pass mill work roll surface, which forms the surface topography required
for outer autobody steel strips and a heat-affected zone beneath it. The characteristics of these thermally influenced layers were studied by means
of optical and scanning electron microscopes, X-ray diffractometer, radio frequency-glow discharge optical emission spectrometer and
microhardness tester. It was found that the electrical discharge texturing led to a dramatic hardness drop in the white layer, which was attributed to
the high amount of retained austenite. Moreover, softening was observed in over tempered section within heat-affected zone. Sub-zero and
cryogenic treatments seem to be potential methods in order to restore the hardness of white layer and over tempered zone with an increase in both.
Additionally, de-ionised water was found to be a promising dielectric liquid to abstain from retained austenite.
© 2007 Elsevier B.V. All rights reserved.

Keywords: Electrical discharge texturing; White layer; Retained austenite; Softening

1. Introduction Electrical discharge texturing (EDT) is an adaptation of formerly

The strict demands of consumers on the cold rolled steel
products dictate controlled topographical surface characteristics
regarding formability and appearance. The key point to satisfy
these characteristics is the production of sheet metal with a
predefined texture, which is imparted to the surface by the use
of textured rolls in both tandem and skin pass mills.
The textured surfaces play an important role in the
manufacturing of outer auto body panels [1,2]. During forming
process, craters formed in the textured surface can provide a good
reservoir for lubricating oil and, if they are produced randomly,
the textured surface would exhibit a uniform reflectivity after
painting. Therefore, dense and deeper craters on the textured
surface will improve the functional and aesthetical behaviour of
the sheet metal. Average arithmetic roughness (Ra) and peak
count in peaks per cm (Pc) are two well-known parameters to
define such a surface. High peak counts with constrained average
surface roughness are the essentials for outer auto body panels [3].
⁎ Tel.: +90 372 3293452.
E-mail address: oelkoca@erdemir.com.tr.
0257-8972/$ - see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.surfcoat.2007.10.004
established electrical discharge machining (EDM) to steel industry
in order to meet the demands for roll surfaces [2,3]. Basically EDM
is an eroding and removing process of the material from the surface
by transient action of electric sparks, commonly used to produce
die cavities. In EDT, this process is achieved by applying
consecutive spark discharges between a rotating roll and electrodes
moving in radial direction, which are separated by a small gap in
hydrocarboneous based dielectric liquid. In both process, each
spark melts and even evaporates a small amount of material due to
the high local temperatures. Then, all evaporated and a fraction of
the melted material removed from the surface due to flushing action
of the dielectric liquid. The result is a small crater on the surface that
has a rapidly re-solidified layer. Successive discharges at high
frequencies produce many randomly placed overlapping craters.
The shape and the depth of the craters, which determine the surface
roughness of the rolls, depend mainly on the operational parameters
such as discharge current, discharge duration, and polarity used [4–
6]. Compared with traditional shot blasting texturing, EDT allows
higher number of peaks at constrained average surface roughness,
which can be obtained in a higher repeatability.
EDM induces a characteristic recast layer at the top region
which is subjected to a surface tensile stress regime [7–9], micro
2766 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774
cracking [9–12], porosity formation [13,14], localized hardening
[9], incidental alloying with the pyrolysis products of cracked
dielectric [11,15–17] and tool electrodes [11,18,19]. Although
both EDT and EDM are similar in principle, the higher discharge
current and the longer discharge duration in EDM, which means
higher input discharge energy, lead to longer reaction-time, slower
cooling rate, thus giving a thicker recast layer and more chance
of absorbing carbon and electrode material. Rebelo et al. [12]
reported that microcrack formation was associated with the
development of high thermal stresses exceeding the ultimate
tensile strength of the material, as well as with plastic deformation.
Furthermore, the microcraks penetrate into the recast layer and
extend to depths, depending on the discharge energy.
Recast layer is known as white layer (WL) due to its resist-
ance to conventional metallographic reagents. The shape, thick-
ness and morphology of the WL depend on base material [9],
tool electrode [8,18], dielectric liquid used [8], and electrical
parameters selected during machining [10,13,20,21]. Lloyd and
Warren [18] obtained a fused outer zone consisting of dendritic
austenite and a cementite-austenite eutectic, when machining
with a graphite electrode and in paraffin dielectric under severe
operating conditions, or a fully austenitic surface followed by an
austenite-cementite matrix, when machining with a copper
electrode under less severe conditions. Optiz [10] reported a
hypereutectic recast layer in hot forging steel. Massarelli and
Marchionelli [8] reported similar structure of carbides in an
austenite matrix, but proposed that different electrodes do not
change the morphology of the white layer; only the ratio of the
carbide and the austenite phases varies. Cusanelli et al. [22]
reported that the white layer machined in dielectric oil presents
dendritic and columnar structures with different sizes and it
essentially consisted of retained austenite with some martensite
sublayers and an austenitic columnar structure with a very thin
thickness located at the WL-HAZ interface. As reported by Lee
et al. [23], WL was about the same for the four types of tool steels
investigated under identical discharge conditions. However,
intermediate recast layers, which was below the WL, consisted
of cellular dendrites and long dendrite arms depending on the
type of tool steels. Ghanem et al. [9] observed a dendritic
structure on the cross sections of the hardenable and non-
hardenable steels machined in hydrocarbon oil using rough
mode, yet it was not visible at low energy settings. Cabanillas et
al. [24] found two different regimes of carbide formation: e-
carbide, retained austenite and martensite for discharge of
energy below 0.5 J and cementite, retained austenite and traces
of martensite, Fe7C3, or Fe5C2 for higher spark energies on the
pure iron in hydrocarbon dielectrics.
Beneath WL, there is a heat-affected zone (HAZ) where the
emerged heat is not enough to cause melting, but is sufficiently
high to induce microstructural transformations. The depth of HAZ
is controlled by the thermal diffusivity, the heat treatment history
Table 1
Chemical composition of the roll material (wt.%)
C Si Mn Cr Mo Ni Fe
0.86 0.56 0.50 3.42 0.31 0.18 Balance
Table 2
EDT test parameters
Band Discharge time Off-time Average current Average energy
(μs) (μs) (A) (A⁎ s)
A 12 25 15 1.80 ⁎ 10− 4
B 17 40 28 4.76 ⁎ 10− 4
C 45 50 15 6.75 ⁎ 10− 4
of bulk material, presence of any allotropic changes and electrical
parameters used [9,10,18,20,21]. Cusanelli et al. [22] reported
that HAZ was composed of tempered martensite and was the
origin of microcraks. Rebelo et al. [12] identified two zones in
HAZ machined in rough regimes for two initial states of steels: a
quenched and tempered layer for quenched and tempered steels,
and a quenched and treated layer for annealed steels. In polished
regimes of machining, one zone was distinguished: a tempered
layer for quenched and tempered steels; and a treated layer for
annealed steels. Ghanem et al. [9] observed a quenched layer
following a thin transition layer in case of hardenable steel, and
only a slight growth of grain size under the WL in case of non-
hardenable steel.
Electrical discharging process can significantly affect
hardness, wear, fatigue, and corrosion resistance [17,18,25].
Since EDMed surfaces contain microcracks and residual tensile
stress, components operating under tensile loading exhibit a
reduced fatigue life. On the contrary, an increase in fatigue life
has been experienced with the components operating under
compressive loading such as in drop forging dies. Therefore in
some circumstances, the recast layer is removed by etching and
hand polishing or modified by shot peening after EDM.
A WL, which is expected to be harder than the bulk work-
piece due to the rapid solidification, would be utilized for roll
applications requiring wear resistance since the wear charac-
teristic of a roll surface is the key factor to determine the roll
performance. The permanence time in mill and the mileage of
the rolled strips are the results of the resistance to the loss of
roughness on the roll surface.
Although there are many investigations on the microstructural
alterations and their effects on the mechanical properties in EDMed
parts, it is very rare for the EDTed ones. Similar microstructural
alterations would be expected in the heat-affected layers of EDTed
rolls, due to its thermal nature despite of the fact of a significant
progress in surface topography. Therefore, the purpose of the
present study is to elucidate the microstructural alterations and
mechanical variations regarding hardness in thermally affected
layers beneath the EDTed roll surface. Also, the effect of sub-zero
and cryogenic treatments on the restoration of alterated sublayers
and the use of de-ionised water substituting for dielectric oil in
terms of required surface topography were investigated.
2. Experimental procedure
2.1. EDT experiments
Experimental studies were conducted on the basis of a work
roll, which had been used for skin passing of the galvanized
 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774 2767

Table 3 Some samples extracted from the ground roll and textured in
EDM test parameters de-ionised water using Furkan 25A-conventional die-sinking
Sample Discharge time Off-time Average current Average energy type EDM machine, which has a transistor type signal generator.
(μs) (μs) (A) (A⁎ s) The texturing parameters were selected in order of providing a
1 25 50 25 6.25 ⁎ 10− 4 surface topography resembling the band B (Table 3).
2 12 50 25 3.00 ⁎ 10− 4
2.2. Subsequent treatments

steel strips. The chemical composition of electro-slag remelted,
forged, induction hardened and eventually tempered of the work
roll is given in Table 1.
The roll surface was first ground and then textured by
Roltex-Sarclad Ltd.'s industrial type EDT machine, which has
transistorised type pulse generators, using a high phosphorous
copper electrode and Esso Somentor 43 dielectric oil. Three
different textured bands denoted A, B, and C on the same roll
were produced under the test parameters shown in Table 2,
which had been established in the industrial trials in order to
obtain required surface texture on the galvanized steel strip for
outer auto body panels. All the bands were machined under
positive polarity with the same roll surface speed of 8 mm/min
and axial feed rate of 30 mm/min. The disks representing each
textured band were cut from the roll using a cutting saw. A
precision cut-off disc was used to extract small samples for
analytical examinations.
Tempering, sub-zero and cryogenic treatments were applied
to the samples to reveal the effects of these treatments after
EDT. The sub-zero treatment was carried out at − 70 °C for 24 h
with Herzog RL 10 CH refrigerated circulators using refriger-
ated alcohol and a calibrated K-type digital thermocouple. The
cryogenic treatment was performed by dipping the EDTed
samples into liquid nitrogen for 24 h. The tempering processes
were carried out at 200 °C for 1 h in Memmert laboratory type
oven.
2.3. Examinations
Ra and Pc values of each EDTed band were measured with a
portable Mahr Perthometer M2 profilometer using evaluation
length of 12.5 mm, cut-off length of 2.5 mm and peak count
setting level of 0.5 μm. The results are the average of minimum
20 readings.

Fig. 1. Surface topography of the band (a) A, (b) B, (c) C, and (d) the sample textured in de-ionised water.
2768 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774
Table 4
Ra and Pc values of the ground roll, the band A, B and C, and the required ones
Band Ra (μm)
Ra 3.60–3.90
Gb 0.66
A 1.91
B 3.69
C 4.08
a
Required values.
b phases were identified from searches in the database of Joint
Ground roll surface.
Topographical observations were performed using a Jeol
JSM-5600 scanning electron microscope (SEM). For micro-
structural observations, samples were prepared using conven-
tional metallographic technique on the cross and taper sections,
which the later were inclined approximately 7° to the roll
surface. The polished sections were etched with Nital 3 and a
strong etching reagent composed of 20 ml HNO3 and 60 ml HCl
to reveal the microconstituents below the textured surface, and
examined through Nikon Epiphot 200 optical microscope and
SEM.
Microhardness measurements were made on Future-Tech
FM-700 hardness tester using Vickers indenter, 25gf loading
and 10 s indentation-time, using the standardized procedures of
ASTM E 384 [26]. Readings of the indentation diagonals were
precisely performed at a magnification of 6000 through SEM.
Microhardness depth profiles were produced on the cross
sections, which had been polished and slightly etched in order
to distinguish the heat-affected layers and remove any residual
deformation caused by metallographic preparation.
Analysis of surface enrichment/depletion of the EDTed
samples was conducted by Jobin Yvon radio-frequency glow
discharge optical emission spectrometer (RF-GDOES), using
qualitative depth profiling. The structure and the amount of
retained austenite in original roll and recast layers were
identified using Rigaku D/MAX-2200 Ultima + X-ray diffrac-
tometer equipped with Cu target and graphite single crystal
monochrometer. The working conditions were 40 KV and
40 mA for both analyses. The data were collected using Cu-Kα
radiation (λ = 1.5405 Å) between 30° and 100° in 2θ. The
Fig. 2. Microcracks on the surface of the band C.
Table 5
Surface roughness measurements of the EDMed sample
Pc (1/cm) Sample Ra (μm) Pc (1/cm)
81–89 Ra 3.60–3.90 81–89
96 1 2.94 61
110 2 2.58 87
82 a
Required values.
67
Committee on Powder Diffraction Standards.
3. Results
3.1. Surface texture
The high temperature gradients within discharge incident
area and violent explosive removal process produced randomly
overlapped craters on the all surfaces disregarding the dielectric
type and test parameters. The low released energy for the high
peak counts induced the local non-textured areas with several
overlapped craters scattered on them in band A. The streaks in
Fig. 1a represent the fragments from the ground roll surface, and
the small crates within these streaks lead to an increase in peak
count (Table 4). The higher discharge energy produced larger
craters in size in ascending order of Fig. 1a to c, leading Ra to
increase, but Pc to decrease as shown in Table 4, which can be
explained with the lower number of craters and rims surround-
ing them within the evaluation length. Additionally, several
microcraks are visible at randomly spaced locations at high
energy levels (Fig. 2). This is the indication of highly stressed
layers due to the high thermal loading in band C.
Alternatively, texturing in de-ionised water produced
comparable surface topographies with those in dielectric oil
(Fig. 1d), however measured Ra values are slightly less than
those specified for the roll surface for outer auto body panels
(Table 5).
At a given pulse energy, the diameter and depth of a crater
influenced due to discharge time and discharge current
respectively [23]. This implies that increasing the discharge
current at low discharge time result in high peak counts due to
deeper craters at specified average roughness (Table 4). In this
Fig. 3. Microstructure of the roll material.
 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774 2769

Fig. 4. XRD patterns of the original roll, EDTed and subsequently treated samples.

context, the surface in the band B (Fig. 1b) represents the
texture required on the roll surface to meet the demands on auto
body panels.
3.2. Microstructural morphologies
The original roll composes of tempered martensite matrix
and M6C and MC type secondary carbides (Fig. 3). XRD
analysis of the polished samples of the original roll reveals some
retained austenite in addition to the other microconstituents
(Fig. 4).
A WL with a heterogeneous thickness is revealed at the top
through all the cross and tangential sections of the EDTed bands
after etching with Nital 3, suggesting that discharges have led to
the high temperatures sufficient to melt the surface and dissolve
the M6C and MC carbides (Fig. 5a–b). Etching tangential
sections in Fig. 5b with the strong reagent reveals martensitic
needles at the border zone of WL-HAZ and cellular structure
within the WL (Fig. 6). Average thickness of the WL changes
with the input discharge energy as shown in Table 6. In the light
of the findings from the previous industrial trials on-site and the
reports of the researchers [12,13] it can be concluded that the
thickness of WL correlates well with the input discharge energy.
Neither the discharge current nor the discharge duration has a
significant effect on the thickness of the WL. In other words, the
magnitude of the WL depends on only the area or size of the
current pulse-form, but not its shape. At high discharge energy
levels, a few microcracks passing through WL can be noticed
2770 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774

Fig. 5. Cross (a) and tangential (b) sections of the EDTed surfaces.

(Fig. 7). The WL of the band B forms the required surface
topography for the skin pass mill work roll, providing a
microcrak-free surface with the required Ra and Pc values.
A non-melted, but heat-affected zone (HAZ) below the WL
is observed, which is consisted of two different layers as shown
in Fig. 5, corroborating the results of Rebelo et al. [12] for
quenched and tempered steels. The first light grey layer
downward in Fig. 5a and to the left side in Fig. 5b is quenched
layer known as untempered martensite (UTM), which is
composed of re-austenitized and subsequently quenched base
material, caused by a rapid heating following quenching. Some
residual secondary carbides in martensite plates can be observed
in UTM as shown in Fig. 7. Dark layer following UTM zone is
known as over tempered martensite (OTM), which is the region
of repeatedly tempered core material by the emerging heat
during consecutive discharges.
X-ray diffractions in Fig. 4 and retained austenite contents in
Table 7 show that the WL occurred during EDT essentially
consists of significant amount of retained austenite with some
martensite (Fe-α) and carbides. It is thought that retained
austenite is situated at the uppermost sections of white layer,
where the carbon content is the highest as shown in qualitative
depth profile (Fig. 8). A small amount of copper has also found
at the top of the WL, indicating a migration from the tool
electrode.
The chosen EDT process parameters give identical micro-
hardness dept profiles in this study. They demonstrate that the
hardness level in WL is noticeably below than the bulk material,
however a sharp increase in the hardness in UTM region is
observed reaching its peak value just below the WL-HAZ
interface, following a decrease in OTM, which is lower than the
bulk material (Fig. 9). Contrary to the hydrocarboneous
dielectric, de-ionised water dielectric liquid gave higher and
more uniform hardness values within the WL (Fig. 9).
After sub-zero and cryogenic treatments, outstanding
hardness increments are observed within WL, and even within
bulk material (Fig. 10). Tempering after EDT alone or following
cold treatments result in higher decrease in hardness through the
hardness dept profile.
4. Discussions
The experimental results clearly show that extremely high
heating and cooling rates of EDT lead to rapid melting and
solidification of textured roll surface, re-austenitizing and over
tempering of layers below it.
A carbon enrichment in the recast top layer confirms
microsegregation from the cracked dielectric oil during dischar-
ging process, which is agreed with many researcher [11,15–
17,22,27]. It is suggested that the carbon enrichment leads to a
high amount of retained austenite and consequently a hardness
drop in this layer. Marder and Krauss [28] propose that martensite
transformation is incomplete in quenched high carbon steels as a

Table 6
Average WL thickness with respect to the test parameters
Band Test parameters Average WL
thickness (μm)
Discharge time Average current Average energy
(μs) (A) (A⁎ s)
A 12 15 1.80 ⁎ 10− 4 4.0
B 17 28 4.76 ⁎ 10− 4 4.8
C 45 15 6.75 ⁎ 10− 4 5.7
Fig. 6. Tangential section etched with the strong reagent.
 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774
Fig. 7. Microcracks within the WL.
result of significant decrease in transformation temperature with
the high carbon content. For a typical low-carbon lean alloy steel,
the martensite transformation range is from 450 to 200 °C,
whereas a case-hardened surface with high carbon concentration
has a martensite transformation range from 200 °C down to about
−100 °C [29]. Therefore, if carburising temperatures are high, and
if austenite is allowed to become saturated with carbon, then large
amounts of retained austenite can be expected. In carburised
steels, retained austenite has a marked effect on hardness,
especially with direct quenching, which is shown by a sharp
decline of hardness. In case of EDT, carbon from dielectric oil
concentrates in a narrow region of solid, where consequently a
complete stabilization of austenite is allowed. Therefore, a front
that entirely consists of retained austenite separates martensitic
region underneath it. These results strongly suggest that the fine
features of the WL are the results of micro segregation associated
with rapid non-equilibrium freezing. The low hardness in WL is
contradictory to the findings of Ghanem et al. [9] suggesting a
surface hardening almost three times higher than the bulk
hardness of the hardenable steels containing 0.95 and 1.58% C,
machined in rough mode. A columnar and dendritic structure
achieved in rough mode is indicative of a slower cooling rate
when compared to finishing mode, which the dendritic structure is
not visible as obtained in this study. It reveals that rough
machining parameters of EDM can cause slow cooling after the
cessation of successive discharges, preventing the formation of
high amount of retained austenite when compared to the fine
texturing parameters of EDT. This finding is ascertained with that
of EDM in de-ionised water with the operation parameters close
to the EDT's, producing a small amount of retained austenite
(Table 7), and higher hardness values in WL (Fig. 9). Hardness
increase in de-ionised water can be correlated with microstruc-
tural refinement caused by extremely high cooling rate after the
cessation of discharges. Ogata et al. [17] reports a decarburised
layer on the SKD 11 steel when EDMed in de-ionised water, but it
cannot be seen in this study probably due to the significantly thin
WL in all the bands produced via EDT.
Possible causes for the variation in the proportion of retained
austenite at room temperature change in one of the following
factors: chemical composition, residual stresses, dislocation
density and grain size, since all these factors affect the martensite
2771
start temperature (Ms) of the steel [30]. Regarding the influence of
composition, it is well-known that the Ms temperature decreases
with increasing content of alloying elements. Therefore, the
reason of high proportion of retained austenite in oil dielectric
could be solute trapping of carbon with increasing solidification
speed in thin WL. This could result in super saturation of austenite
leading to its stabilization at room temperature. Colaço et al. [31]
proposes that the decrease in the primary interdendritic spacing in
the sense of grain size is most probably the main reason of the
large proportion of retained austenite in laser surface melted tool
steels. In agreement, only microstructural refinement caused by
rapid cooling can be responsible for the stabilization in de-ionised
water case, which produces slightly higher proportion of retained
austenite than the original roll material (Table 7).
A high level of retained austenite usually result in tool failure
after very short service periods and is currently one of the main
reasons in tools made of high speed steels with carbon con-
centrations exceeding 0.8% [32]. Also, retained austenite being a
metastable phase appears to be the main reason for spalling of
indigenous rolls [33]. It has been reported that retained austenite
possibly converts to martensite resulting in expansion of volume
that creates internal pressure and causes spalling. Conducting a
sub-zero treatment is a practical method to remove the retained
austenite after conventional induction hardening [34]. In dis-
agreement, the retained austenite content in this study has not
significantly changed after the sub-zero and cryogenic treatments
as shown in Table 7, however the hardness within the WL, HAZ,
and even the bulk material has increased (Fig. 10). The result is
similar to the Lloyd et al.'s [18], suggesting that the austenite
phase saturated with carbon is stable and unaffected by cryogenic
treatment. Hardness increase can be attributed to the preferential
precipitation of fine carbides by slightly shifting carbon atoms due
to the lattice deformation through cold treatments, without
noticeably reducing the amount of retained austenite [35].
Considering the hardness increase with the cryogenic treatment
at −197 °C compared to the sub-zero one at −70 °C, it can be
concluded that lower temperatures are much more effective on the
lattice deformation to enhance the preferential precipitation of fine
carbides via shifting. The tempering treatment after neither EDT
alone nor following cold treatments seem to be a solution to
restore the low hardness level of the roll, on the contrary causing
softening probably due to the decomposition of martensite in
addition to retained austenite into ferrite and carbide precipitation.
In UTM, austenite grain boundaries disappear and undissolved
primary carbides increase in size towards the WL. Since this light
etched region has been heated to the austenite region, the fine
Table 7
Retained austenite content of the original roll material and treated samples
Sample Retained austenite Standard deviation
(%) (%)
Original roll material a 21.41 0.98
EDTed 89.20 3.34
EDTed + sub-zero treated 88.68 4.09
EDTed + cryogenically treated 81.33 5.30
EDTed in water 28.96 5.38
a
Polished to the flat.
2772 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774

Fig. 8. Depth profiling of the EDTed surface.

secondary carbides, which precipitated during the original
tempering, dissolve. The dark regions observed on the cross
and tangentional sections are the over tempered base material
(OTM). Below HAZ, original roll material structure comprising
tempered martensite with a dispersion of fine globular carbides
can be visualized.
EDT deteriorates mechanical properties of the skin pass mill
work roll through softening of WL and OTM layer. The softening,
particularly in the WL, would be a negative effect on the service
life and the performance of work rolls. Consequently chromium
plating of EDTed work rolls has currently been a common
method, which provides four times longer service life with an
additional advantage of a higher Pc value for a skin pass mill work
roll [36]. OTM layer could also lead to a decrease in the strength
of the core that supports the textured surface layer. Cold
treatments have little influence on recovering the hardness of
this zone, still lying below the original roll's as shown in Fig. 10.
De-ionised water can be used as a dielectric liquid in EDT so
as to avoid from retained austenite. Performance of the de-
ionised water is generally lower than that of hydrocarboneous oil
in EDM, which is attributed to its lower viscosity that produces
less restriction at the discharge channel, thus reduces the energy
density, and consequently decreases the material removal rate
[37]. Moreover, in EDM, large amounts of energy requiring to
heat and vaporize water compared to oil results in lower gas
pressure in the gap [38]. However, EDT with a low material
removal rate presents an opportunity for de-ionised water to be
used as a dielectric liquid. As shown in this study, the texturing in
water results in comparable surface topographies with those of
dielectric oil, however it needs further work to carried out to
determine the discharge conditions that would give the Ra value
required.
5. Conclusions
The following conclusions have been deduced from the
study.
1. EDT leads to a softening in thermally affected layers beneath
the textured surface though it produces the required surface
topography. The softening is caused by the hardness drop in
WL and OTM zone, with the formation of high amount of
retained austenite in the former and as a result of re-
tempering of tempered martensite in the latter.

Fig. 9. Hardness depth profile on the cross-sectioned surfaces.

 O. Elkoca / Surface & Coatings Technology 202 (2008) 2765–2774
Fig. 10. Microhardness distribution after EDT and subsequent treatments.
2. The carbon enrichment in WL, diffused from the cracked
hydrocarboneus dielectric liquid, is thought that leads the
martensite start temperature to go down the lower degrees
and, consequently, yields the stabilization of austenite.
3. Carbon content gradually decreases through the WL,
separating the upper region having a sharp drop in hardness
from the underlying region with higher hardness, that under-
gone the austenite-martensite transformation.
4. Alloying with carbon is limited within the WL, therefore the
only reason for hardness increase in UTM is re-austenizing
and quenching of this zone, owing to the high discharge
temperatures and extremely high cooling rates emerged du-
ring EDT.
5. Retained austenite phase is quite stable and unaffected by
sub-zero and cryogenic treatments. Therefore, the hardness
increase after these treatments can be attributed to the
preferential precipitation of fine carbides by slightly shifting
carbon atoms due to the lattice deformation through cold
treatments.
6. Sub-zero and cryogenic treatments, as the later being more
effective, after EDT appear to be the potential methods to
restore the hardness within WL, HAZ, and even within the bulk
material.
7. De-ionised water seems a promising dielectric in EDT to
abstain from retained austenite. However, it needs further
work to carry out to determine the discharge conditions that
would give the Ra value required.
Acknowledgements
The author is grateful to the employees of Eregli Iron and
Steel Works Inc. for their continuous support and patience.
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