Journal of Manufacturing Processes 60 (2020) 384–399

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Journal of Manufacturing Processes

journal homepage: www.elsevier.com/locate/manpro

Technical Paper

Three-dimensional topography analysis of electrical discharge textured

SS304 surfaces
S. Jithin, Upendra V. Bhandarkar, Suhas S. Joshi *
Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai 400076, India

A R T I C L E I N F O A B S T R A C T

Keywords: In the current work, a comprehensive three-dimensional topography characterization of electrical discharge
Surface topography textured SS304 surfaces is performed under the following heads: quantitative representation, microstructures
Surface texture and their distributions, and surface functionality. Topography analysis reveals that peak count distribution tends
Areal texture parameters
to become flattened with their mean shifting to higher heights when discharge energy increases. Higher
EDT
discharge energy generates rougher textured surfaces with taller and sharper, but less densely distributed peaks.
SS304
These textured surfaces also show improvement in wetting and sealing properties, more running-in period wear
MSC:
00-01
volume, more surface area for load carrying, and improved lubricant retention capacity.
99-00

1. Introduction section. Thus, these parameters are identified as a better representation

Electrical discharge texturing (EDT), which is evolved from the spark
erosion or electrical discharge machining (EDM) process, generates
random surface textures. Researchers have employed these random
surface textures in a variety of components, such as mill rolls [1], or­
thopedic implants [2], and tool inserts [3] to improve their functional
performance. Such random surface generation using EDT is also found to
influence specific surface properties, such as wettability, as evident from
the hydrophilic-to-hydrophobic transformation of SS304 surfaces on
subjecting to EDT [4]. More recently, these textures were also found to
be suitable for anti-fouling (in heat transfer) [5], anti-bacterial [6], and
self-cleaning [7] applications. Surface characterization of these random
surfaces generated using EDT was historically performed in terms of
profile roughness parameters, such as Ra, Rq, and Rz, due to limitations
in surface measurement methods. Since these parameters are measured
along a 2D profile taken on the surface, a majority of surface points are
omitted. Therefore, they tend to give only a limited information about
the surface. Moreover, in the case of directional surfaces, the measured
profile roughness parameters vary drastically with a variation in the
direction of the selected section. The recent improvements in surface
measurement methods enable scanning three-dimensional topography
of the textured surfaces, and thereby, the measurement of areal texture
parameters (or 3D roughness parameters), which are evaluated consid­
ering the whole surface topography, as opposed to a single profile or
of surface topography.
There are a few attempts on three-dimensional surface topography
characterization in the available literature. In one such work, Ram­
asawmy and Blunt [8] characterized the surface topographies generated
on tool steel using EDM, in terms of areal texture parameters, such as
arithmetic mean height (Sa), root mean square height (Sq), density of
summits (Sds), material volume (Sm), core void volume (Sc or Vvc),
valley void volume (Sv or Vvv), and core roughness depth (Sk). They
also analyzed the influence of operating factors, such as discharge cur­
rent and pulse on-time, on these parameters, and found that current is
the most significant factor influencing the surface texture generated
during EDT. In a related work [9], they tried to establish a correlation
between average white layer thickness (AWLT) of the textured surface,
and areal texture parameters. Since the measurement of AWLT usually
required destructive methods, the authors aimed to develop regression
models to evaluate AWLT in terms of these areal texture parameters,
which are comparatively easy to measure and does not require
destructive measurement methods. They found that the regression
model of AWLT in terms of Sds gave the best fit. Sds was also identified
by Deltombe et al. [10] to be the most significant parameter to represent
the topography of EDT surfaces. Jithin et al. [11] characterized SS316L
surfaces textured using copper, tungsten, and copper-tungsten tool
materials, in terms of Sa. They found that the copper electrode induced a
larger variation in Sa of these surfaces for varying pulse on-time and gap

* Corresponding author.
E-mail address: ssjoshi@iitb.ac.in (S.S. Joshi).

https://doi.org/10.1016/j.jmapro.2020.10.066
Received 18 July 2020; Received in revised form 20 October 2020; Accepted 23 October 2020
Available online 2 November 2020
1526-6125/© 2020 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
S. Jithin et al. Journal of Manufacturing Processes 60 (2020) 384–399

voltage compared to that with the other two electrode materials.

Świercz and Świercz [12] performed EDM on high conductivity tool
steel and characterized the resultant surface topographies in terms of
areal texture parameters such as Sa, Sds, and arithmetic mean summit
curvature (Ssc). They found that an increase in discharge current and
pulse duration resulted in higher roughness, larger crater dimensions,
and taller and rounder peaks. In another work, they [13] compared
surface topographies generated in EDM using pure dielectric and 0.1%
reduced graphene oxide (RGO) mixed dielectric, by means of bearing
area parameters. They correlated increase in reduced summit height
(Spk) with improvement in wear resistance and found that use of RGO
improves the texture’s wear resistance. Random or periodic nature of
EDT surfaces was analyzed and quantified by Aich and Banerjee [14] in
terms of a parameter known as periodicity-to-randomness ratio (PR
ratio). They reported that PR ratios for EDT surfaces are very low, which
indicates dominance of randomness over periodicity. In another work,
Aich [15] reported the dominance of deterministic chaos on surface
Fig. 1. Experimental setup for electrical discharge texturing (EDT) of SS304.
topographies generated using EDM. Jithin et al. [16] developed two
modes of EDT based on the electrode movement for surface texture
to analyze different aspects of the surface, such as a quantitative rep­
generation: circular-face EDT (CirEDT) and cylindrical-face EDT
resentation of the textured surface, characterization of surface micro­
(CylEDT). They reported that CirEDT gave lunar-craters-like surface
structures and their distributions, and the surface functionality in
patterns, whereas CylEDT results in sea-waves-like surface patterns.
various applications, and to analyze the influence of discharge energy on
Besides, they performed extensive areal texture parameter analyses on
these surface aspects.
the surface topographies generated. They found that CylEDT surface
topographies have more points below mean plane, sharper peaks, more
2. Materials and methods
running-in wear volume, and less lubricant retention capacity, as
compared to those of CirEDT counterparts. Recently, some interest in
The experimental materials and methodologies used to perform
the analysis of surface topographies generated using micro-EDM, a
characterization of surface topographies generated using EDT are dis­
micro-scaled version of EDM, could also be found in the literature. Hyde
cussed in this section. These are selected based on the various aspects of
et al. [17] performed micro-EDM of stainless steel and studied the in­
the surface topographies to be analyzed.
fluence of operating factors on the conventional and fractal texture
The authors selected stainless steel 304 (SS304) as the work material
parameters measured on the textured surface. They also found the
for this study. SS304 is used in several surface contact applications, such
discharge current to be the most significant factor. D’Urso et al. [18]
as food processing equipment, chemical containment, and heat ex­
utilized surface characterization in terms of areal texture parameters to
changers. Thus, a comprehensive characterization of random and
distinguish between topographies of micro-EDM milled stainless steel
isotropic surface topographies generated on SS304 by EDT, is of much
and ceramic surfaces. They found that topographies of the former
interest in improving its functionality in current applications and
display negative skewness (Ssk), whereas those of the latter exhibited
feasibility for new applications. SS304 samples of dimensions 40 mm ×
positive skewness. It is understood from their findings that the surface
20 mm × 5 mm are precision milled and polished (up to Grade 220
topographies generated on different materials using the EDT process at
emery paper). The tool material selected was copper, as it gives an
similar operating conditions show a significant variation among them­
extensive range of roughness values on the work surface, in terms of Sa,
selves. In addition to the experimental surface topography character­
against variation in discharge current and pulse on-time [11]. We used
izations, certain researchers such as Izquierdo et al. [19] and Jithin et al.
copper rods of 10 mm diameter with their circular faces polished (up to
[20,21] have developed three-dimensional mathematical models to
Grade 220 emery paper). The dielectric material selected for EDT ex­
predict EDT surface topographies with reasonable accuracy and char­
periments was paraffin oil.
acterized them. However, these models are unable to simulate surface
The authors conducted the EDT experiments on a CNC EDM, and the
irregularities such as micro-cracks, micro-globules, blow holes, etc.
experimental setup used is shown in Fig. 1. The milled workpiece is fixed
Hence, experimentally obtained surface topographies gives more infor­
parallel to the machine table using a drill press vice and a magnetic v-
mation about the textured surfaces as compared to that given by their
block. The circular face of the copper electrode is used for texturing the
modelled counterparts.
SS304 samples, which results in a circular textured region. External
From the above study, it could be understood that three-dimensional
dielectric flushing is provided to the tool-work gap to prevent debris
topography characterizations of EDT surfaces are not extensively carried
accumulation and thus reduce surface damages.
out in the literature. Those available do not cover a significant number
The study is conducted varying discharge energy (E) to analyze its
of areal texture parameters. A comprehensive characterization needs to
effect on the different areal texture parameters evaluated. Discharge
encompass several areal texture parameters to cover the different as­
energy is varied from fine to rough finish levels in the range of 0.5 to
pects of the surface topography they represent. Moreover, in the avail­
500 mJ. The variation in discharge energy is obtained by varying EDM
able literature, the majority of areal texture parameters analyzed are
operating parameters, such as discharge current (I), pulse on-time (ton ),
areal field parameters, which take into consideration all surface points
and gap voltage (V) in ranges of 5 to 50 A, 10 to 100 μs, 10 to 100 V,
in the evaluation area. However, areal feature parameters, another class
respectively.
of areal texture parameters, which only considers specific distinguish­
The main goal of the current work is to perform a comprehensive
able features of the surface, such as points, lines, or areas, are scarcely
three-dimensional analysis of EDT SS304 surface topographies. We
analyzed [22]. These parameters are more influential on surface per­
desire to achieve a quantitative representation of the textured surfaces,
formance [22], and hence, they are essential to be analyzed. Therefore,
characterize the surface microstructures and their distributions, and
the current work deals with a comprehensive three-dimensional
analyze surface functionality in various applications through this three-
topography characterization of SS304 surfaces subjected to EDT, in
dimensional topography analysis. Therefore, we performed surface
terms of different areal texture parameters. We group these parameters
topography analysis with several areal texture parameters, which cater

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Fig. 2. Classification of parameters used in surface topography characterization.
to each of these aspects. The different aspects of surface topography
classification, their sub-focuses/purposes, and the corresponding areal
texture parameters used in this analysis are given in Fig. 2. Initially, the
authors perform a quantitative representation of the textured surfaces
under two heads: roughness estimation and surface height. Secondly, we
characterize the microstructures and their random distribution in EDT
surface topographies generated under groups such as surface symmetry,
isotropy or anisotropy, peak distribution, peak roundedness or sharp­
ness, and surface complexity. Finally, we investigate the applicability of
the textured surfaces in various functions under four classes: wetting and
sealing properties, wear volume available for the running-in period,
surface post-running-in wear, and lubricant retention. We also investi­
gate how these topography aspects vary with a change in discharge
energy used for generating the EDT SS304 surfaces. Thus, we arrive at a
comprehensive characterization of EDT SS304 surface topography.
We employ a 3D optical profilometer known as Alicona Infinite
Focus Microscope for scanning the surface topography of EDT SS304
samples. Readings are taken at each quadrant of the textured circular
region on SS304 samples, at 10× magnification. Readings are repeated
at these quadrants a few times and averaged to reduce errors. We used
MountainsMap software to process the scanned data and to evaluate the
different areal texture parameters required. Initially, the scanned sur­
face is leveled, and then, the outliers are removed. Form and waviness
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Journal of Manufacturing Processes 60 (2020) 384–399
components are filtered on the scanned surface to get roughness (S-L)
surface, which has only the roughness components. A Gaussian filter
with a suitable cut-off wavelength (λc ) needs to be applied to obtain the
S-L surface. It is essential to select a proper λc for filtering. The average
inter-peak and inter-valley distance on the surface topography was
evaluated to be 100 μm, at the lowest discharge energy (0.5 mJ) used for
EDT experiments. As per the usual rule of thumb, the cut-off wavelength
(λc ) is selected as five times this inter-peak distance. Thus, λc is 500 μm
or 0.5 mm. Short-wave (λs ) filtering also needs to be applied on the
surface. ISO suggests a bandwidth (λc /λs ) of 300:1 for S-filtering or
short-wave filtering [23]. Thus, S-filter is performed with a λs value of
1.67 μm. The topography images and areal texture parameters are
measured on this S-L surface obtained after filtering. The areal feature
parameters such as ten-point height (S10z), density of peaks (Spd), and
arithmetic mean peak curvature (Spc) are evaluated at 5% Wolf pruning.
3. Results and discussion
In this section, initially, we analyze the scanned surface topography
images to study the surface characteristics. Further, EDT SS304 surfaces
are characterized to obtain a quantitative representation of the textured
surfaces, to characterize the surface microstructures and their distribu­
tions, and to analyze surface functionality in various applications.
S. Jithin et al. Journal of Manufacturing Processes 60 (2020) 384–399

Fig. 3. Surface topographies (a–f) obtained at different discharge energies (E).

3.1. Topography analysis

Topography analysis is performed in terms of scanned topography

images. The surface topographies obtained at varying values of
discharge energies are represented in Fig. 3. The authors observe that
surface topographies obtained at all levels of discharge energies display
random distribution of peaks and valleys in shape, size, and location. On
the other hand, we also observe that the dimensions of peaks and valleys
tend to increase with the rise in discharge energy used for texturing. This
increase in peak and valley dimensions is indicated in the increase in
maximum height (Sz) of the surface from 26.6 to 95.0 μm (257% in­
crease) as discharge energy increases from 0.5 to 500 mJ. As the
discharge energy increases, it leads to a corresponding increase in spark
eroded cavity dimensions, and these larger cavities lead to taller peaks
and deeper valleys. The increase in dimensions of the peaks and valleys
result in a general increase in the arithmetic mean height (Sa), which is a
common field parameter used to represent 3D roughness. We observe
that an increase in discharge energy from 0.5 to 500 mJ results in an Fig. 4. Peak count distribution histograms for surface topographies at
increase in Sa from 1.64 to 7.54 μm (360% increase). Thus, varying the discharge energies (E) of (a) 0.5 mJ, (b) 50 mJ, and (c) 500 mJ.
discharge energy in the EDT process can help achieve textured surfaces
of low to high roughness. On the contrary, the increase in peak and reduction of the textured surface. Thus, the height range of the majority
valley dimensions with an increase in discharge energy, results in an peaks will have a significantly greater influence on the surface func­
overall decrease in the density of peaks (Spd), which is a feature tionality, as compared to that by the tallest peak. Therefore, peak count
parameter used to quantify peak distribution on the surface. We identify distribution histograms for surface topographies obtained with
the density of peaks (Spd) as a better representation of peak distribution discharge energy values of 0.5, 50, and 500 mJ are compared (see
on the EDT surface as compared to the more commonly used field Fig. 4). We observe that for all the EDT surface topographies considered
parameter known as the density of summits (Sds). This is because the in Fig. 4, the peak count distribution for various heights follows a normal
former only considers the significant peaks, whereas the latter also in­ distribution. Considering the peak count distribution histogram of
cludes smaller and insignificant peaks that do not have a significant role topography obtained at 0.5 mJ (see Fig. 4(a)), we observe that even
in contact applications. An increase in discharge energy from 0.5 to though the highest peak height is near 25 μm, the unit evaluation area of
500 mJ results in a decrease in Spd from 251.9 to 105.0 /mm2 (58% the surface has only two peaks at that height. The majority (≈66 nos) of
reduction). Thus, high discharge energies result in textured surfaces peaks on this surface are at the height ∼17 μm. This due to the random
with fewer peaks and valleys (as seen in Fig. 3). nature of surfaces generated using the EDT process. We also infer that at
It is also important to characterize the surface topographies in terms low discharge energies of 0.5 mJ, the normal distribution is compara­
of peak count distribution at various heights. Spd only quantifies the tively steep, with the highest peak count of 66 peaks/mm2 at the low
number of significant peaks, and Sz only gives the height of the tallest height of 17 μm (see Fig. 4(a)). However, as the discharge energy in­
peak. Therefore, analyzing the peak count distribution will give an idea creases, the normal distribution tends to become flattened and shifts its
about the height range for a majority of the peaks. The tallest peak can mean to higher surface heights. This change in the peak count histogram
wear off initially during contact applications, which results in a height of surface topographies as discharge energy increases to a value of 50 mJ

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Fig. 5. Variation in roughness estimation parameters with discharge energy (E).

Fig. 6. Surface profiles at random locations of textured surfaces generated at different discharge energy (E).

(see Fig. 4(b)), can be observed by a reduction in the highest peak count
to 29 peaks/mm2 , which is at a higher surface height of 45.5 μm. As the
discharge energy is further increased to 500 mJ (see Fig. 4(c)), we
observe that the highest peak count reduces to 16 peaks/mm2 , which is
at an even higher surface height of 60 μm.
3.2. Quantitative representation of textured surface
A quantitative representation of the EDT surfaces is required as an
identifier of the topographies generated. The section aims at developing
a quantitative representation of the textured surface topographies under
two heads: roughness estimation and surface heights.
3.2.1. Roughness estimation
Roughness estimation is aimed at forming a representation of the
roughness of the textured surface. This enables classification of the
textured surface as a fine or a rough finish. The areal texture parameters
used in roughness estimation are arithmetic mean height (Sa), and root
mean square height (Sq). Their variation with discharge energy is rep­
resented in Fig. 5. It is observed that there are two sets of data at three
discharge energy levels of 100, 250, and 375 mJ. Such double data sets
were because two different combinations of current, pulse on-time, and
voltage used for these experiments, which resulted in the identical
discharge energy. We understand from the graphs that Sa and Sq show
an increase with an increase in discharge energy (see Fig. 5(a) and (b)).
Thus, the roughness of the textured surfaces, in terms of common
roughness indicators, such as Sa and Sq, increases with an increase in
discharge energy. This is due to larger peaks and valleys generated at
high discharge energies, as discussed in the previous section. We can
observe this increase in heights of peaks and valleys with an increase in
discharge energy by making a visual comparison of surface profiles
evaluated at random locations on these textured surfaces (see Fig. 6).
The curve fit equations for Sa and Sq show a good fit with high R2 values,
indicating a consistent trend for these parameters with varying
discharge energy. It is also observed that for the initial increase in
discharge energy from 0.5 to 5 mJ (10 times increase), Sa and Sq show a
significant increase from 1.78 to 3.65 μm (105% increase) and 2.28 to
4.65 μm (104% increase), respectively. Whereas for further increase in
discharge energy from 5 to 50 mJ (10 times increase), Sa and Sq show
increase from 3.65 to 5.45 μm (49% increase) and 4.65 to 7 μm (51%
increase), respectively. At last, the increase in discharge energy from 50
to 500 mJ (10 times increase), Sa and Sq only show an increase from
5.45 to 7.35 μm (35% increase) and 7 to 9.58 μm (37% increase),
respectively. This gradual decline in percentage increases of Sa and Sq
with increasing discharge energy is because the crater dimensions do not
increase linearly with an increase in discharge energy. This trend of

Fig. 7. Variation in surface height parameters with discharge energy (E).

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Fig. 8. Variation in surface symmetry parameters with discharge energy (E).

crater dimensions is due to a larger volume of material to be eroded (as 3.2.2. Surface heights
the volume is the third power of crater dimensions) and an increase in We undertake this analysis for forming an estimate of surface
molten material resolidification, as discharge energy increases. heights. This forms another mode of quantitative representation of the
surface topography. This analysis is performed with the help of two areal

Fig. 9. Projected area percentages above and below mean plane for different discharge energy (E).

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Fig. 10. Variation in surface isotropy/anisotropy parameters with discharge energy (E).
texture parameters: maximum height (Sz) and ten-point height (S10z).
The variation of Sz and S10z with discharge energy is shown in Fig. 7.
We understand that from Fig. 7(a) that the maximum height (Sz) of the
surface topography shows an increasing trend with discharge energy.
This increase in Sz can be attributed to the increase in crater dimensions
with discharge energy, as explained before.
Ten-point height (S10z), which takes into consideration the five
topmost and bottom-most surface points, also display an increasing
trend with an increase in discharge energy (see Fig. 7(b)). S10z, an areal
feature parameter, is a more reliable measure for maximum peak-to-
valley height of the surface compared to Sz, as it is not significantly
affected by a single surface outlier as that by Sz. Both Sz and S10z curve
fit equations display a good fit with high R2 values.
3.3. Characterization of microstructures and their distributions
The surface topographies generated using EDT have microstructures
of irregular shapes and sizes, and are randomly distributed over the
surface. Hence, the characterization of microstructures and their dis­
tribution on EDT surface topographies is essential to understand the
contours and appearance of the surface. In this section, we undertake
this characterization with five purposes: surface symmetry, isotropy or
anisotropy, peak distribution, peak roundness or sharpness, and surface
complexity.
3.3.1. Surface symmetry
The EDT surface topographies needs to be analyzed to understand
whether they are symmetric about their mean plane or not. This aspect is
analyzed in terms of parameters such as skewness (Ssk) and kurtosis
(Sku). Skewness (Ssk) of the EDT surface topographies indicates the
degree of symmetricity of the surface. A perfectly symmetric surface has
an Ssk value of 0. A positive Ssk indicates that more surface points lie
below the mean plane than those above, whereas a negative Ssk in­
dicates that a majority of surface points are above the mean plane. Since
the mean Ssk values of the textured surfaces under consideration are
positive at all discharge energy levels (see Fig. 8(a)), we infer that a
majority of the surface points lie below the mean plane. Ssk shows a
large variation for different locations of the same EDT surface topog­
raphy at some discharge energy values. This is because Ssk is very sen­
sitive to surface outliers, which may be present. We observe that the
skewness value generally tends to increase with the increase in
discharge energy. This indicates that as the EDT process takes place at
higher discharge energy, the textured surfaces tend to be more positively
skewed with an even higher majority of surface points lying below the
mean plane. This aspect is confirmed by slicing the surface topography
using its mean plane into two groups of points: those lying above mean
plane and those lying below mean plane. The projected area images for
points lying above the mean plane (white color) and points lying below
mean plane (black color) for surface topographies generated at different
discharge energy values are represented in Fig. 9. It is observed that at a
low discharge energy value of 0.5 mJ, the topography is almost sym­
metric with comparable projected area percentages for points lying
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above and below mean plane (see Fig. 9(a)). However, for the topog­
raphy generated at 5 mJ, we observe that the projected area percentage
below mean plane (52.11%) is larger than that above mean plane
(47.89%) (see Fig. 9(b)). As discharge energy is increased to 50 mJ, the
projected area percentage of points below the mean plane increases to
54% (see Fig. 9(c)). And for topography generated at 500 mJ, this pro­
jected area percentage further increases to 55.86% (see Fig. 9(d)). This
confirms that as the discharge energy increases, we observe that the
surface tends to become asymmetric with more points lying below mean
plane as compared to those lying above the mean plane. This shift of
surface points could be because the crater dimensions increase with an
increase in discharge energy, which leads to larger valley regions
(formed by craters) compared to the peak regions (formed between
craters). The curve fit model for Ssk in terms of E shows a good fit with a
high R2 value of 0.8298.
Kurtosis (Sku) is an indicator of the presence of sharp (Sku > 3) or
blunt (Sku < 3) peaks on the surface. A perfectly symmetric surface will
have a Sku value of 3. It is observed that the Sku values of the textured
surfaces are more than 3 at all discharge energy levels (see Fig. 8(b)).
This indicates that the textured surfaces display slightly sharper peaks
and valleys as compared to those on a perfectly symmetrical surface.
However, Sku does not show any significant change with discharge en­
ergy. This could be understood from the curve fit equation of Sku in
terms of E, which has a poor R2 value. Sku tends to vary slightly around a
value of 4.
3.3.2. Isotropy and anisotropy
The directionality or non-directionality of surface properties influ­
ence the topography’s functionality in different applications. The
isotropic or anisotropic nature of the surface topographies is analyzed in
terms of parameters such as texture aspect ratio (Str), and texture di­
rection (Std). The variation of these parameters with discharge energy is
represented in Fig. 10. Texture aspect ratio (Str) is a parameter that
indicates whether the surface topography is dominantly isotropic or
anisotropic. Str can have a value between 0 to 1. An ideal anisotropic
surface has an Str value of 0, whereas an ideal isotropic surface has an Str
value of 1. We observe that Str displays values near 1 for surface to­
pographies generated at all discharge energy values (see Fig. 10(a)). This
indicates that the surface topographies generated at all values of
discharge energy have dominant isotropic properties. However, it is
observed that as discharge energy increases from 0.5 to 500 mJ, Str
shows a decrease from 0.94 to 0.82. From this, we understand that the
surface shows a higher isotropic nature at low values of discharge
energies.
Texture direction (Std) represents the angular direction of the
dominant lay of the surface topography. For directional surfaces, polar
direction graphs will show a single prominent direction. We observe
from Fig. 10(b) that Std shows very large variations for topographies
scanned at different locations of the same sample. Such substantial
variation is observed because the textured surfaces have dominant
isotropic nature, and thus, there is no dominant texture direction for the
surface topographies. To verify this, we plot polar texture direction
S. Jithin et al. Journal of Manufacturing Processes 60 (2020) 384–399

Fig. 11. Polar direction graphs (a–d) obtained for surface topographies obtained at similar parameter settings (50 A, 50 μs, & 100 V).

Fig. 12. Variation in peak distribution parameters with discharge energy (E).

Fig. 13. Surface topographies obtained at E = 100 mJ with different parameter combinations.

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Fig. 14. Variation in density of peaks (Spd) with operating parameters.
graphs for surface topographies scanned at four different locations of the
textured surface at a parameter setting (50 A, 50 μs, & 100 V) are shown
in Fig. 11(a–d). From these polar graphs, we observe that there are no
individual prominent arms in any direction in the polar direction graphs.
Thus, we can conclude that no direction has significant prominence over
the other directions, which indicates a high isotropic nature of the EDT
surfaces.
3.3.3. Peak distribution
Peak distribution is essential to be analyzed to get an understanding
of the microstructure distribution on the EDT surface topography. The
parameters analyzed for this purpose are density of summits (Sds) and
density of peaks (Spd). The influence of discharge energy on these pa­
rameters is represented in Fig. 12. Density of summits (Sds) represents
the number of summits per unit evaluation area. As Sds decreases, the
contact stresses increase, which leads to surface damage. Hence, low Sds
is not desirable in contact applications. Sds does not show any identifi­
able trend against a change in discharge energy (see Fig. 12(a)). The
curve fit equation for Sds does not give a good fit. Hence, we proceed to
analyze the density of peaks (Spd), which is a more reliable parameter to
characterize the peak distribution on the surface.
Density of peaks (Spd) represents the number of significant peaks in a
unit of evaluation area. For the evaluation of Spd, all smaller and
Fig. 15. SEM images of textured surfaces at different energy levels.
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Journal of Manufacturing Processes 60 (2020) 384–399
insignificant summits are merged to nearby significant peaks. Spd is a
better parameter to represent EDT surfaces, compared to Sds as it takes
into consideration only significant peaks. Spd displays a decrease with
an increase in discharge energy, as per the curve fit model (see Fig. 12
(b)). However, the model does not give a good fit, according to its low R2
value. It was also observed that Spd of surface topographies obtained for
similar discharge energies, but different combinations of operating pa­
rameters, display large differences (see Fig. 13). Hence, the variation of
Spd with current, pulse on-time, and voltage is thus of interest and is
plotted in Fig. 14. It is understood that a significant variation in Spd is
only observed with an increasing pulse on-time (ton ). Spd decreases with
an increasing ton . Spd displays a slight decrease with an increasing
discharge current (I) and a decreasing gap voltage (V). Hence, we
conclude that the peak density of the surface decreases with an increase
in pulse duration. Furthermore, this decrease in peak density can lead to
an increase in contact stresses of the surface.
The microstructures or peaks on the textured surfaces are also
studied using SEM images to form a better understanding of their shape,
size, and distribution. SEM images of textured surfaces obtained at
discharge energy values of 200 mJ and 2000 mJ are compared in Fig. 15.
For both textured surfaces, a random distribution of microstructures in
location, size, and shape can be observed. This is due to the stochastic
nature of spark occurrence during the EDT process. Individual discharge
S. Jithin et al.
Fig. 16. Variation in peak roundness or sharpness parameters with discharge energy (E).
craters are distinguishable for textured surface generated at 200 mJ (see
Fig. 15(a)). Molten material splashing results in formation of micro-
globules which are visible on the textured surface. Surface deformities
such as micro-cracks, blow holes, and micro-cracks are very few or ab­
sent in surface topographies generated at 200 mJ. Similar was the case
for textured surfaces generated at discharge energies lower than 200 mJ.
However, for textured surface generated at a very high discharge energy
value of 2000 mJ, we observe a significant presence of surface de­
formities such as micro-cracks, blow holes, and micro-pores (see Fig. 15
(b)). These surface damages are caused due to the process being more
chaotic at large discharge energies and a large amount of molten ma­
terial resolidification at high pulse on-times. These deformities give the
textured surfaces generated at very high discharge energies a porous
nature. Due to this porous nature, optical profilometer fails to capture
points which come inside these surface damages and gives an incom­
plete or improper reading. Hence, we did not consider surface topog­
raphies generated at very high discharge energies in current surface
topography characterization. We also observe that generally the mi­
crostructures or peaks on surfaces textured at high discharge energy are
larger in size. Since microstructures are formed mostly at crater in­
tersections, they are placed farther apart in topographies generated at
higher discharge energies and thereby, leading to a decrease in peak
density.
3.3.4. Peak roundness or sharpness
The shape of the peaks, whether they are round or sharp, is also
important to be analyzed. Round or blunt peaks can handle contact
stresses better and are not easily worn off contrary to sharp peaks. The
presence of sharp peaks increases the frictional forces encountered
during contact applications. The shape of the peaks on EDT surface to­
pographies are analyzed using two parameters: arithmetic mean summit
curvature (Ssc) and arithmetic mean peak curvature (Spc). The variation
of these parameters with discharge energy is represented in Fig. 16.
Arithmetic mean summit curvature (Ssc) indicates whether the summits
are sharp or rounded. Surface topographies with sharp peaks have a high
Ssc value, whereas those with rounded peaks have a low Ssc value. Ssc is
found to increase with an increase in discharge energy (see Fig. 16(a)).
Therefore, the summits tend to be sharper as the topographies are
generated using higher discharge energies.
Arithmetic mean peak curvature (Spc), an areal feature parameter,
can be a better representation of peak shapes than arithmetic mean
summit curvature (Ssc). Spc represents the average of principal curva­
tures of significant peaks. In contrast, Ssc considers even small and
insignificant summits. A low Spc indicates rounded peaks, whereas a
high Spc indicates sharp peaks. Spc is observed to increase with an in­
crease in discharge energy for EDT surface topographies (see Fig. 16(b)).
Thus, we can infer that the peaks tend to be slightly sharper as discharge
energy used for surface generation increases.
3.3.5. Surface complexity
Surface complexity can be quantified in terms of an areal texture
parameter known as the fractal dimension of the surface (Sfd). Sfd
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Journal of Manufacturing Processes 60 (2020) 384–399
Fig. 17. Variation in fractal dimension (Sfd) with discharge energy (E).
represents the degree of surface complexity. Higher the Sfd value, the
higher will be the surface complexity. As per Kang et al. [24], Sfd offers a
better representation of the surface topography, being independent of
the evaluation area, compared to the conventional 3D roughness pa­
rameters such as Sa and Sq, which are dependent on the size of evalu­
ation area. The variation of Sfd with discharge energy is given in Fig. 17.
Fractal dimension decreases with an increase in discharge energy,
indicating that the surface complexities decrease with an increase in
discharge energy.
3.4. Functionality in various applications
Certain topographical aspects of the textured surface enhance its
functionality for specific applications. An investigation into these
topographical aspects in terms of areal texture parameters helps
improve the performance of topographies in respective applications. We
perform such an investigation in this section under four heads: wetting
and sealing properties, wear volume available for running-in period,
surface post running-in wear, and lubricant retention.
3.4.1. Wetting and sealing properties
Wetting and sealing properties of the surface topography can be
analyzed in terms of root mean square gradient (Sdq) and developed
interfacial ratio (Sdr). The influence of discharge energy on these pa­
rameters is represented in Fig. 18. Root mean square gradient (Sdq) is
evaluated as the root mean square of slopes at all surface points in the
evaluation region. A perfectly planar surface has an Sdq value of 0. Sdq is
observed to increase with an increase in discharge energy (see Fig. 18
(a)). The developed interfacial ratio (Sdr) gives a measure of the addi­
tional surface area available as a result of the texture over the planar
surface area. Thus, a perfectly planar surface has an Sdr value of 0.
Discharge energy is observed to have a positive influence on Sdr (see
Fig. 18(b)). Such an increase in Sdr indicates that the additional surface
area provided by the texture generated increases with an increase in
input discharge energy. The curve fit equations of both Sdq and Sdr show
a good fit with high R2 values. An increase in Sdq and Sdr with discharge
S. Jithin et al. Journal of Manufacturing Processes 60 (2020) 384–399

Fig. 18. Variation in wetting and sealing parameters with discharge energy (E).

Fig. 19. Measured contact angles (θm ), Sdq, and Sdr at discharge energy (E) values of (a) 0 mJ (non-textured surface), (b) 0.5 mJ, and (c) 250 mJ.

Fig. 20. Representation of functional (volume) parameters in Abbott-Firestone curve for different discharge energy (E).

394
S. Jithin et al.
Fig. 21. Representation of functional (stratified) parameters in Abbott-Firestone curve for different discharge energy (E).
energy indicates an improvement in the wetting and sealing properties
of the textured surfaces [25]. Guo et al. [26] analyzed the sealing effect
in terms of a parameter known as area ratio, which is similar to Sdr. They
found that higher the area ratio of the texture, more efficient is the
sealing effect. They have also reported that the preferable area ratio for
good sealing is 5 to 20%, which is similar to Sdr range obtained in
current work using EDT process. Since surface textures generated using
EDT at higher discharge energies have higher Sdr as compared to that of
textures generated at lower discharge energies, the former offers more
efficient sealing.
The improvement in wetting property of textured surfaces generated
at higher discharge energies is confirmed by performing a few contact
angle measurement experiments. This also enables checking of variation
in wetting property with Sdq and Sdr parameters. The contact angle
measurements were made using water droplets (of size 1.8 μl) on the
textured surfaces, following the sessile droplet method. The measured
contact angle (θm ) on non-textured and textured surfaces at different
energy levels, and their corresponding Sdq and Sdr values are given in
Fig. 19. The contact angle reading on the non-textured surface was
observed to be 42.5◦ (see Fig. 19 (a)). This indicates that the non-
textured SS304 has a hydrophilic or water-attracting nature, as θm is
Fig. 22. Variation in running-in wear volume parameters with discharge energy (E).
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Journal of Manufacturing Processes 60 (2020) 384–399
less than 90◦ . In contrast, we observe that for both textured surfaces, θm
is greater than 90◦ , indicating that they are hydrophobic or water-
repelling in nature. This indicates that the EDT process results in
changes in surface chemistry which lead to wetting property change. It is
observed that at a low discharge energy value of 0.5 mJ, the textured
surface has Sdq and Sdr values of 0.32 and 4.9%, respectively, and
correspondingly θm measured has a value of 112◦ (see Fig. 19(b)). As
discharge energy increases to 250 mJ, Sdq and Sdr on the textured sur­
face increase to 0.57 and 12%, respectively, and correspondingly θm
measured on the textured surface increases to 127.5◦ (see Fig. 19(c)).
Therefore, we can conclude that with an increase in discharge energy,
Sdq and Sdr parameters increases, which leads to an improvement in the
wetting property of textured SS304 surfaces.
For the next three studies in this section, we utilize functional pa­
rameters, which fall into two categories: volume (includes Vmp, Vmc,
Vvc, and Vvv) and stratified (includes Sk, Spk, and Svk) parameters.
These parameters are derived from the Abbott-Firestone curve or
bearing area curve of the surface topography. The functional (volume)
and functional (stratified) parameters for EDT surface topographies
generated at different energy levels are represented in Abbott-Firestone
curves, as shown in Figs. 20(a–d) and 21 (a–d), respectively. Their
S. Jithin et al.
Fig. 23. Variation in parameters representing surface post running-in wear with discharge energy (E).
variations are discussed in the upcoming subsections.
3.4.2. Wear volume available for running-in period
Wear volume available for running-in period represents the amount
of material removed from the surface during the running-in period of
contact applications. This surface aspect is studied in terms of peak
material volume (Vmp) and reduced peak height (Spk). Peak material
volume (Vmp) represents the volume of peak material eroded from the
surface during its running-in period in contact applications. From
Figs. 20 and 22 (a), it is understood that Vmp increases with an increase
in discharge energy. As the discharge energy increases from 0.5 to
500 mJ, Vmp increases from 1.161 × 10− 4 to 7.153 × 10− 4 mm3 /mm2
(516% increase) (see Fig. 20(a–d)). For various increments of discharge
energy from 0.5 to 5 mJ, 5 to 50 mJ, and 50 to 500 mJ, the corre­
sponding increases in Vmp are 123%, 69%, and 63.5%, respectively (see
Fig. 20(a–d)). Thus, there is a significant increase in the wear volume
available for running-in period, as discharge energy is increased.
Reduced peak height (Spk) is the height difference between the
Abbott-Firestone curve and the equivalent line at 0% material ratio. It
represents the average of peak heights above the core surface. From
Figs. 21 and 22 (b), we understand that Spk increases with an increase in
discharge energy. For an increase in discharge energy from 0.5 to
500 mJ, Spk increases from 2.325 to 14.64 μm (530% increase) (see
Fig. 21(a-d)). For various increments of discharge energy from 0.5 to
5 mJ, 5 to 50 mJ, and 50 to 500 mJ, the corresponding increases in Spk
are 122.5%, 75%, and 62%, respectively (see Fig. 21(a–d)). This in­
crease in Spk indicates that the surface topography generated at higher
discharge energy comprises taller peaks compared to those on topog­
raphies generated at low discharge energy. The presence of high peaks
increases the volume available to be worn-off during the running-in
period. Thus, a study of variation of Vmp and Spk with discharge en­
ergy indicates an increase in running-in wear volume.
3.4.3. Surface post running-in wear
After the completion of running-in wear, the resultant surface is the
one that takes part in contact applications for a majority of the com­
ponent’s running life. Thus, it is essential to characterize this aspect of
the EDT surface topography. The surface post running-in wear is
analyzed in terms of parameters such as core material volume (Vmc),
core void volume (Vvc), and core roughness depth (Sk). Core material
volume (Vmc) represents the surface volume that does not play any
significant role in contact applications or lubrication. From Figs. 20 and
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Journal of Manufacturing Processes 60 (2020) 384–399
23 (a), it is understood that Vmc increases with an increase in discharge
energy. An increase in discharge energy from 0.5 to 500 mJ, leads to an
increase in Vmc from 1.972 × 10− 3 to 8.206 × 10− 3 mm3 /mm2 (316%
increase) (see Fig. 20(a–d)). From Fig. 20(a–d), we also understand that
for incremental increases from 0.5 to 5 mJ, 5 to 50 mJ, and 50 to 500 mJ,
Vmc shows corresponding increases of 117%, 41%, and 36%,
respectively.
Core void volume (Vvc) represents the core space available on the
surface after the running-in period is completed. We understand that
Vvc increases with an increase in discharge energy (see Figs. 20 and 23
(b)). An increase in Vvc from 2.695 × 10− 3 to 1.266 × 10− 2 mm3 /mm2
(370% increase) is resulted when discharge energy increases from 0.5 to
500 mJ (see Fig. 20(a–d)). We also observe that incremental increases in
discharge energy from 0.5 to 5 mJ, 5 to 50 mJ, and 50 to 500 mJ, results
in corresponding increases of 112.5%, 57%, and 41% in Vvc, respec­
tively (see Fig. 20(a–d)). Thus, the core space available on surface post
running-in wear increases for topographies generated using higher
discharge energies.
Core roughness depth (Sk) is the height difference for material ratios
0% and 100% on the equivalent line. Sk is a measure of the peak-to-
valley height of the surface with predominant peaks and valleys
removed. From Figs. 21 and 23 (c), we understand that Sk increases with
discharge energy. We observe that an increase in discharge energy from
0.5 to 500 mJ results in an increase in Sk from 5.683 to 22.41 μm (294%
increase) (see Fig. 21(a–d)). We also observe increases in Sk of 115%,
38%, and 33% for corresponding increments in discharge energy from
0.5 to 5 mJ, 5 to 50 mJ, and 50 to 500 mJ, respectively (see Fig. 21
(a–d)). This increase in Sk with an increase in discharge energy indicates
that the surface area for load-carrying after the running-in period of the
texture is higher when generated at higher discharge energy.
3.4.4. Lubricant retention
EDT surface topographies have previously been employed in the
texturing of rake face of tool inserts for lubricant retention leading to a
reduction in cutting forces [3]. Thus, an analysis of the lubricant
retention property of the EDT surface topography is critical. It is also
desired to understand the variation in lubricant retention for surface
topographies generated at different discharge energies. Lubricant
retention of EDT surface topographies is analyzed in terms of two pa­
rameters: valley void volume (Vvv) and reduced valley height (Svk).
Valley void volume (Vvv) represents the volume available for lubricant
retention on the surface. We understand that Vvv increases with an
S. Jithin et al. Journal of Manufacturing Processes 60 (2020) 384–399

Fig. 24. Variation in lubricant retention parameters with discharge energy (E).

Fig. 25. Furrows on surface topographies generated at different discharge energy (E).

increase in discharge energy (see Figs. 20 and 24 (a)). An increase in
discharge energy from 0.5 to 500 mJ results in a corresponding increase
in Vvv from 2.459 × 10− 4 to 7.735 × 10− 4 mm3 /mm2 (214.5% in­
crease) (see Fig. 20(a–d)). For increments of discharge energy from 0.5
to 5 mJ, 5 to 50 mJ, and 50 to 500 mJ, the corresponding percentage
increases in Vvv are 118%, 36.5%, and 6%, respectively (see Fig. 20
(a–d)). Thus, the lubricant retention capacity of surface topographies
increases when they are generated using higher discharge energies.
Reduced valley height (Svk) is the height difference between the
equivalent line and the Abbott-Firestone curve at 100% material ratio. It
represents the average of valley depths below the core surface. Svk is
found to increase with an increase in discharge energy (see Figs. 21 and
24 (b)). We observe that Svk increases from 2.103 to 5.608 μm (167%
increase) as discharge energy increases from 0.5 to 500 mJ (see Fig. 21
(a–d)). For incremental increases in discharge energy from 0.5 to 5 mJ, 5
to 50 mJ, and 50 to 500 mJ, there are 127% increase, 37% increase, and
a 17% decrease, respectively (see Fig. 21(a–d)). A higher Svk for to­
pographies generated at higher discharge energies indicates a higher
depth of the area for liquid accumulation, thereby improving lubrication
properties. Thus, an increase in Svk with discharge energy, combined
with an increase in Vvv, indicates an improvement in the lubrication
retention capacity of the EDT surface topographies.
Furrow analysis of topographies is also performed to study the
change in lubricant retention capability of textured surfaces generated
at different discharge energy values. The furrows on the surface texture
act as a lubricant reservoir in contact applications. Hence, as furrow
dimensions increases, the lubricant retention capability of the surface
texture also increases. The furrow images of topographies generated at

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S. Jithin et al. Journal of Manufacturing Processes 60 (2020) 384–399

Table 1 lying below the mean plane, while accompanied by a slight reduction in
Concluding remarks of surface characterization of EDT SS304 surfaces. the surface’s isotropic nature. Textured surfaces generated at higher
Surface topography Specific purpose Low discharge High discharge discharge energies display a reduction in peak density, but the indi­
aspect energy energy vidual peaks tend to become sharper. Higher discharge energy also re­
Roughness sults in a reduced surface complexity of the textured surface. The
Low surface High surface textured surfaces show high wetting and sealing properties as a conse­
estimation (in
Quantitative roughness roughness
terms of Sa and Sq) quence of being generated at high discharge energy. Similarly, textures
representation of the
textured surface
Surface heights (in Low peaks and High peaks generated at high discharge energy tends to provide higher running-in
terms of Sz and shallow and deep wear volume, more surface area for improved load carrying capacity,
S10z) valleys valleys
and higher lubricant retention capacity.
Symmetry (in terms Lower surface Higher surface
of Ssk and Sku)
Acknowledgement
asymmetry asymmetry
Higher Lower
Isotropy (in terms
isotropic isotropic We want to express our gratitude towards Department of Science and
of Str and Std)
nature nature Technology, Advance Manufacturing Technology Committee, Govern­
Peak distribution ment of India, for supporting this work under the project titled
Characterization of Higher peak Lower peak
(in terms of Sds and
microstructures and density density “Generating Functional Quality Textured Surfaces using Electrical
Spd)
their distributions Discharge Machining for Biomedical And Machining Applications” (DST
Peak roundness or
sharpness (in terms
Rounded
Sharper peaks
File No: DST/TSG/AMT/2015/239). We also thank Digital Surf, France,
peaks for exceptionally extending the free trial of their MountainsMap® soft­
of Ssc and Spc)
Slightly more Slightly less ware for this study.
Surface complexity
(in terms of Sfd)
complex complex Conflict of interest: The authors declare no conflict of interest.
surface texture surface texture

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