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Procedia CIRP 68 (2018) 40 – 45

19th CIRP Conference on Electro Physical and Chemical Machining, 23-27 April 2018,
2017, Bilbao, Spain

A Novel Discharge Status Inspection Method for EDM of Thermal-barrier-

coated Nickel-based Superalloys
Li Wanga, Yongfeng Guoa*, Guowei, Zhanga, Durisula, Keliea, Lin Tang b
a
School of Mechatronics Engineering, Harbin Institute of Technology, No. 92 West Dazhi Street, Harbin, 150001, PR China
b
Xi’an Technological University, School of Mechatronic Engineering, Xi’an, China
* Corresponding author. Tel.: +86-0451-86418084; fax:+86-0451-86418084. E-mail address: guoyf@hit.edu.cn

Abstract: The aircraft-engine hot end components were generally made of thermal-barrier-coated nickel-based superalloys(TBCs) that consist
of insulating ceramic coating, electrical conductive coating and metal superalloy substrate. The discharge status of insulating ceramics is
significantly different from that of metal materials, especially for the spark voltage. Existing discharge status inspection approaches have been
focusing on the machining of metal materials, and cannot effectively identify the discharge status of insulating ceramics. Hence, aim to the
EDM of TBCs, a novel inspection method, utilizing the prominent difference of the spark voltage and ignition delay of discharging pulse, is
proposed to distinguish the discharge status for both ceramic coating and metal substrate. In this paper, the discharge status both ceramic
coating and substrate material were analyzed and distinguished. A specialized inspection circuit based on field programmable gate array (FPGA)
is developed to realize the inspection of 15 typical discharge statuses. Finally, a confirmation experiment is employed to demonstrate the
validity and feasibility of this approach.

©©2018
2018TheTheAuthors. Published
Authors. by Elsevier
Published B.V. This
by Elsevier is an open access article under the CC BY-NC-ND license
B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 19th CIRP Conference on Electro Physical and Chemical Machining.
Peer-review under responsibility of the scientific committee of the 19th CIRP Conference on Electro Physical and Chemical Machining
Keywords:EDM; Dishcharge status inspection; Thermal-barrier-coated Nickel-based superalloys; threshold voltage; ignition delay

1. Introductions resistance short circuit

LRS/HRS /LRS low resistance short circuit converting into
high resistance short circuit, and then converting into low
Nomenclature resistance short circuit

EDM electrical discharge machining

TBCs thermal-barrier-coated nickel-based superalloys Recent years, Effusion cooling holes has being extensively
3YSZ 3% Y2O3-stabilized ZrO2 introduced to further improve the working temperature of
SHRD super high resistance discharge aircraft engine. Hence, Approximately 10,000 small holes are
HRD high resistance discharge required to drill into the hot end components of the engine
LRD low resistance discharge [1,2]. Generally, the hot end components are made of thermal-
barrier-coated nickel-based superalloys (TBCs) that consists
SHRS super high resistance short circuit
of three layers, i.e., a top ceramic coating, a bonding coating,
HRS high resistance short circuit
and a superalloy substrate. As the top coat of the components,
LRS Low resistance short circuit
the insulating ceramic coatings are composed of 3-8% Y2O3-
SHRD/HRD super high resistance discharge converting into stabilized ZrO2, which is used to protect the superalloy
high resistance discharge substrate from direct exposure to corrosive high temperatures,
SHRD/LRD super high resistance discharge converting into and make the hot end components approach a higher working
low resistance discharge temperature[3]. Considering the machining of approximately
HRS/LRS high resistance short circuit converting into high 100,000 holes, EDM based on assisting electrode method was
resistance short circuit utilized to directly drilled holes on TBCs for improving the
LRS/HRS low resistance short circuit converting into high machining efficiency . It is well known that the EDMed

2212-8271 © 2018 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 19th CIRP Conference on Electro Physical and Chemical Machining
doi:10.1016/j.procir.2017.12.019
 Li Wang et al. / Procedia CIRP 68 (2018) 40 – 45 41

machining of ceramic materials depends on the generation of
conductive layer, and its erosion mechanism is significantly
different from that of metal materials [4]. Compared to the
EDMed machining of metal materials, one of prominent
characteristics of ceramic materials is discharge status. For
instance, the spark voltage is varied with spark status in the
discharge gap. Therefore, in order to achieve an accurate
servo control of tool electrode and pulse power response. The
inspection device of discharge status is required to identify the
discharge status from both ceramic and metal materials.
However, existing EDM have been focusing on the machining
of metal materials, and cannot effectively identify the
discharge status of insulating ceramics, which can give rise a
inaccurate servo motion of tool electrode, and even the
failure for EDM of TBCs [5]. To address this issue, a novel
inspection method with combination of voltage threshold
technology and ignition delay approach is proposed, utilizing
the prominent difference of the spark voltages, is proposed to
distinguish 15 discharge statuses for both ceramic coating and
metal substrate, and confirmation experiments is carried out to
demonstrate the validity and feasibility of this approach.
2. Discharge status inspection on EDM of TBCs
Discharge Status Analysis on EDM of TBCs
During EDM of 3YSZ, it is observed using oscilloscope
that the discharging statuses of 3YSZ are significantly varied
with those of superalloy substrate. The 11 typical discharge
statuses of 3YSZ are classified in Figure 2 a). Obviously, the
spark voltage is varied within the range of 7 to 60V.
Furthermore, it is interesting to note that discharging status
can also be changed even in a single discharging pulse. As
shown in Figure 2 a, in the discharge status of super high
resistance discharge converting into high resistance discharge.
In contrast, in the discharge status of high resistance short
circuit converting into low resistance short circuit, a higher
discharge status is converted into a relatively lower one.
Furthermore, a relatively lower discharge status is converted
into a higher one. Figure 2 b shows the typical discharge
status. To the machining of Nickel-based superallys, there are
four discharge status including: open circuit, spark, arc, and
short circuit. Therefore, to realize the discharge status
identification for EDM of TBCs, 15 typical discharge statuses
need to distinguish.

2.1. Machining principle on EDM of TBCs

To investigate the typical discharging status both 3YSZ

and superalloy substrate, a single-factor experiment is
designed as follows: a peak current of 8 A, an open voltage of
100 V, a pulse duration of 20 μs, a duty cycle of 0.35. A
workpiece of TBCs (top ceramic coating is 3YSZ) with 2 mm
was selected. A hollow barras electrode (60.2% Cu, 38.8%
Zn, and 1.0% impurities) with an inner diameter of 0.3mm
and external diameter of 1 mm was selected as tool electrode.
Furthermore, the principle of EDM of TBCs is illustrated
as Figure 1. During EDM of ceramic coating, the kerosene in
the plasma gap undergoes pyrolysis. A continuously
generated carbon is deposited into the machining zone, which
is attributed to the generation of a conductive layer at the
interface between the assisting electrode and insulating
ceramic coating. Simultaneously, ceramic coating can also be
thermally eroded with selection of the appropriate process
parameters. Therefore, the cooling effusion hole can proceed
stably, after 3YSZ has been drilled through.

Fig.2. The typical discharging status for EDM of TBCs: (a) the typical
discharging status of ceramic coating, (b) the typical discharging status for
Nickel-based superalloys

Based on the observation results, one of the most

Fig. 1. The machining principle for EDM of TBCs
significant characteristics for 3YSZ is that the spark voltage is
varied with discharging status. Simultaneously, it can be
deduced from Figure 2 a) that the gap resistance varies with
the spark voltage, and the resistance increases with increasing
spark voltage, as shown in Figure 3. It indicates that under a
42 Li Wang et al. / Procedia CIRP 68 (2018) 40 – 45

lower spark voltage, and a better electrically conductive layer

can be generated. Hence the spark voltage can be used to
evaluate the formation of conductive layer. Hence, the
identification criterion of discharging status of 3YSZ can be
established based on the spark voltage.

Figure 4. The classification of typical discharging status of TBCs

2.2. Discharge Status Analysis on EDM of TBCs

To realize an accurate detection of above 15 discharge

statuses, the MOSFET pulse power supply is developed, as
shown in Figure 5. The power supply consists of inspection
Fig. 3. The relationship between the spark voltage and gap resistance module, power-amplified module, and the main-controlled
during EDM of 7YSZ module, respectively. During the machining, the inspection
module was used to detect gap voltage generated by power
In contrast, during EDM of Nickel superalloy and assisting supply module. To be specific, the inspection principle is
electrode, the spark voltages of spark and arc are shown in Figure 6. The gap voltage was collected and reduced
approximately 13-17V, and short circuit is approximately1V. within 15V with the use of reduction voltage circuit. Each
Therefore, based on above experimental analysis, the descended voltage was then transformed to 6 comparative
discharge status both 3YSZ and superalloy can be circuits, and preceded the evaluation of voltage threshold.
distinguished based on the threshold of spark voltage. Similarly, discharging current can also be evaluated using this
To the best of the authors’ knowledge, a comprehensive method. To avoid the interference of external circuit, after
discharge status investigation for the EDM of TBCs has not comparative threshold value, each comparative signal need to
been reported in the literature. It have detected from the above experience the photoelectric coupled isolate circuit, and
experiment that the spark voltage is significantly different converted as the signals of 3.3V. Finally, combining with
between 3YSZ and Nickel-based alloy. The value of spark ignition delay time method, the 6 threshold signals were
voltage can evaluate the deposition performance of sending to the main-controlled circuit designed utilizing field
conductive layer since the 3YSZ can also be thermally eroded programmable gat array (FPGA). The Above-mentioned
when conductive layer was removed. Therefore, as shown in discharge statuses can be identified by programming code.
Figure 4, 15 typical discharge statuses is classified based on Finally, the identified results send to the DSP of PMAC for
the discharging waveform, ignition delay, and the value of further servo control.
spark voltage because these discharge statuses can
comprehensively describe the discharge statuses for EDM of
TBCs
In this paper, the discharge status for EDM of TBCs was
detected combining with threshold technology and ignition
delay method . The typical discharge status of TBCs are
defined as follows: : the high resistance discharge with spark
voltage of 45-60V (SHRD), the high resistance short circuit
Fig.5. Mosfet power supply: (a) the inspection module, (b) the main-
with spark voltage of 40-60V (SHRS), the high resistance controlled module, (c) the power-amplified module
discharge with spark voltage of 30-45V (HRD), the high
resistance short circuit with spark voltage of 20-45V (HRS),
the supper high resistance discharge converting into high
resistance discharge(SHRD/HRD), the super high resistance
discharge converting into low resistance discharge
(SHRD/LRD), the low resistance discharge with spark voltage
of 22-30V (LRD), the low resistance short circuit with spark
voltage of 7-10V (LRS), high resistance short circuit
converting into low resistance short circuit (HRS/LRS), low
resistance short circuit converting into high resistance short
circuit (LRS/HRS), and then converting into low resistance
short circuit (LRS/HRS/LRS), open circuit, spark(13-17V),
arc (13V), and short circuit, respectively.
Fig.6. The schematic of discharge status device
 Li Wang et al. / Procedia CIRP 68 (2018) 40 – 45 43

To realize the identification of 15 typical discharge statuses,

the detection program was written bas VHDL language, and
the flow plot of the code as shown in Figure 6, considering
that the pulse interval is useless and affect the precision of
servo control. In this paper, only pulse duration was detected.
Simultaneously, to eliminate the hardware delay time and
phase inconsistency of inspection module, the software delay
is introduced. Using this code, the special discharge status
including SHRD/HRD, SHRD/LRD, HRS/LRS, and so on,
can be taken apart. For instance, to the HRD/LRD, the content
of HRD in this status was distinguished and classified as HRD.
Simultaneously, the content of LRD was distinguished and
classified as LRD. After discharge status inspection, each
discharge status was counted using 20 MHz system clock of
FPGA. As long as a certain counting time is reached, this
discharge status signal was send to PMAC controller in which
all discharge status were counted and calculated again by
percentage and act as servo criterion of tool electrode.
Obviously, the open circuit and short circuit are easiest to
distinguish and the identification principle is illustrated as
Fig. 8. The flow plot for the inspection of SHRD and SHRS
Figure 7. It can be observed that from Figure 4 the discharge
statuses including LRD, LRS, arc, and spark are difficult
todirectly distinguish because the value of spark voltage has
not a significant difference. Therefore, to realize accurate
inspection, the material property needs to be identified before
distinguishing the discharge status. Since the SHRS, SHRD,
HRS and HRD is most frequently taken place during EDM of
3YSZ. Furthermore, their spark voltages are significantly
higher that those of metal. Hence, they can be used to act as a
criterion of material identification and their identification
principle are shows as Figure 8 and 9. After distinguishing
the SHRS, SHRD, HRS and HRD, the material identification
can be realized and its specific details are shown in Figure 10.

Fig. 9.The flow plot for the inspection of HRD and HRS

Fig. 7. The flow plot for the inspection of open circuit and short circuit
44 Li Wang et al. / Procedia CIRP 68 (2018) 40 – 45

Fig. 10. The flow plot for material identification

Based on the results of material identification, the discharge

status including: LRD, LRS, Arc, and Spark can be
distinguished. Figure 11 and 12 illustrate the identification Fig. 12. The flow plot for the inspection of Spark and Arc
principle of these discharge statuses.
3. Confirmation test

In this section, a conformation test is performed to

demonstrate the validity of this inspection method. Each
discharge status was detected using oscilloscope. It can be
observed from Figure 13 to 18 that SHRD, SHRS, HRD, LRD,
HRS, LRS, open circuit, spark, arc, and short circuit can be
effectively distinguished. Furthermore, the complicated
discharge statuses including SHRD/HRD, SHRD/LRD,
HRS/LRS, LRS/HRS, LRS/HRS/LRS, also can be detected,
as shown in Figure 15, 19, and 20. Hence it is concluded that
with combination of threshold technology and ignition delay
method, the 15 typical discharge statuses for EDM of TBCs
can be effectively distinguished

Fig. 13. Identification of SHRD and SHRS

Fig. 11. The flow plot for the inspection of LRD and LRS

Fig. 14. Identification of HRD and LRD

 Li Wang et al. / Procedia CIRP 68 (2018) 40 – 45
Fig. 15. Identification of HRS, LRS, and HRS/LRS
Fig. 16. Identification of LRS/ HRS
Fig. 17. Identification of open circuit and short circuit
Fig. 18. Identification of spark and arc
Fig. 19. Identification of SHRD/HRD and SHRD/LRD
45
Fig. 20. Identification of SHRD/HRD and SHRD/LRD
4. Conclusions
In this paper, a novel discharge status inspection method is
proposed for EDM of TBCs with the combination of threshold
technology with ignition delay method. The typical discharge
statuses both ceramic coating and Nickel-basd superally is
observed analyzed. The results show hat the gap resistance
was varied with the spark voltage during the EDM of TBCs.
the 15 typical discharge statuses including SHRD, HRD, LRD,
SHRD/HRD, SHRD/LRD, SHRS, HRS, LRS, HRS/LRS,
LRS/HRS, LRS/HRS/LRS, open voltage, spark, arc, and short
circuit, was used to evaluate the discharge status during EDM
of TBCs. To realize an accurate detection, a special inspection
device was developed based on FPGA. Finally, a
confirmation test was carried out to demonstrate the validity
of this approach. The test shows that with combination
threshold technology and ignition delay methods, the 15
typical discharge statuses can be accurately distinguished. In
the future work, the servo control strategy for EDM of TBCs
will be focused on, based on the above detection results.
Acknowledgements
This research is supported by Chinese National Nature
Science Foundation (51275110), Heilongjiang Province
Nature Science Foundation (E2016037), Harbin Innovation
Fund (2015RAXXJ026) and Fund of visiting scholar Program
of Shaanxi Key Laboratory (No. 14JS033).
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