The present article focused on the surface characterization of electric discharge machined duplex stainless steel (DSS-2205) alloy with three variants of electrode material (Graphite, Copper-Tungsten and Tungsten electrodes). Experimentation was executed as per Taguchi L18 orthogonal array to inspect the influence of electric discharge machining (EDM) parameters on the material removal rate and surface roughness. The results revealed that the discharge current (contribution: 45.10%), dielectric medium (contribution: 18.24%) majorly affects the material removal rate, whereas electrode material (contribution: 38.72%), pulse-on-time (contribution: 26.11%) were the significant parameters affecting the surface roughness. The machined surface at high spark energy in EDM oil portrayed porosity, oxides formation, and intermetallic compounds. Moreover, a pin-on-disc wear analysis was executed and the machined surface exhibits 70% superior wear resistance compared to the un-machined sample. The surface thus produced also exhibited improved surface wettability responses. The outcomes depict that EDMed DSS alloy can be considered in the different biomedical and industrial applications.

Electrical discharge machining (EDM) is a highly precise technology that not only facilitates the machining of components into desired shapes but also enables the alteration of the physical and chemical properties of workpieces. The complexity of the process is due to a number of regulating factors such as the material of the workpiece and tools, dielectric medium, and other process parameters. Based on the material type, electrode shape, and process configuration, various shapes and degrees of accuracy can be generated. The study of erosion is based on research into processing techniques, which are the primary tools for using EDM. Empirical knowledge with subsequent optimization of technological parameters is one of the ways to obtain the required surface quality of the workpiece with defect minimization, as well as mathematical and numerical modeling of the EDM process. This article critically examines all key aspects of EDM, reflecting both the early foundations of electrical erosion and the current state of the industry, noting the current trends towards the transition of EDM to the 5.0 industry zone in terms of safety and minimizing the impact of the process on the environment.

This paper presents wear and corrosion resistance analysis of carbon nanotubes coated with Ti-6Al-4V alloy processed by electro-discharge treatment. The reported work is carried out using Taguchi’s L18 orthogonal array to design the experimental matrix by varying five input process parameters i.e., dielectric medium (plain dielectric, multi-walled carbon nanotubes (MWCNTs) mixed dielectric), current (1–4 A), pulse-on-time (30–60 µs), pulse-off-time (60–120 µs), and voltage (30–50 V). The output responses are assessed in terms of microhardness and surface roughness of the treated specimen. X-ray diffraction (XRD) spectra of the coated sample reveal the formation of intermetallic compounds, oxides, and carbides, whereas surface morphology is observed using scanning electron microscopy (SEM) analysis. For the purpose of the in-vitro wear behavior of treated samples, the surface with superior microhardness values in plain dielectric and MWCNTs mixed dielectric is compared using a pin-on-disc type wear test. Furthermore, electrochemical corrosion test is also conducted to portray the dominance of treated substrate of Ti-6Al-4V alloy for biomedical applications. It is concluded that the wear-resistant and the corrosion protection efficiency of the MWCNTs treated substrate enhanced to 95%, and 96.63%, respectively.

This study presents the analysis of wire-cut electro-discharge machining (WIRE-EDM) of polymer composite material (PCM). The conductivity of the workpiece is improved by using 1 mm thick titanium plates (layers) sandwiched on the PCM. Input process parameters selected are variable voltage (50–100 V), pulse duration (5–15 μs), and pause time (10–50 μs), while the cut-width (kerf) is recognized as an output parameter. Experimentation was carried out by following the central composition design (CCD) design matrix. Analysis of variance was applied to investigate the effect of process parameters on the cut-width of the PCM parts and develop the theoretical model. The results demonstrated that voltage and pulse duration significantly affect the cut-width accuracy of PCM. Furthermore, the theoretical model of machining is developed and illustrates the efficacy within the acceptable range. Finally, it is concluded that the model is an excellent way to successfully estimate the correction factors to machine complex-shaped PCM parts.

The applicability of electrolytic plasma surface polishing to complex components produced by selective laser melting (SLM) is analyzed. By electrolytic plasma polishing by electrolyte spraying, the...

In the present work, a hybrid magnetic field assisted powder mixed electrical discharge machining had been carried out on the Aluminum-Silicon Carbide (Al-SiC) metal matrix composite. The aim of the study was to obtain higher surface finish, and enhanced material removal rate. The dielectric mediums employed were plain EDM oil, SiCp mixed and graphite powder mixed EDM oil for flushing through the tube electrode. The magnetic field intensity, discharge current, T-on/off duration and type of dielectric were the control variables used for present investigation. From the results, it was observed that the machining variables for instance, discharge current, T-on/off duration and type of dielectric conditions remarkably affected the material removal rate, micro-hardness and surface roughness of the machined composite material. The MRR augmented considerably with an increase in the magnetic field intensity along with peak current. Subsequently, the composite with lesser vol.% of SiC particulates witnessed sharp rise in MRR in maximum magnetic field environment (0.66T). In addition, quality of the machined surface improved significantly in graphite powder mixed dielectric flushing condition with intermediate external magnetic field environment. Besides, an enhancement of micro-hardness was quantified as compared to base material due to the transfer of the material (SiCp) during powder mixed ED machining.