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Unraveling the technological performance of low-energy ED-machining for processing Inconel 718 alloy: a comparative study of electrode materials

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Abstract

This study investigates the impact of different tool electrode materials on the thickness of the resolidified layer produced by sinking electrical discharge machining (SED-machining) on Inconel 718 alloy. The experiments were conducted with various discharge durations and duty factor levels, using an open voltage of 120 V and a discharge current of 2.4 A. Three grades of tool electrode materials were used: graphite (both polarities), copper, and copper-tungsten. The study found that ED-machining performance improved significantly at a duty factor of 0.33, a discharge duration of 24 μs, and a discharge energy of 6.91 mJ. The material removal rate increased to 1.05 mm3/min with the Graphite (−) tool electrode, while the volumetric relative wear improved to 1.66% with the copper-tungsten tool electrode. X-ray diffraction and scanning electron microscopy analyses revealed phase changes, complex carbide formation, and primary dendritic growth in the recast layer due to abrupt thermal gradient changes and material-electrode interactions. The maximum recast layer thickness was 16.52 μm with the graphite (−) tool electrode, while the copper-tungsten tool electrode produced the smoothest surface with the lowest roughness of 1.3 μm. The copper tool electrode yielded the thinnest recast layer at 9.08 μm.

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Abbreviations

FLTt :

Flatness using least squares reference plane (μm)

î e :

Discharge current (A)

Pin :

Dielectric inlet pressure (mPa)

Ra :

Average roughness - two-dimensional (μm)

Sa :

Average height of the selected area—three-dimensional (μm)

Sdq :

Root mean square gradient (−)

Sdr :

Developed interfacial area ratio (%)

Sku :

Kurtosis (−)

Smr 2 :

Peak material component, the fraction of the surface which will carry the load (%)

Sp :

Maximum peak height of selected area (μm)

Ssk :

Skewness (−)

Sv :

Maximum valley depth of selected area (μm)

t d :

Ignition delay time, (μs))

t e :

Discharge duration (μs)

t i :

Pulse duration (μs)

t o :

Pulse interval time (μs)

t p :

Pulse cycle time (μs)

û e :

Discharge voltage (V)

V e :

Electrode wear rate (mm3/min)

V w :

Material removal rate (mm3/min)

W e :

Discharge energy (We = ûe.îe.te) (mJ)

ϑ :

Volumetric relative wear (Ve/Vw) (%)

τ :

Duty factor (ti/tp) (−)

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Authors and Affiliations

  1. Department of Mechanical Manufacturing, Instituto Federal de Santa Catarina – IFSC, R. dos Imigrantes, 445, Rau, 89, Jaraguá do Sul, SC, .254-430, Brazil

    Giovani Conrado Carlini

  2. Mechanical Engineering Graduate Program – PPGEM, Pontifícia Universidade Católica do Paraná – PUCPR, Av. Imaculada Conceição, 1155, Prado Velho, 80, Curitiba, PR, .215-901, Brazil

    Giovani Conrado Carlini, Ricardo Diego Torres & Fred Lacerda Amorim

  3. Department of Mechanical Engineering, Technology, Innovation and Manufacturing Center – NTIF, Centro Universitário de Brusque – UNIFEBE, R. Vendelino Maffezzolli, 333, Santa Terezinha, 88, Brusque, SC, .352-360, Brazil

    Rodrigo Blödorn

  4. Department of Mechanical Engineering, Vaugh Institute of Agricultural Engineering and Technology, Sam Higginbottom University of Agriculture, Technology and Sciences, Prayagraj, 211007, India

    Rahul Davis

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  1. Giovani Conrado Carlini
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Carlini, G.C., Blödorn, R., Davis, R. et al. Unraveling the technological performance of low-energy ED-machining for processing Inconel 718 alloy: a comparative study of electrode materials. Int J Adv Manuf Technol 131, 4755–4772 (2024). https://doi.org/10.1007/s00170-024-13334-z

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