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Surface Integrity Characteristics and Multi-response Optimization in Wire-EDM of Al–Al3Fe Composites

  • Research Article-Mechanical Engineering
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Abstract

Wire-electrical discharge machining (wire-EDM) is gaining wider acceptance for producing components of Al-matrix composites (Al-MCs) that are hard to machine by traditional methodologies. The related research is primarily limited to ex-situ Al-MCs commonly reinforced with ceramic particles; however, Al-MCs reinforced with in-situ ordered intermetallics have evolved as superior composites nowadays. This research has focused on wire-EDM of in-situ Al/Al3Fe composites developed by the reactive stir-casting route. The influence of three machining variables (pulse-on-time, servo voltage, and peak-current) and one material parameter (vol% of reinforcement) have been studied following the L27 Taguchi design. The integrity of the machined surface has been characterized via measurements of surface roughness (SR) and the alteration of surface chemistry (ASC, ΣCu + Zn + O), in addition to the evaluation of kerf width (KW) as a machining performance indicator. It has been established that all four control factors are significant for KW, while ASC is influenced by all factors except vol% of reinforcement; however, only pulse-on-time is substantial for SR. Analytical models of individual responses are developed while the desirability approach helps to accomplish the multi-response optimization; several confirmation experiments establish the authenticity of these predictions with an error < 8%. Characterizations of machined surfaces and wire electrodes by FESEM and EDS techniques reveal that the surface integrity of in-situ Al/Al3Fe composites varies significantly with machining conditions.

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  1. Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Shibpur, Howrah, West Bengal, 711103, India

    Gaurav Anand, Santanu Sardar & Ashim Guha

  2. Department of Metallurgy and Materials Engineering, Indian Institute of Engineering Science and Technology, Shibpur, Howrah, West Bengal, 711103, India

    Debdulal Das

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Anand, G., Sardar, S., Guha, A. et al. Surface Integrity Characteristics and Multi-response Optimization in Wire-EDM of Al–Al3Fe Composites. Arab J Sci Eng (2024). https://doi.org/10.1007/s13369-024-08969-9

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