Process Regulations and Mechanism of WEDM of Combustor Material

This study discusses the experimental investigation on WEDM of combustor material (i.e., nimonic 263). Experimentation has been executed by varying pulse-on time (T_on), pulse-off time (T_off), peak current (I_p), and spark gap voltage (S_v). Material removal rate (MRR), surface roughness (SR), and wire wear rate (WWR) are employed as process performance characteristics. Experiments are designed as per the box-Behnken design technique. Parametric optimization has also been performed using response surface methodology. Besides this, field-emission scanning electron microscope (FE-SEM) and an optical microscope are utilized to characterize WEDMed and worn-out wire surfaces. It is observed that both surfaces contain micro-cracks, craters, spherical droplets, and a lump of debris. Furthermore, the mechanism of recast layer formation has been critically evaluated to apprehend a better understanding of the technique. The key features of the experimental procedure are also highlighted.