Machinability Evaluation of WAAM-Fabricated Alloys Using Wire EDM and Parameter Optimization Techniques

Wire Arc Additive Manufacturing (WAAM) is increasingly utilized for fabricating near-net shape metal components due to its high deposition rates and cost-effectiveness. However, post-processing of WAAM-fabricated parts, especially to achieve precise dimensions and surface finish, is essential. Wire Electrical Discharge Machining (WEDM) presents an effective solution for such requirements due to its ability to machine hard-to-cut materials with high precision. This study investigates the machinability of WAAM-fabricated alloy specimens using WEDM by analyzing key output responses such as material removal rate (MRR), surface roughness (Ra), and kerf width. Taguchi and other optimization techniques were employed to identify the optimal combination of WEDM parameters including pulse-on time, pulse-off time, peak current, and wire feed. Experimental results demonstrated that specific parameter settings significantly enhance machinability while maintaining structural integrity. The findings offer valuable insights for integrating WEDM as a viable post-processing method in WAAM-based manufacturing workflows for aerospace, automotive, and tooling applications.