Surface Integrity and Process Efficiency studies on Wire EDM Parameters for Machining Hastelloy Components for automobile parts

Hastelloy, a high-performance nickel-based alloy, is widely used in aerospace, chemical, and marine industries due to its exceptional corrosion resistance and mechanical strength. However, its superior properties also make it difficult to machine using conventional processes. Wire Electrical Discharge Machining (WEDM) offers a non-conventional approach to accurately machine Hastelloy components with minimal thermal damage. This study focuses on optimizing key WEDM process parameters pulse-on time, pulse-off time, peak current, servo voltage, and wire feed to enhance surface quality and material removal rate. A Taguchi L9 orthogonal array was used to design experiments, and analysis of variance (ANOVA) was applied to identify the most significant factors affecting performance. The results revealed that optimized settings led to a notable reduction in surface roughness and improved cutting efficiency. The study provides a strategic framework for the effective machining of Hastelloy alloys using WEDM, enabling their broader application in high-precision engineering components.