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<p>This study investigates the machining characteristics of Wire-Laser Metal Deposition (Wire-LMD) processed Inconel 718 using die-sinking Electrical Discharge Machining (EDM) and its performance in terms of surface roughness and overcut. Initially, the Inconel 718 wire was additively manufactured with a Meltio M450 system. The fabricated as-built Inconel 718 exhibited a density of 8.12&#xa0;g/cm³ and a Vicker’s microhardness of 337.02 HV0.1 ± 12. The metallurgical examination exhibits a defect-free optical microscope and Field Emission Scanning Electron Microscope (FESEM) microstructure with fine columnar dendrites, interdendritic regions, minimal porosity, and Laves phase formation, confirming high-quality printability. An orthogonal array of Taguchi L9 was used to design experiments with the EDM by changing spark current (2–6&#xa0;A), spark-on time (20–60 ms), and servo voltage (50–100&#xa0;V) and then optimized by Analysis of Variance (ANOVA). ANOVA revealed that spark current contributed 85.55% to surface roughness and spark on time contributed 58.24% to overcut. Relative to the recent research on EDM of Additively Manufactured (AM) Inconel 718, which usually indicates a range of 2.5–4.5&#xa0;μm in surface roughness and an overcut value of 0.20–0.35&#xa0;mm on average, the current investigation shows that the current study has improved on surface finish by about 30–60% and overcut value by about 25–50%. Finally, FESEM analysis confirmed crater formation with diameters ranging from 152.73&#xa0;μm at 2&#xa0;A to 299.13&#xa0;μm at 6&#xa0;A, an increase of 95%. These results highlight spark current as the most influential factor for surface roughness, while spark-on time governs dimensional accuracy in Wire-LMD Inconel 718 machining.</p>

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Electrical discharge machining of Wire-LMD Inconel 718: Surface integrity and process optimization using a Taguchi–ANOVA approach

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • Radhika Koganti,
  • Prathap Singh Sundar,
  • Binayak Sen,
  • Abhijit Bhowmik

摘要

This study investigates the machining characteristics of Wire-Laser Metal Deposition (Wire-LMD) processed Inconel 718 using die-sinking Electrical Discharge Machining (EDM) and its performance in terms of surface roughness and overcut. Initially, the Inconel 718 wire was additively manufactured with a Meltio M450 system. The fabricated as-built Inconel 718 exhibited a density of 8.12 g/cm³ and a Vicker’s microhardness of 337.02 HV0.1 ± 12. The metallurgical examination exhibits a defect-free optical microscope and Field Emission Scanning Electron Microscope (FESEM) microstructure with fine columnar dendrites, interdendritic regions, minimal porosity, and Laves phase formation, confirming high-quality printability. An orthogonal array of Taguchi L9 was used to design experiments with the EDM by changing spark current (2–6 A), spark-on time (20–60 ms), and servo voltage (50–100 V) and then optimized by Analysis of Variance (ANOVA). ANOVA revealed that spark current contributed 85.55% to surface roughness and spark on time contributed 58.24% to overcut. Relative to the recent research on EDM of Additively Manufactured (AM) Inconel 718, which usually indicates a range of 2.5–4.5 μm in surface roughness and an overcut value of 0.20–0.35 mm on average, the current investigation shows that the current study has improved on surface finish by about 30–60% and overcut value by about 25–50%. Finally, FESEM analysis confirmed crater formation with diameters ranging from 152.73 μm at 2 A to 299.13 μm at 6 A, an increase of 95%. These results highlight spark current as the most influential factor for surface roughness, while spark-on time governs dimensional accuracy in Wire-LMD Inconel 718 machining.