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<p>Wire arc additive manufacturing (WAAM) enables the fabrication of large Inconel 625 components. However, post-processing is required to achieve acceptable surface quality and dimensional accuracy. In this study, WAAM-fabricated Inconel 625 components were post-processed using near-dry electrical discharge machining (EDM). A full factorial experimental design was employed to investigate the influence of discharge current, duty cycle, and dielectric flow rate on material removal rate (MRR), tool wear rate (TWR), and the diametrical deviation of machined circular profiles using copper and brass tool electrodes. Regression models were developed and statistically validated through analysis of variance (ANOVA). The results indicate that discharge current is the most dominant parameter governing MRR for both electrodes, while the optimal duty cycle and dielectric flow rate depend strongly on the current level. Copper electrodes exhibited approximately 235% higher MRR and nearly 14 times lower TWR compared with brass electrodes, owing to their superior electrical and thermal conductivity, which promotes stable plasma formation, efficient energy transfer, and reduced tool wear. Brass electrodes produced undersized but more repeatable circular profiles, whereas copper electrodes achieved dimensions closer to the nominal value with increased variability, highlighting a trade-off between repeatability and dimensional accuracy. Negative TWR values observed under low-energy conditions were attributed to material redeposition on the tool surface. The developed MRR models demonstrated high predictive capability (R<sup>2</sup> = 0.94 for copper and 0.92 for brass), confirming the robustness of the proposed near-dry EDM process for post-processing WAAM Inconel 625 components.</p>

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Near-dry EDM Performance with Two Different Electrode Materials of Inconel Super Alloy Built by Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年2月9日

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  • Udutha Raghupathi,
  • Suresh Gudipudi

摘要

Wire arc additive manufacturing (WAAM) enables the fabrication of large Inconel 625 components. However, post-processing is required to achieve acceptable surface quality and dimensional accuracy. In this study, WAAM-fabricated Inconel 625 components were post-processed using near-dry electrical discharge machining (EDM). A full factorial experimental design was employed to investigate the influence of discharge current, duty cycle, and dielectric flow rate on material removal rate (MRR), tool wear rate (TWR), and the diametrical deviation of machined circular profiles using copper and brass tool electrodes. Regression models were developed and statistically validated through analysis of variance (ANOVA). The results indicate that discharge current is the most dominant parameter governing MRR for both electrodes, while the optimal duty cycle and dielectric flow rate depend strongly on the current level. Copper electrodes exhibited approximately 235% higher MRR and nearly 14 times lower TWR compared with brass electrodes, owing to their superior electrical and thermal conductivity, which promotes stable plasma formation, efficient energy transfer, and reduced tool wear. Brass electrodes produced undersized but more repeatable circular profiles, whereas copper electrodes achieved dimensions closer to the nominal value with increased variability, highlighting a trade-off between repeatability and dimensional accuracy. Negative TWR values observed under low-energy conditions were attributed to material redeposition on the tool surface. The developed MRR models demonstrated high predictive capability (R2 = 0.94 for copper and 0.92 for brass), confirming the robustness of the proposed near-dry EDM process for post-processing WAAM Inconel 625 components.