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<p>Superalloys have become integral to advanced engineering sectors due to their exceptional thermal stability, corrosion resistance, and strength retention at high temperatures. These superior properties, however, present significant challenges to conventional machining methods, making electric discharge machining (EDM) a critical non-traditional process for the precise shaping of nickel-, titanium-, and cobalt-based superalloys. This review synthesizes research developments in the EDM of these materials, focusing on their electro-thermal behavior, process parameters, and microstructural responses. A thorough examination of existing literature indicates a predominant focus on nickel-based alloys, especially the Inconel series, while alloys such as René 80, Waspaloy, Udimet 720, and Stellite, L-605 have been less extensively studied. The review explores how EDM process input variables such as discharge energy, pulse timing, dielectric composition, and electrode characteristics collectively affect material subtraction rate, surface morphology, and metallurgical transformations. Innovations in powder-mixed, ultrasonic-assisted, cryogenic, and near-dry-EDM configurations are assessed for their potential to improve machining efficiency, reduce surface degradation, and support sustainable processing. Recent progress in biodegradable dielectrics, energy-efficient control systems, and hybrid EDM architectures suggests a shift towards eco-friendly and digitally enhanced manufacturing. Additionally, the integration of AI-based modeling, digital twins, and data-driven optimization frameworks heralds the emergence of intelligent EDM systems capable of real-time adaptation and predictive control. By consolidating experimental insights, material-specific trends, and emerging technological directions, this review offers a comprehensive understanding of EDM’s current state and its transformative role in the sustainable and intelligent machining of advanced superalloys.</p>

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Shaping superalloys with sparks: Electric discharge machining for next-generation manufacturing

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Rahul Davis,
  • Gaurav Ninawe,
  • Vishal Francis,
  • Abhishek Singh,
  • Danil Yu. Pimenov,
  • Fred Lacerda Amorim

摘要

Superalloys have become integral to advanced engineering sectors due to their exceptional thermal stability, corrosion resistance, and strength retention at high temperatures. These superior properties, however, present significant challenges to conventional machining methods, making electric discharge machining (EDM) a critical non-traditional process for the precise shaping of nickel-, titanium-, and cobalt-based superalloys. This review synthesizes research developments in the EDM of these materials, focusing on their electro-thermal behavior, process parameters, and microstructural responses. A thorough examination of existing literature indicates a predominant focus on nickel-based alloys, especially the Inconel series, while alloys such as René 80, Waspaloy, Udimet 720, and Stellite, L-605 have been less extensively studied. The review explores how EDM process input variables such as discharge energy, pulse timing, dielectric composition, and electrode characteristics collectively affect material subtraction rate, surface morphology, and metallurgical transformations. Innovations in powder-mixed, ultrasonic-assisted, cryogenic, and near-dry-EDM configurations are assessed for their potential to improve machining efficiency, reduce surface degradation, and support sustainable processing. Recent progress in biodegradable dielectrics, energy-efficient control systems, and hybrid EDM architectures suggests a shift towards eco-friendly and digitally enhanced manufacturing. Additionally, the integration of AI-based modeling, digital twins, and data-driven optimization frameworks heralds the emergence of intelligent EDM systems capable of real-time adaptation and predictive control. By consolidating experimental insights, material-specific trends, and emerging technological directions, this review offers a comprehensive understanding of EDM’s current state and its transformative role in the sustainable and intelligent machining of advanced superalloys.