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This study investigates the effects of key micro-electrical discharge machining (micro-EDM) process parameters on the recast layer characteristics during the micromachining of Inconel 718, a nickel-based alloy widely used in aerospace applications. The influence of open circuit voltage, peak current, and duty factor was systematically investigated with respect to their impact on average recast layer thickness (AVLT), a critical indicator of surface integrity. In addition, the role of pulse generator type was evaluated by comparing a conventional transistor pulse generator (TPG) with a modified ISO pulse generator (IPG). While the TPG produces irregular energy discharges that contribute to uneven crater formation and a thicker recast layer, the IPG enables uniform energy delivery, resulting in more stable material removal. The findings contribute to optimizing micro-EDM performance for high-precision machining of difficult-to-cut aerospace materials.

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Micro-electrical Discharge Machining for a Difficult-to-Cut Aerospace Alloy

  • 章节

  • 发表日期：

    2026年

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  • Muthuramalingam Thangaraj,
  • Geethapriyan Thangamani,
  • Panagiotis Karmiris-Obratański

摘要

This study investigates the effects of key micro-electrical discharge machining (micro-EDM) process parameters on the recast layer characteristics during the micromachining of Inconel 718, a nickel-based alloy widely used in aerospace applications. The influence of open circuit voltage, peak current, and duty factor was systematically investigated with respect to their impact on average recast layer thickness (AVLT), a critical indicator of surface integrity. In addition, the role of pulse generator type was evaluated by comparing a conventional transistor pulse generator (TPG) with a modified ISO pulse generator (IPG). While the TPG produces irregular energy discharges that contribute to uneven crater formation and a thicker recast layer, the IPG enables uniform energy delivery, resulting in more stable material removal. The findings contribute to optimizing micro-EDM performance for high-precision machining of difficult-to-cut aerospace materials.