Influence of near-dry ambiance on WEDM of Monel superalloy

Progress in the manufacturing sector resulted in the need for products with enhanced mechanical properties, corrosion, and heat resistance. Thus, superalloy was produced with desired mechanical properties. Monel Alloy is one of those nickel-based superalloys, commonly used in industry for its high strength and resistance to corrosion. Monel is also acid- and saltwater resistant. Some properties such as gummy behavior and job hardening make machining superalloys by traditional methods difficult. For this purpose, in this analysis, near-dry wire electric discharge machining (WEDM) is chosen for Monel machining. The present research explores the feasibility of nearly dry Monel alloy WEDM using air and deionized water in nebulous or mist form to achieve the optimal surface finish and resolve environmental issues associated with wet WEDM. This work reflects the study of the influence of various input parameters on the output calculated in terms of the rate of material removal (MRR) and surface roughness (Ra). On an inference, near-dry WEDM formed a smooth surface on Monel alloy over traditional WEDM; however, ranges of MRR still elevate their support to wet WEDM.

Automated summary

This study investigated the feasibility of nearly dry WEDM for machining Monel alloy and utilized air and deionized water in nebulous or mist form to achieve optimal surface finish. Results showed that near-dry WEDM can achieve a smooth surface, but the range of material removal rate still tends to support wet WEDM.