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<p>Monel K-500 is a Ni-Cu-based superalloy known for its high strength, corrosion resistance, and thermal stability. These qualities make it ideal for a wide range of applications, including marine settings, aerospace, nuclear reactors, gas turbines, and petrochemical components. However, machining superalloys like Monel K-500 is difficult due to their low thermal conductivity and work-hardening. These difficulties can be handled with appropriate machining techniques and specifications. As a result, Electrical Discharge Machining (EDM) was chosen to successfully manufacture Monel K-500. Experiments were organized using Taguchi’s L9 orthogonal array, with three major controllable process parameters such as current, voltage, and electrode materials (brass, copper, and aluminum with ∅15&#xa0;mm). The outputs of the EDM process included average surface roughness (Ra), material removal rate (MRR), and hardness changes (HRC). The results showed that Ra values ranged from 1.363 to 8.041&#xa0;μm, MRR from 0.08 to 0.724&#xa0;g/min, and HRC from 54 to 84. Analysis found that the copper (Cu) electrode produced better machining results on Monel K-500 than brass and aluminum (Al), owing to its increased thermal and electrical conductivity. The machined surfaces were photographed using a scanning electron microscope (SEM) to obtain information about the machining process and any microstructural alterations. To improve Monel K-500’s machinability and open the door for better machining results in subsequent applications, ideal process parameters were found.</p>

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Enhancing machining performance of monel alloy through EDM parameter optimization

  • 期刊论文

  • 发表日期：

    2026年4月13日

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  • K. Jayakumar,
  • R. Anitha,
  • Trendy S. Kishore

摘要

Monel K-500 is a Ni-Cu-based superalloy known for its high strength, corrosion resistance, and thermal stability. These qualities make it ideal for a wide range of applications, including marine settings, aerospace, nuclear reactors, gas turbines, and petrochemical components. However, machining superalloys like Monel K-500 is difficult due to their low thermal conductivity and work-hardening. These difficulties can be handled with appropriate machining techniques and specifications. As a result, Electrical Discharge Machining (EDM) was chosen to successfully manufacture Monel K-500. Experiments were organized using Taguchi’s L9 orthogonal array, with three major controllable process parameters such as current, voltage, and electrode materials (brass, copper, and aluminum with ∅15 mm). The outputs of the EDM process included average surface roughness (Ra), material removal rate (MRR), and hardness changes (HRC). The results showed that Ra values ranged from 1.363 to 8.041 μm, MRR from 0.08 to 0.724 g/min, and HRC from 54 to 84. Analysis found that the copper (Cu) electrode produced better machining results on Monel K-500 than brass and aluminum (Al), owing to its increased thermal and electrical conductivity. The machined surfaces were photographed using a scanning electron microscope (SEM) to obtain information about the machining process and any microstructural alterations. To improve Monel K-500’s machinability and open the door for better machining results in subsequent applications, ideal process parameters were found.