Surface Integrity Characteristics and Multi-response Optimization in Wire-EDM of Al–Al₃Fe Composites

Wire-electrical discharge machining (wire-EDM) is gaining wider acceptance for producing components of Al-matrix composites (Al-MCs) that are hard to machine by traditional methodologies. The related research is primarily limited to ex-situ Al-MCs commonly reinforced with ceramic particles; however, Al-MCs reinforced with in-situ ordered intermetallics have evolved as superior composites nowadays. This research has focused on wire-EDM of in-situ Al/Al₃Fe composites developed by the reactive stir-casting route. The influence of three machining variables (pulse-on-time, servo voltage, and peak-current) and one material parameter (vol% of reinforcement) have been studied following the L₂₇ Taguchi design. The integrity of the machined surface has been characterized via measurements of surface roughness (SR) and the alteration of surface chemistry (ASC, ΣCu + Zn + O), in addition to the evaluation of kerf width (KW) as a machining performance indicator. It has been established that all four control factors are significant for KW, while ASC is influenced by all factors except vol% of reinforcement; however, only pulse-on-time is substantial for SR. Analytical models of individual responses are developed while the desirability approach helps to accomplish the multi-response optimization; several confirmation experiments establish the authenticity of these predictions with an error < 8%. Characterizations of machined surfaces and wire electrodes by FESEM and EDS techniques reveal that the surface integrity of in-situ Al/Al₃Fe composites varies significantly with machining conditions.