Electro-discharge machining of microholes on 3d printed Hastelloy using the novel tool-feeding approach

Hastelloy, a nickel-based superalloy renowned for its exceptional resistance to corrosion at high temperatures, is widely used in sectors such as nuclear, aerospace, chemical processing, and pharmaceuticals. Microelectrical discharge machining (μ-EDM) is crucial for generating microholes and channels on Hastelloy. Since it effectively addresses difficulties like work hardening, high strength & wear resistance, and low thermal conductivity in traditional machining. Microholes play a major role in many critical components for precise control of fluids in fuel injectors, managing heat in turbine blades, controlled gas exchange, etc. The current research investigates the drilling of 8:1 aspect ratio microholes machined by 400 μm diameter electrodes. This study investigated the influence of tool material (tungsten carbide, carbide drill bit, and brass) on μ-EDM performance. Compared to tungsten carbide and carbide drill bits, brass exhibited significantly lower electrode wear, leading to more precise microholes with reduced overcut and taper angle. However, brass also required a substantially longer machining time. Carbide drill bits offered a balance between wear resistance, machining time, and overcut/taper angle.