Unlocking the potential of WEDM for LM26 hybrid composites: multi-objective optimization using RSM and desirability approach

Abstract Aluminium-based hybrid composites have tremendous potential on account of their enhanced structural and functional characteristics in technological applications, including aerospace, automotive, defence, and thermally sensitive sectors. However, the addition of hard ceramic reinforcements makes these materials tougher, requiring sophisticated machining processes for cutting. This study explores the machinability of LM26 alloy-based hybrid composites strengthened with 10 wt% ZrB 2 and 5 wt% CCSF during wire electrical discharge machining. The microstructure analysis revealed that the CCSF and ZrB 2 particles were distributed uniformly in the LM26 hybrid composite along with the low porosity level. XRD analysis revealed the nonappearance of intermetallic compounds and confirmed the presence of elements such as Al, Si, Fe, Zr, and Cu phases, which enhanced the matrix bonding, increased resistance to crack formation, and enabled efficient load transfer. This study focuses on improving the surface finishing and material removal rate by analyzing a consequence of machining parameters by using response surface methodology with a central composite design. The outcome of the characterization substantiates the evenly dispersed reinforcing particles in the matrix and improved mechanical characteristics. The developed RSM model demonstrates the highest accuracy, with R 2 values of 0.9756 for MRR and 0.9674 for Ra. Parameter settings of 8.81 μs (T off ), 12.9386 μs (T on ), and 4.70873 Amp (I) are identified as the best in the present study, generating an MRR of 0.627 g min −1 and Ra of 16.1197 μm with 0.915 composite desirability. These findings suggest the suitability of these composites for high-temperature automotive applications such as pistons, piston rings, and internal combustion engine parts.