Experimental Investigation on Super Alloys using Al7178 Metal Matrix Tools (Aluminum Oxide Materials of Different Weight Percentages 3%, 6%, 9%, 12%) on Electrical Discharge Machining

The primary nonferrous metals consist of aluminum, copper, lead, nickel, chromium, manganese, magnesium, titanium, zinc, and alloys like brass. These metals are typically extracted from minerals such as sulfides, carbonates, and silicates. The addition of alloying elements enhances their properties when added in appropriate quantities. Non-ferrous metals are widely utilized due to their favorable characteristics, such as lightweight (e.g. aluminum), high electrical conductivity (e.g. copper), non-magnetism, and corrosion resistance (e.g. zinc). One of the most significant nonferrous alloys is the Al 7178 series alloy, which is commonly used in technical applications. EDM is a method for controlled removal of metal that uses electrical discharge. This process uses an electric spark to erode the workpiece and shape the finished part. Metal removal is accomplished by applying a pulsed charge (ON/OFF) to the workpiece through an electrode using a high-frequency current. The workpiece is subjected to controlled erosion, resulting in the removal of tiny metal fragments. Typically, electrodes made of copper, graphite, and brass are utilized in EDM. The current project investigates the use of the metal matrix material Al7178 (Al2O3-reinforced Al7178) as a tool/electrode for machining the superalloy Superni 90. In this study, aluminum alloy 7178 is utilized as the base metal, Al2O3 is chosen as the reinforcement material, weight fraction 3%, 6%, 9%, 12% as the tool material, and nickel-based alloy as the workpiece being studied. Superni90 has been selected. Material removal rate, surface roughness and tool wear rate in electrical machining discharge. Regression models were developed for MRR and TWR based on experimental data. The Mitutoyo surface roughness measuring machine is utilized to measure the surface roughness of the processed workpiece. The geometric accuracy of the surfaces created on the workpiece is evaluated using MATLab software.