Optimized surface morphological characterization employing LASER-drilled hole to enhance the EDM efficiency of MoSi ₂ -SiC intermetallic composites

Die-sinking electrical discharge machining with a constant spark gap uses a LASER-machined electrode with 38 holes of 0.16 mm diameter to machine a Molybdenum disilicide and Silicon Carbide (MoSi 2 -SiC) ceramic composite for high-temperature and high-performance applications like aerospace components, gas turbine parts, heating elements, and nuclear systems. Qualitative results are shown through EDM using multi-hole copper electrodes and pure EDM fluid to create holes in MoSi 2 -SiC.Significant performance outcomes, including trends in MRR, EWR and surface roughness (Ra), have been explicitly quantified. A design of experiments and analysis of variance (ANOVA) were employed to examine the link between experimental variables and outcomes.Pulse current is the most significant metric for Ra, with pulse on-time ranking closely behind.This study implemented Taguchi-Data Envelopment Analysis-based Ranking (DEAR) for identifying the optimal multi-response optimization parameter.Experimental research reveals optimal EDM settings for MoSi 2 -SiC ceramic composite, including laser-drilled multi-hole copper electrode, 3 A peak current, 7 μs pulse-on time, 4 μs pulse-off time, and 14 Kg/cm 2 dielectric pressure. Microstructural analysis will be done for each experiment session to find any unusual features in the machined composites. Machining time, flushing efficiency, and productivity are enhanced by laser-drilled multi-hole electrodes. The Taguchi-DEAR optimization method is used to balance performance outcomes, making it effective for practical EDM process improvements.