Microstructural and compositional analysis of debris in micro‐electrical discharge machining of Ni‐Ti shape memory alloy and stainless‐steel (SS304)

This research provides an extensive and sophisticated analysis of debris produced by micro‐electrical discharge machining processing of Ni‐Ti shape memory alloys and austenitic stainless steel (SS304) using brass electrodes. The research examines how different discharge energy levels controlled by capacitance and voltage affect debris shape and electrode wear and workpiece erosion. The analysis of particle morphology and elemental distribution uses scanning electron microscopy and energy dispersive X‐ray spectroscopy. The research shows that irregular debris forms at low energy levels but higher discharge energies lead to spheroidization through localized melting. The analysis shows that debris composition receives material contributions from both the workpiece and electrode sources. The substantial oxidation levels demonstrate how dielectric decomposition affects the process. The research findings directly affect micro‐fabrication operations that need both high surface quality and precise dimensional control.