Optimization of process parameters for WEDM of Inconel 825 using grey relational analysis

Inconel 825 is high nickel-chromium-based superalloy which retains its mechanical properties and exhibits good corrosion and oxidation resistance at elevated temperature. Inconel 825 is extensively used for making aircraft engine parts like combustor casing and turbine blades in aero space industry. This research proposed the Response Surface Methodology with GRA to optimize multiple responses during Wire-cut EDM of Inconel 825. At optimum combination of input parameters i.e. A4B1C1D5E4F2, increase in MRR from 36.13 mm2/min to 41.822 mm2/min, decrease in SR from 2.842μm to 2.445μm and decrease in WWR from 0.01832 to 0.01758 was obtained. Experimental results showed that pulse-on time, wire feed, pulse-off time, and peak current significantly affected the MRR, and surface integrity of specimen and electrode with the formation of craters, pockmarks, debris, micro cracks, and recast layer. The optimal parametric combination obtained from the present study will be advantageous for working on high strength; high thermal conductivity and low melting point materials like nickel alloys