Parametric Appraisal for EDM of Inconel 825 Superalloy Using Cu and Cu–Ni Electrodes

The chapter investigates the performance of copper and cupronickel electrodes in Electrical Discharge Machining (EDM) of Inconel 825, a nickel-based superalloy known for its exceptional oxidation and corrosion resistance. The study examines the impact of peak discharge current on material removal rate (MRR) and electrode wear rate (EWR), revealing that copper electrodes outperform cupronickel electrodes in terms of MRR due to their higher thermal conductivity. However, copper electrodes also experience lower EWR due to carbon deposition, which reduces mass loss. The study also analyzes the surface integrity of the machined parts, including surface roughness and crack density, highlighting that copper electrodes produce better surface finish and lower crack density compared to cupronickel electrodes. Additionally, the thickness of the white layer, a critical factor in surface integrity, is found to be thicker when using copper electrodes due to their higher heat dissipation capacity. The chapter concludes with practical insights that can guide engineers in optimizing EDM processes for Inconel 825, making it a valuable resource for professionals in the field of manufacturing and materials science.