7. Powder-Mixed Microelectric Discharge Machining

Microelectric discharge machining (µEDM) is introduced to the manufacturing industry to produce microfeatures and microholes on difficult to machining materials such as titanium- and nickel-based alloys and other heat-resistant electrically conductive metals and alloys. Even though µEDM can be used to machine any electrically conductive materials, there are many problems to be addressed in order to make it as an accurate and reliable process. Some of the problems associated are low material removal rate, tool wear rate, high surface roughness, and poor dimensional accuracy. This chapter presents powder-mixed microelectric discharge machining as one of the viable alternatives to overcome some of the inherent difficulties associated with microelectric discharge machining process. Suspension of electrically conductive and semiconductive powders in the dielectric can strongly influence the process in a desirable manner. Moreover, the added powder particle gets re-solidified along with the tool material on the machined surface and opens a new possibility to modify the machined surface by selecting the appropriate alloying elements in the required proposition. This approach needs to be thoroughly addressed to explore as ‘µEDM alloying’.