Surface and Subsurface Layers Defects Analysis After WEDM Affecting the Subsequent Lifetime of Produced Components

Wire electrical discharge machining is an on-traditional technology of machining, which is used in many industries. This technology of utilizing electrical impulses to cut material at high temperatures tends to create many types of surface and subsurface defects on machined surfaces. The occurrence of defects in the form of cracks or burned cavities may represent a significant limitation of the functionality and lifetime of the component. For this reason, the analysis of the occurrence and formation of surface and subsurface defects was carried out in this study, depending on the type of material used and the parameters setup of the machine. The object of the study was three metallic and three non-ferrous materials, three samples of which were produced with different parameters setting of the machine. The processed samples were analysed using both light and electron microscopy, and their cross sections as well. In addition, the topography of all samples was evaluated using a contactless profile meter, and the visualization of the 3D surface of the sample was performed using the semi-contact atomic force microscope technique. On the basis of the analyses performed, materials have been found in which the occurrence of defects is influenced by the parameters setup and they can, therefore, be prevented.