International Journal on Interactive Design and Manufacturing (IJIDeM) (2023) 17:859–867

https://doi.org/10.1007/s12008-022-01185-5

ORIGINAL PAPER

Investigation of wire-cut EDM process parameters on Nimonic 90

made by wire arc additive manufacturing process
Midthur A. Salman Khan1 · C. Senthilkumar2

Received: 28 September 2022 / Accepted: 23 December 2022 / Published online: 3 January 2023
© The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2023

Abstract
Incurrent times wire arc additive manufacturing is becoming popular and alternate to conventional machining because of its
eco-friendly as wastages. Wire arc additive manufacturing (WAAM) develops the parts by depositing wire material one layer
above other because it is based on old technology i.e., welding. It even has ability to generate complex parts. As WAAM requires
post processing to obtain the better surface and accuracy of dimensions. To study about the post processing of WAAM specimen,
in this work Wire cut EDM is used, which can machine complicated shapes with high accuracy for any conducting material
without taking into account the hardness of the material. Selection of input parameters is the key for better material removal
and surface finish in Wire EDM.In this study Pulse on time, Wire tension, Servo Voltage withthree levelswereconsidered as
input parameter and Material removal, Surface roughness are considered as output responses. Response surface Methodology
is used for designing the experiment. It is observed that wire tension plays vital role in material removal and surface finish,
pulse on time is important in material removal but not in surface finish. Servo voltage predominant for surface roughness but
less influenced on material removal rate.

Keywords WAAM · Subtractive manufacturing · Wire EDM · Nimonic 90 · RSM · Wire tension · Servo voltage · Pulse on
time · MRR · Surface roughness

1 Introduction The production environment will, however, be dramati-

cally altered by the use of metals or ceramics in additive
Manufacturing techniques have seen major industrial manufacturing in the aerospace and medical sectors. By pre-
advancements over the past 50 years, despite many ineffi- dominantly using metal and ceramic in the form of fused
ciencies such as the inability to process particular materials, powders, AM varies from traditional manufacturing or sub-
create complicated shapes, and manufacture in huge quanti- tractive manufacturing, because there aren’t enough machine
ties. In subtractive manufacturing, a lot of waste is produced makers and quantifying surface texture in additive manufac-
[1]. Architects and designers have used 3D printing exten- turing is more difficult than it is in traditional machining,
sively to make aesthetically beautiful and useful prototypes WAAM hasn’t fully industrialized [3]. The demand for high
in the past due to its speedy and economical prototyping quality production and complicated metal structures has
capabilities[2]. However, until recently, 3D printing wasn’t fueled the growth of additive manufacturing over the past few
being used effectively in a number of businesses. Many decades. One AM method that employs metallic materials in
plastic parts, including the vacuum cleaner’s body and cloth- its fabrication is called wire arc additive manufacturing [4].
ing, were initially produced using additive manufacturing. When compared to conventional manufacturing, this technol-
ogy’s utilization of industrial robots and welding equipment
improves performance by 40–60% and speeds up production
B Midthur A. Salman Khan by 15–20%, depending on the size of the product [5]. In AM,
[email protected] Materials are efficiently joined layer by layer, and net shapes
are created with little expense and geometry resolution [6].
1 Department of Manufacturing Engineering,
Arc-based technology, used by WAAM, has increased pro-
AnnamalaiUniversity, Chidambaram 608002, India
ductivity, high energy efficiency, and lower material costs.
2 Department of Manufacturing Engineering, Annamalai
Compared to traditional welding, where the buy-to-fly ratio
University, Chidambaram 608002, India

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is 4.9 and includes machining finish, WAAM saves material brittleness. In WEDM energy is discharged as discrete, which
[7]. Wire is used as a filler in the Direct Energy Deposi- occurs at between wire electrode and workpiece through
tion form of additive manufacturingor WAAM, in which dielectric fluid. The energy discharged produces a temper-
an electric arc serves as the heat source to melt the wire. ature of around 20,000 °C between electrodes in very less
One arc process that works best in WAAM is cold metal microseconds [19]. To get a superior surface finish, tool wear
transfer; in this process, consistent, well-controlled current and vibration during machining must be controlled. This is
waves are present, along with filler feed. This results in the because direct contact between the wire electrode and the
weld bead being deposited with fewer protrusion [8]. WAAM workpiece occurs during WEDM, which causes mechanical
has capacity to produce goods with higher quality, robust stress. It is never easy to attain acceptable surface rough-
structures, and favorable mechanical properties has helped it ness and a higher rate of material removal because better
gain appeal [9]. Although WAAM is a new technique within material cutting and better surface finish are always at odds
AM, there are various challenges that must be overcome, with one another [20]. In order to provide insulation and ion-
such as: (i) The major loss in WAAM is tolerance, which isation between the workpiece and the wire electrode, the
is produced by residual stress and input heat distortion. (ii) de-ionized water functions as a dielectric medium. A spark
Accuracy in dimensions and component resolution. (iii) The caused by electricity generates a significant quantity of heat,
surface quality of WAAM component manufacturers is low which is cooled by a dielectric medium, which also removes
[10]. To achieve precise dimensional accuracy, subtractive the eroded material from the surface of the material [21].
manufacturing and WAAM are coupled. In the course of post- For better material removal rate, surface roughness, and kerf
processing, subtractive manufacturing should only be used width, many researchers have tried to optimise the process
after WAAM [11]. Kindermann et al. studied about disso- parameters, such as pulse on time, pulse off time, wire ten-
lution of Nb in eutectic phase around the interlayer regions sion, open servo voltage, and flushing pressure. However,
in CMT WAAM of processing parameters [12]. Effect of experimental evidence from Manna et al. suggests that wire
IN 718 alloy cold rolled with isothermally aging for 8 h at tension and wire feed have good effects on surface rough-
800 °C is investigated by Mei et al. [13]. Jung Hyun park ness while open servo voltage, pulse on time have significant
et al.has investigated the development of 9% nickel steel effects on material removal rate [22].
with 625 alloy of super TIG welding, it has been observed Although WAAM has gained industrial acceptance by pro-
that compared to conventional fluxed cored arc welding, ducing final parts in accordance with the specified designs,
Super TIG welding exhibited high tensile strength, Impact a secondary subtractive operation is still required. In order
toughness, hot cracking resistance which are due to low non- to produce the specimen’s surface polish and to first detach
metal inclusion in metal [14]. Nickel-based super alloys are the WAAM specimen from the substrate, subtractive man-
used in additive manufacturing which are second to titanium ufacturing is required. It has been noted that while many
alloy in popularity. Due to its favourable mechanical qualities academics have produced extensive research on the WAAM
and corrosion resistance, particularly at high temperatures, method utilising a variety of materials, very few papers have
nickel super alloys are used in the aerospace, energy, and focused on Nimonic 90 which is one of the nickel-based super
petrochemical industries [15]. One of the nickel-based super alloys that is widely utilised in various applications due to
alloys, Nimonic 80, is resistant to heat, oxidation, and cor- its resistance to oxidation at high temperatures as well as its
rosion, especially at high temperatures, making it valuable resistance to corrosion. Few researchers have integrated a few
for gas turbine engine parts, the space industry, and nuclear additive and subtractive manufacturing processes, however
reactors [16, 17]. Nimonic 90 is a nickel-based super alloy. It WAAM and WEDM have not yet been integrated. There-
has excellent corrosion resistance, high thermal stability, and fore, a part is created in this article using Nimonic 90 wire in
unique properties like strong affinity to heat, low thermal con- WAAM, and then WEDM is utilised to analyse how param-
ductivity, and low diffusivity, which makes it challenging to eters affect the part’s machining. Servo voltage, pulse on
build via subtractive manufacturing [17]. When nickel alloys time, and wire tension were selected as the input parame-
are machined using conventional techniques, a built-up layer ters in accordance with previous studies and the objective of
forms on the cutting tool face, the surface integrity is sub- this investigation, which is to obtain a high material removal
par, and there are numerous microcracks, including surface rate and minimal surface finish. By using Design of Experi-
ripping, material pull-out/cracking, and drag [18]. This type mentsthree levels of WEDM input parametersservo voltage,
of hard materials can be machined by using chemical reac- wire tension, and pulse on time are designed using the RSM
tions, melting and evaporation with electrical energy known technique.
as non- traditional machining, WEDM is one among non-
traditional machining which can machine any material that
is conductive in nature without considering its hardness and

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Table 1 Composition Nimonic 90 Table 2 Technical specification of maxi-cut eWEDM machine

Element Content (%) 1 Max. table size 440 × 650 mm

Iron (Fe) 58.5 2 Max. height 200 mm

Chromium (Cr) 19.5 3 Max. weight 300Kg
Cobalt (Co) 18 4 Controlled axes X &Y, U&V
Titanium (Ti) 2.5 5 Wire range in dia. 0.25 mm (std) &
Aluminium (Al) 1.5 0.15–0.3 mm (Opt)
6 Memory 1000 blocks with
battery backup
7 Tank capacity 250 L
8 Generator ELPULS 20e
2 Experimental set-up
9 Load 07 Kilo VA

2.1 Material and machine 10 Average consumption of power 3.5 to 05 Kilo VA

11 Input power supply 3Phase, AC 415 V,
50 kHz
Nimonic 90 wire material of 1.2 mm diameter whose chemi-
cal composition is shown in Table 1. The Schematic diagram
of WAAM machine is shown in Fig. 1. Teach pendent is the
technique used in this study. Experiments were designed by using RSM Central Com-
Welding torch can moves about X axis,Y axis and Z axis. posite design.Square profile of 5 mm is designed in CAD
The shielding gas used in this study is Argon. MIG welding software and is imported into NCP file and loaded to Maxi
technology. A part of 12 cm×12 cm×6 cm of nimonic 90 is E Cut WEDM machine. Material removal rate and Surface
developed on Stainless Steel substrate of 10 mm thick. roughness were taken as output responses. Material removal
Wire electric discharge machine of Maxi-cut eis used to rate is calculated using the formula [25].
perform the experimentation. The technical details of the
MRR
machine are shown in Table 2 and it is shown in Fig. 2.  
Copper, Brass, Zinc coated brass are wire electrodes of V olume o f material r emoved mm 3

diameters ranging from 0.05 to 0.25 mm are generally used in T ime takem f or complete cutting o f one specimen (min)
WEDM. The eroded material is flushed by passing dielectric (1)
fluids like De-ionized water, Kerosene. Dielectric fluid helps
in reducing the short circuit between workpiece and wire
[23]. De-ionized water as dielectric medium, Zinc coated • Volume removed  Perimeter of specimen × Dia. of
brass wire of 0.25 mm is used for cutting of the specimen wire× thickness of work-piece.
because zinc coating gives better tensile strength and zinc • Perimeter  4 × each side size (5 mm)
vaporizes quickly and enhances gap between wire electrode • Diameter of wire  0.25 mm.
and specimen which intern leads to flushing of eroded mate- • Thickness of specimen  5 mm.
rial, brass inside will get better cooling and avoids wire • Time taken to cut each specimen.
breakage.Range of parameters are shown in Table 3 [24].
The input parameters and its level are shown in Table 4.

Fig. 1 WAAM machine

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Fig. 2 Maxi-cut e WEDM

machine

Table 3 Maxi-cut eWire EDM process parameters & its range 3 Results and discussion
S. No Process parameter Range
3.1 Variation of responses with input parameters
1 Pulse on time 0–131 (μs)
2 Pulse off time 0–63 (μs)
The variations in responses with input parameters are stud-
ied using main plots. Main plots are drawn using Minitab
3 Wire tension 0–15 (N)
2021software.
4 Servo voltage 0–99 (V)
5 Water pressure 0–15 (kg/sq cm)
3.2 Effects of Input parameters on MRR
6 Wire feed rate 0–15 (m/min)
7 Peak current Upto 230 (A)
Main effect Plot of MRR with Pulse on time, Servo volt-
age and Wire tension are shown in Fig. 3. With increase
in wire tension, Pulse on time there is increase in material
2.2 Calculation of MRR removal rate and with increase in servo voltage MRR increase
initially then material cutting rate decreases. During initial
increase of servo voltage MRR increases, as there is increase
in sparks between the electrodes which heats and evapo-
4 × 5 × 0.25 × 5 rates the material. Whereas when voltage increases there
MRR   6.25(mm3 /min).
7 is increase in current but less amount of heat gets transmit
to workpiece since gap increases between electrode, which
By using above formula, we can able to calculate the MRR leads to decrease in MRR [26]. As Wire tension increases
of all the specimens and surface roughness are calculated by there is decrease in vibrations and makes wire electrode
using Taylor surf device. The responses are tabulated for all straight which leads to increase in cutting of material from
the 20 experiments in Table 5. work piece[27]. It is observed that with increase in pulse-on

Table 4 Input parameters with its

levels Parameters Unit Levels

– 1 0 1

Pulse-on time μs 7 8 9
Servo voltage Volts 2 3 4
Wire tension N 1000 1150 1300

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Table 5 Experimentation
responses S. No Ton (μs) SV (V) WT (N) MRR (mm3 /min) SR (μm)

1 80 50 10 3.570 3.257
2 110 50 12 6.950 3.658
3 80 80 12 3.650 3.106
4 95 65 11 5.950 3.298
5 95 65 11 6.100 3.997
6 110 80 10 6.512 3.842
7 110 80 12 7.210 3.675
8 95 65 11 6.085 3.705
9 80 50 12 5.850 2.890
10 80 80 10 3.256 3.756
11 95 65 11 6.085 3.551
12 110 50 10 6.521 4.499
13 95 80 11 5.750 2.988
14 110 65 11 6.480 3.992
15 95 65 11 6.224 3.530
16 80 65 11 4.125 3.306
17 95 65 10 5.325 3.885
18 95 50 11 5.810 3.499
19 95 65 11 5.980 3.516
20 95 65 12 6.350 3.257

there is increase in cutting of material i.e., material removal. 3.4 Contribution of process parameters
This is due to increase in length of pulse will increase in
energy discharged, melting of material and flushing of mate- Contribution of process parameter for output responses with
rial [28]. respect to input parameters are shown by Figs. 5 and 6.

3.3 Effect of input parameters on Ra 3.5 Analysis of surface topology of WEDM process
Main effect Plot of Surface roughness with Pulse on time, After WEDM operations, the scanned electron micro-
Servo voltage and Wire tension are depict in Fig. 4. From scope(SEM) made by Joel 6067 been used to investigate the
figure it is observed that with increase in Pulse on time change insurface properties of work material after WEDM
there is increase in Surface roughness whereas with increase process. It has been examined that large number of micro
in wire tension, Servo voltage surface roughness decreases. cracks, crater formation,white layer formation and recast
With increase in servo voltage stability in spark and uni- layer formation takes placeon the surface of the work mate-
formity in dispersion occurs which leads to improvement rial after WEDM which were confirmedby SEM image. This
in surface finish [29]. When wire tension is low surface can be observed that higher Ton results in generation of
roughness is more and less for high values of wire tension, higher thermal energy, when the temperature reaches above
this due to fact thatas wire tension increases there is reduc- 10,000 °C, which is high enough to melt and evaporate the
tion in deflection of wire which is due to reactional force metal and pressure is being buildup inside the melt,when
to the sparks developed and water pressure. This reduction it reaches its limit, it explode, which can splatter melted
in deflection of wire from path, leads to proper machining material on the surface, produce pockmarks, micro holes
and produces better surface finish [30]. During pulse time, and globules, resulting in an irregular surface as can be seen
bridge of spark is developed between the electrodes, which in Fig. 7 [32]. It can also be observed that with the rise in
generate current. As pulse time increases sparks becomes SV, the roughness of the surfacealso increases as it generate
longer which leads to formation to formation of deeper, more thermal energy in the gap, causing stern cracking of the
boarded cuts on surface, thus surface roughness increases dielectric to happen more frequently, leading to the formation
[31]. of a molten pool that is becoming overheated. This molten
metal condenses onto gas bubbles since it evaporates [33].

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Fig. 3 Main Effect plot for MRR

Fig. 4 Main Effect Plot for Ra

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Fig. 5 % Contributionof
Responses on MRR

Fig. 6 % Contribution of
Responses on Ra

When the charge stops, the gas bubbles shatter, expelling • It has been found that servo voltage has less of an impact
the molten metal from the surface of the Nimonic alloy. on MRR than do pulse-on time and wire tension. The
Consequently, a big lump of re-solidifiedmass has appeared plot demonstrates that as pulse on time and wire tension
on the machined surface with big and wide crack. Further increase, MRR also does. This is because an increase in
size and population of craters were increased extremely and discrete energy with increasing pulse on time melts and
overlapped craters were extended to the complete surfaceas evaporates more material, whereas an increase in wire ten-
illustrated in SEM micrograph Fig. 8 [34]. sion results in a stiffer wire and more evenly distributed
energy, leading to an increase in MRR.
• MRR first rises as servo voltage rises, but falls as voltage
rises more. There is a tiny space between the electrodes
4 Conclusion when the servo voltage rises, and this heat-generating gap
causes additional material to melt and evaporate. MRR,
Nimonic 90 was made in WAAM for experimental purposes, however, diminishes when servo voltage increases the
and it was machined using WEDM. For 20 experiments that space between the wire electrode and workpiece, which
were designed using RSM, the outcomes are as follows. With in turn reduces the heat generated between them.
varying input parameters, main graphs were created for the • Surface roughness is seen on plots to grow with pulse on
output responses. time but decrease with servo voltage and wire tension.

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the dielectric medium, craters are created when material

resolidifies on the surface of the substance.

Acknowledgements The author acknowledges Department of Man-

ufacturing Engineering, Annamalai University, for the support and
facilities provided to conduct the research.

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