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Current research work aims at improving the surface integrity characteristics of Inconel 625 (a nickel-based super alloy) during electric discharge machining (EDM) process. Powder particles such as graphite, aluminium and silicon were added to kerosene dielectric during the EDM process to enhance the surface integrity characteristics. A specially designed and fabricated dielectric recirculating system was attached to the EDM setup to carry the experiments. Design of experiments was carried out using response surface methodology. Influence of process variables such as powder material, particle concentration in dielectric, peak current, pulse on time, duty cycle and gap voltage was investigated on surface integrity characteristics of machined specimens. Mixing of powder particles with dielectric resulted in reduced surface cracking, recast layer thickness and surface microhardness. While EDM with conventional dielectric primarily demonstrated FCC structure of γ-phase of Inconel 625 along with some δ(Ni 3 Nb) phase, powder-mixed EDM has promoted formation of carbides of Ni, Cr and Mo along with Ni 3 Nb from Inconel 625. Addition of powder with dielectric also caused reduction in crystallite size as well as lattice strain due to enlargement of crater while maintaining uniform discharge over a large area.

Influence of powder-mixed EDM on surface morphology and metallurgical alterations of Inconel 625