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This research put forth an effort to produce AA5083 (Al-4.4 Mg-0.7 Mn-0.15 Cr)-12 wt.% MoO3 composite via the stir casting (SC) process, and the effects of process parameters such as pulse on time (TON), pulse off time (TOFF), and current (I) on the wire electrical discharge machining (WEDM) characteristics such as metal removal rate (MRR) and surface roughness (SR) were investigated using the Taguchi method. Numerous unconventional machining methods are accessible to machine MMCs; among that, WEDM is a significant method. ANOVA was utilized to identify the suitable parameters to obtain maximum MRR and least SR. From the analysis, it is clear that TON 120 (μs), TOFF 50 (μs), and I 3 (A) are the noteworthy parameters to acquire maximum MRR and TON 100 (μs), TOFF 40 (μs), and I 3 (A) are the noteworthy parameters to acquire least SR. ANOVA results for MRR showed that TOFF is the extreme inducing factor with the percentage contribution of 27.92% tracked by TON and I with the percentage contribution of 12.09% and 5.07%, respectively. ANOVA results for SR showed that TOFF is the extreme inducing factor with the percentage contribution of 60.33% tracked by TOFF and I with the percentage contribution of 12.31% and 0.33%, respectively.

Wire Electrical Discharge Machining Characteristics of Al-4.4 Mg-0.7 Mn-0.15 Cr-12 wt.% MoO3 Composites Using Taguchi Technique