Productivity and workpiece surface integrity when WEDM aerospace alloys using coated wires

MT Antar; Sein Soo; David Aspinwall; D Jones; R Perez

doi:10.1016/j.proeng.2011.11.071

Productivity and workpiece surface integrity when WEDM aerospace alloys using coated wires

MT Antar
, Sein Soo
, David Aspinwall
, D Jones
, R Perez

Research output: Contribution to journal › Article

78 Citations (Scopus)

Abstract

Following a brief review of recent minimum damage EDM pulse generator developments, experimental data is presented for workpiece productivity & integrity when WEDM Udimet 720 nickel based superalloy and Ti-6Al-2Sn-4Zr-6Mo titanium alloy, using Cu core coated wires (ZnCu50 and Zn rich brass). Up to a 70% increase in productivity was possible compared to when using uncoated brass wires with the same operating parameters. Surfaces measuring ∼ 0.6 μm Ra, with near neutral residual stresses and almost zero recast were produced following two trim passes. Cross-sectional micrographs of specimens following rough machining (∼180mm2/min) showed the recast to be < 7 μm thick (up to 11 μm for uncoated wire), with comparable results for both alloys. Surface cracking, when evident, was restricted to within the recast layer.

Original language	English
Pages (from-to)	3-8
Number of pages	6
Journal	Procedia Engineering
Volume	19
DOIs	https://doi.org/10.1016/j.proeng.2011.11.071
Publication status	Published - 1 Jan 2011

Access to Document

10.1016/j.proeng.2011.11.071

Cite this

@article{f1f742e895c24983b18e015ae262dbe1,

title = "Productivity and workpiece surface integrity when WEDM aerospace alloys using coated wires",

abstract = "Following a brief review of recent minimum damage EDM pulse generator developments, experimental data is presented for workpiece productivity \& integrity when WEDM Udimet 720 nickel based superalloy and Ti-6Al-2Sn-4Zr-6Mo titanium alloy, using Cu core coated wires (ZnCu50 and Zn rich brass). Up to a 70\% increase in productivity was possible compared to when using uncoated brass wires with the same operating parameters. Surfaces measuring ∼ 0.6 μm Ra, with near neutral residual stresses and almost zero recast were produced following two trim passes. Cross-sectional micrographs of specimens following rough machining (∼180mm2/min) showed the recast to be < 7 μm thick (up to 11 μm for uncoated wire), with comparable results for both alloys. Surface cracking, when evident, was restricted to within the recast layer.",

author = "MT Antar and Sein Soo and David Aspinwall and D Jones and R Perez",

year = "2011",

month = jan,

day = "1",

doi = "10.1016/j.proeng.2011.11.071",

language = "English",

volume = "19",

pages = "3--8",

journal = "Procedia Engineering",

publisher = "Elsevier Korea",

}

TY - JOUR

T1 - Productivity and workpiece surface integrity when WEDM aerospace alloys using coated wires

AU - Antar, MT

AU - Soo, Sein

AU - Aspinwall, David

AU - Jones, D

AU - Perez, R

PY - 2011/1/1

Y1 - 2011/1/1

N2 - Following a brief review of recent minimum damage EDM pulse generator developments, experimental data is presented for workpiece productivity & integrity when WEDM Udimet 720 nickel based superalloy and Ti-6Al-2Sn-4Zr-6Mo titanium alloy, using Cu core coated wires (ZnCu50 and Zn rich brass). Up to a 70% increase in productivity was possible compared to when using uncoated brass wires with the same operating parameters. Surfaces measuring ∼ 0.6 μm Ra, with near neutral residual stresses and almost zero recast were produced following two trim passes. Cross-sectional micrographs of specimens following rough machining (∼180mm2/min) showed the recast to be < 7 μm thick (up to 11 μm for uncoated wire), with comparable results for both alloys. Surface cracking, when evident, was restricted to within the recast layer.

AB - Following a brief review of recent minimum damage EDM pulse generator developments, experimental data is presented for workpiece productivity & integrity when WEDM Udimet 720 nickel based superalloy and Ti-6Al-2Sn-4Zr-6Mo titanium alloy, using Cu core coated wires (ZnCu50 and Zn rich brass). Up to a 70% increase in productivity was possible compared to when using uncoated brass wires with the same operating parameters. Surfaces measuring ∼ 0.6 μm Ra, with near neutral residual stresses and almost zero recast were produced following two trim passes. Cross-sectional micrographs of specimens following rough machining (∼180mm2/min) showed the recast to be < 7 μm thick (up to 11 μm for uncoated wire), with comparable results for both alloys. Surface cracking, when evident, was restricted to within the recast layer.

U2 - 10.1016/j.proeng.2011.11.071

DO - 10.1016/j.proeng.2011.11.071

M3 - Article

VL - 19

SP - 3

EP - 8

JO - Procedia Engineering

JF - Procedia Engineering

ER -

Productivity and workpiece surface integrity when WEDM aerospace alloys using coated wires

Abstract

Access to Document

Fingerprint

Cite this