Materials and Manufacturing Processes

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Experimental investigation on wire electric

discharge machining (WEDM) of Nimonic C-263
superalloy

Himanshu Bisaria & Pragya Shandilya

To cite this article: Himanshu Bisaria & Pragya Shandilya (2018): Experimental investigation
on wire electric discharge machining (WEDM) of Nimonic C-263 superalloy, Materials and
Manufacturing Processes, DOI: 10.1080/10426914.2018.1532589

To link to this article: https://doi.org/10.1080/10426914.2018.1532589

Published online: 04 Dec 2018.

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MATERIALS AND MANUFACTURING PROCESSES
https://doi.org/10.1080/10426914.2018.1532589

Experimental investigation on wire electric discharge machining (WEDM) of Nimonic

C-263 superalloy
Himanshu Bisaria and Pragya Shandilya
Mechanical Engineering Department, MNNIT Allahabad, Allahabad, India

ABSTRACT ARTICLE HISTORY

Nimonic C-263 superalloy offers a wide range of outstanding properties, namely, high-temperature Received 28 May 2018
resistance, high specific strength, high thermal fatigue, and hot corrosion resistance. The concern of the Accepted 12 September 2018
present study is mainly focused on the effect of wire electrical discharge machining (WEDM) process KEYWORDS
parameters namely, spark energy, spark frequency, and peak current on surface roughness, average Nimonic C-263; WEDM; CR;
cutting rate, and surface integrity aspects of Nimonic C-263 superalloy by using one-parameter-at-a-time SR; XRD; SEM; EDS
(OPAT) approach. Surface roughness and average cutting rate were showing the increasing trend with
the spark energy and peak current and reverse trend with the spark frequency. Surface integrity aspects
of Nimonic C-263 such as surface topography, surface morphology, recast layer thickness, elemental
composition, and phase analysis have been also considered in this study. Scanning electron microscope
(SEM) micrograph of the machined surface shows the presence of micro-voids, discharge craters, micro-
globules, and droplets of molten material. A recast layer of minimum thickness, with less transfer of
foreign atoms (Mo, C, and O) from dielectric fluid and molybdenum wire, has been formed at lower
spark energy compared to higher spark energy. The various compounds of Ni, Fe, Al, and Ti such as
Fe1.2Ni0.8, Fe1.5Ni0.5, Co0.06Fe0.94, and Alo.29Ni0.27Ti0.44 were formed on the machined surface identified
through analysis of XRD peaks.

Introduction close dimensional tolerance using computer numerical con-

trol (CNC) programming.[9,10] As WEDM is an advanced
Nowadays, the concern of scientists and researchers on the
machining process which utilizes the thermal energy of
machining of Ni-based superalloys has been increased due to
spark for melting of material, the outer machining surface
their rising demand for the gas turbine engine. Nimonic
experiences very high temperature around 10,000°C during
C-263 is a high-temperature resistant superalloy which exhi-
spark on-time and sudden quenching from the dielectric
bits high oxidation resistance and high hot corrosion resis-
during spark off-time. This huge temperature gradient experi-
tance up to about 1100°C.[1,2] Recently, Nimonic C-263 has
enced by the outer machining surface led to the deposition of
been used in the aerospace, power generation, blades of the
a layer of transformed phases.[11] This layer of transformed
gas turbine, and heat exchangers applications due to their
phases or re-solidified layer of melted material is called recast
outstanding characteristics. The conventional machining of
layer. The formation of the recast layer of considerable thick-
these superalloys is another extremely difficult task due to
ness on the machined surface during machining which is
low thermal conductivity, high tool wear, high hardness, and
enormously damaging to the aerospace application can be
work hardening tendency.[3,4] Due to the huge requirement of
reduced in WEDM with the use of low spark energy.[12,13]
super-finished components in aircraft applications, aircraft
Gostimirovic et al.[14] experimentally explored the effect of
manufacturing industries are looking for an alternative
discharge energy on performance parameters such as material
approach for machining of these superalloys with high
removal rate (MRR), recast layer, gap distance, and surface
production rate (cutting rate), high surface quality, and low
roughness (SR) for tool steel ASTM 681 in electrical discharge
cost.[5,6] To overcome the hurdle in the machining of these
machining (EDM). It was observed that with the increase in
superalloys by conventional machining practices, the
discharge energy, MRR, SR, and recast layer thickness
advanced machining processes such as laser beam machining,
increased. Punturat et al.[15] studied the effect of WEDM
electrochemical machining, and discharge machining (EDM/
variable parameters on damage in the machining of silicon
WEDM) can be successfully exploited.[7,8] Among the
and characteristics of cut surface and concluded that high
advanced machining processes, wire electrical discharge
spark energy density causes the formation of deeper craters,
machining (WEDM) is an effective and economical approach
high SR, and high deposition of foreign elements (Cu and Zn)
for machining of these superalloys. WEDM process is flexible
from brass wire. Soni et al.[16] applied WEDM process for
in machining of any complex profile with high accuracy and

CONTACT Himanshu Bisaria rme1509@mnnit.ac.in Mechanical Engineering Department, MNNIT Allahabad, Allahabad, India
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/lmmp.
© 2018 Taylor & Francis
2 H. BISARIA AND P. SHANDILYA
machining of Ti50Ni49Co1 shape memory alloy and studied
the influence of input parameters on cutting rate (CR) and SR.
It was noticed that CR and SR were increased with the
increase in pulse on-time, while spark gap voltage showed
the reverse trend and high surface crack density was also
observed at higher value of CR and SR. Sharma et al.[17]
examined the influence of material of wire electrode on CR
and surface integrity aspects for Inconel 706 superalloy in
WEDM. It was reported that the improved surface quality in
terms of lower SR, smoother topography, and thin recast layer
was obtained with the hard brass wire, whereas higher cutting
speed as productivity was obtained with zinc-coated wire.
However, the effect of diffused wire was moderate. The effect
of discharge energy on the machinability of AISI 4340 steel
was also investigated by Giridharan and Samuel.[18] It was
found that the MRR, SR, and recast layer thickness were
increased with the increase in discharge energy.
The conclusions from the comprehensive analysis of
previous literature can be made that the most of the past
research work was focused on the machinability of Ni-
based superalloys, but consideration of spark energy and
spark frequency for the performance characteristics of
these superalloys in WEDM was rarely reported. Hence,
the goal of this investigation is to explore the influence of
WEDM process parameters such as spark energy, spark
frequency, and peak current on SR, average CR, and sur-
face integrity aspects for Nimonic C-263 superalloy using
one-parameter-at-a-time (OPAT) approach. Under surface
integrity aspects, the surface morphology, surface topogra-
phy, elemental composition, recast layer thickness, and
phase analysis have been studied by using Scanning elec-
tron microscope (SEM), optical profilometer, energy dis-
persive spectroscopy (EDS), and X-ray diffraction (XRD)
technique, respectively.
Figure 1. Elemental composition of Nimonic C-263 superalloy using EDS.
Materials and methods
Material
Nimonic C-263 superalloy, which is extensively used in aero-
space industries for the turbine blade manufacturing, was
selected as target material for the experimental studies. For
the elemental composition of the Nimonic C-263, EDS test
was used which is shown in Fig. 1. The procurement of
material was in the square-shape plate of dimensions
155 × 155 × 5 mm3. The mechanical and physical properties
of Nimonic C-263 are given in Table 1.
Experimental methodology
The experiments were performed on Nimonic C-263 super-
alloy by using four-axis, CNC Express cut 7732C wire cut
machine which is shown in Fig. 2. For this experimental
study, the most influencing parameters of WEDM such as
spark energy (Es), spark frequency (fs), and peak current (Ip)
with five levels were selected based on preliminary experi-
ments which are tabularized in Table 2, whereas some WEDM
parameters were kept at a fixed level during experimentation
are listed in Table 3. SR, average CR, and surface character-
istics have opted as response parameters. For measuring the
surface quality of the machined surface, average SR (Ra) has
been considered, whereas average CR epitomizes the produc-
tivity. The detail description of response parameters and their
measurements are summarized in Table 4.
The energy required for material removal in WEDM is
gained from the conversion of spark energy to thermal energy.
Thus, the spark energy or discharge energy may be defined as
the average electrical energy per pulse. The spark energy can
be given as Eq. (1)[11]:
 MATERIALS AND MANUFACTURING PROCESSES 3

Table 1. Physical and mechanical properties of Nimonic C-263 superalloy.[4,5]

Properties Density (g/cm3) Avg. hardness (Hv) Yield strength (MPa) Elongation (%) Creep stress (MPa) Tensile strength (MPa)
Specification 8.36 300 ≥400 24.1 120 ≥540

Figure 2. Pictorial view during the machining of Nimonic C-263 in WEDM (EX7732).

Table 2. Variable parameters and their levels of WEDM for Nimonic C-263 superalloy.

Variable parameters Levels Response parameters

Spark energy (mJ) 6.72 8.40 10.08 11.76 13.44 Avg. cutting rate
Spark frequency (kHz) 18.19 20 22.23 25 28.57 Surface roughness
Peak current (A) 1 2 3 4 5 Surface integrity

Table 3. Fixed parameters for WEDM of Nimonic C-263 superalloy. Es ffi Ve  Ie  tON (2)
Parameters Specification where tON is pulse on-time, the five levels of tON, 40, 50, 60,
Wire electrode Molybdenum (Ø 180 µm) 70, and 80 µs and pulse off-time (tOFF), 5, 10, 15, 20, and 25 µs
Dielectric fluid De-ionized water
were selected during experiments. The discharge voltage and
Dielectric pressure (MPa) 0.98
Dielectric conductivity (µs/m) ±20–23
peak current 28 V and 6 A were, respectively, maintained
Working temperature (°C) 25 constant during the study. Sparks frequency (number of
Polarity Straight polarity sparks per second) is given according to Eq. (3),[11] which
Wire feed rate 7 m/min increases with the decrease in tON.
Sparkfrequency ðkHzÞ ¼ 103 =ðTON þ TOFF Þ (3)
te
Spark energy ðJ Þ ¼ ò Ve ðtÞ  ie ðtÞ  dt ffi Ve  Ie  te
0 Results and discussion
(1) Surface roughness and average cutting rate
where Es is the spark energy (J), Ve is discharge voltage (V), te The effect of separate WEDM process parameters on SR and
is discharge duration (µs), and Ie is discharge current (A). For CR is shown in Figs. 3–5, while other WEDM process para-
ideal discharge condition i.e. zero delay in ignition, the dis- meters are kept at the middle level. Figure 3 displays the
charge duration becomes equal to pulse duration and spark influence of spark energy on SR and CR. CR and SR are
energy can be written as Eq. (2)[11]: significantly increased with an increase in ES, whereas the
4 H. BISARIA AND P. SHANDILYA

Table 4. Detail description of response parameters of Nimonic C-263 superalloy.

Parameters Description Calculation/condition Apparatus used

Avg. cutting rate
Surface roughness
Surface morphology
3D, Surface topography
Recast layer thickness
Phase analysis
It is defined as the average rate of length of cut ðmmÞ Stop watch for measuring cutting
cutting at which desire profile is cut.
CR ¼ cutting time ðminÞ time
[7]
It is the component of surface texture Stylus speed Mitutoyo SJ-410 surface roughness
and quantification of surface quality. It (0.1 mm/s) tester
is defined as the average of the vertical cutoff length
deviations from the nominal surface (0.8 mm)
over a specified surface length.[19] evaluation length
(5 mm)
It is defined as the texture of machined Magnification value was 500 i.e. JEOL JSM-6010LA
surface. 500 × SEM attached with energy dispersive
X-ray spectroscopy
It is defined as the three-dimensional Area for measurement Bruker Contour GTK
surface texture, showing the protrusion 240 × 180 µm2 optical profiler
and depression on the machined
surface.
It is defined as thin layer of re-solidified Area of recast layer Cross-sectional SEM image,
molten material on the machined
RLT ¼ length of reacst layer ImageJ software
surface during discharge.[13] [7]
Formation of different phases and Radiation Cu-Kα Pan Analytical X’PERT XRD machine
compound on the machined surface. range of 2θ (5–100°)
scanning rate 2° min−1.

Figure 3. Effect of spark energy on average cutting rate and surface roughness.

other WEDM process parameters were kept at a fixed level.
The spark energy directly affects the amount of thermal
energy required for material removal. With the increase in
Es, more thermal heat transferred to material causes high
temperature which assists in the removal of material and
hence CR is increased.[20] It can be observed from Fig. 3
that the SR also exhibited the similar trend with ES i.e. it
increases with the increase in ES. This is because at the higher
value of Es, deeper and wider craters are formed on the
machined surface, and as a result, SR is increased. This effect
of ES on SR can also be explained with the help of the
mathematical relationship between crater depth and spark
energy as given in Eq. (4).[21] As spark energy is increased,
the deeper craters are formed because of high crater depth.
hc ðmmÞ  K Es 0:33 (4)
where hc is crater depth (mm), Es is spark energy (J), K is
constant whose value depends on the material.
The variation of CR and SR with spark frequency, keeping
other WEDM process parameters at the middle level, is shown

Figure 4. Effect of spark frequency on average cutting rate and surface roughness.
in Fig. 4. The CR was found to decrease with the increase in fs.
This is because of shorter pulse duration at higher fs. At
shorter pulse duration i.e. pulse on-time, the spark energy
and spark’s intensity are decreased which causes low MRR
and thus CR is decreased. The similar trend is shown by SR, it
decreased with the increase in fs. As fs increases, sparking
ampere output i.e. sparking current decreases. So, lower fs is
generally used for rough cutting operation, whereas higher fs
is preferred for the finishing operation.[11]
Figure 5 depicts the effect of peak current on CR and SR
keeping other WEDM process parameters at the middle level.
Similar to spark energy, the CR and SR are increased with an
increase in IP. At the higher value of IP, the amount of spark
energy is increased which led to increasing MRR and crater
size. Therefore, the CR and SR are found to be increased at
higher IP compared to lower IP.
Surface morphology
For microstructural analysis of machined surface, SEM
images were captured at 500 × magnification. Fig. 6(a–b)
shows the morphology of the machined surface generated
at lower and higher spark energy, respectively. SEM
micrograph of machined surface illustrates the formation
of discharge craters, micro-voids, droplets of molten mate-
rials, and micro-globules. It was also detected that there
was no formation of micro-cracks on the machined sur-
face due to the high toughness of Nimonic C-263 super-
alloy. The similar findings were also observed by Sharma
et al.[17] during machining of Inconel 706 in WEDM. It
can be also noticed that at higher Es, the surface has more
distorted morphology compared to lower Es because at
MATERIALS AND MANUFACTURING PROCESSES 5
higher Es, more material is melted which led to the for-
mation of surface irregularities.
Surface topography
The machined surface’s 3D surface topography generated
at lower and higher ES are shown in Fig. 7(a–b), respec-
tively. From 3D surface topography, it can be concluded
that at lower ES, fine surface with higher smoothness was
obtained compared to higher Es. At higher ES, deeper
craters (average depth 42 µm shown in Fig. 7(b)) are
formed compared to the shallow crater (average depth
18.443 µm) formed at lower Es which also experimentally
rectifies the Eq. (4) i.e. the mathematical relationship
between crater depth and spark energy. At higher Es,
more thermal heat is transferred to workpiece surface
which led to more melting of material and hence the
formation of wider and deeper craters is increased.
Recast layer thickness and EDS analysis
Figure 8 illustrates the thickness of the recast layer depos-
ited with the elemental composition of constituent ele-
ments present on outer machining surface at higher Es.
It can be observed that a thick recast layer of thickness
32 µm is deposited on the outer machining surface with
high deposition of foreign atoms, for example Mo, C, and
O form the dielectric fluid and the wire electrode. At
higher Es, the amount of thermal energy transferred to
workpiece material is enhanced which causes the more
melted material to re-solidify on the outer machining sur-
face which led to the deposition of thick recast layer. The
6 H. BISARIA AND P. SHANDILYA
Figure 5. Effect of peak current on average cutting rate and surface roughness.
Figure 6. SEM micrograph of machined surface at (a) lower Es (6.72 mJ) and (b) higher Es (13.44 mJ).
elemental composition of Mo-wire is shown in Fig. 9.
Since the Mo-wire was used for machining, Mo atoms
on the machined surface were recorded approximately
2.80 times more compared to the base material composi-
tion. Oxygen and the high carbon content from ionization
of dielectric besides base material were also observed on
the outer machining surface in EDS analysis. The deposi-
tion of recast layer on the outer machining surface is
unfavorable to applications related to aerospace industries.
So, this recast layer was significantly reduced at lower Es.
As can be seen in Fig. 10, a recast layer of lower thickness
with less transfer of foreign atoms was formed on the
outer machining surface compared to higher Es. Similar
observations were recorded by Bisaria and Shandilya[7] for
electrical discharge wire cutting of Ni-rich NiTi-shape
memory alloy. It was noticed that a thick recast layer
with high percentage of foreign elements (Cu, Zn, C, and
O) was deposited on the machined surface at higher pulse
on-time as compared to lower pulse on-time. Similar find-
ings were also supported by Sharma et al.[17] for Inconel
706 superalloy in WEDM. A thick recast layer was depos-
ited on the machined surface at higher discharge energy
compared to lower discharge energy.
XRD phase analysis
The XRD pattern of the outer machining surface at lower and
higher Es is illustrated in Fig. 11(a-b), respectively. The surface
after WEDM comprises the various compounds such as
Fe1.2Ni0.8, Fe1.5Ni0.5, Co0.06Fe0.94, and Alo.29Ni0.27Ti0.44 identi-
fied through analysis of XRD peaks. The high reactivity of
titanium and nickel are mainly accountable for the various
 MATERIALS AND MANUFACTURING PROCESSES 7

Figure 7. 3D surface topography of machined surface at (a) lower Es (6.72 mJ) (b) higher Es (13.44 mJ).

Figure 8. Recast layer and elemental composition of machined surface at higher Es (13.44 mJ).

compounds formation. XRD pattern of machined surface
divulges that the peak intensity has been decreased with the
increase in Es. This is due to fact that the crystal size of the
surface after WEDM has been reduced at higher Es; however,
crystal structure remains unchanged only orientation of pre-
ferred is changed. The shifting of peaks in XRD pattern is also
noticed toward right side which shows the existence of resi-
dual stress of tensile in nature within the surface after WEDM
of Nimonic C-263 superalloy. Similar observations are also
observed by Sharma et al.[17] for Inconel 706 in WEDM. The
detail information of identified peaks in XRD pattern is given
in Table 5.
8 H. BISARIA AND P. SHANDILYA
Figure 9. Elemental composition of molybdenum wire using EDS test.
Figure 10. Recast layer and elemental composition of machined surface at lower Es (6.72 mJ).
Conclusions
In this present study, an attempt has been made to study
the effect of variable parameters of WEDM on perfor-
mance characteristics of Nimonic C-263 superalloy;
experimentally, the following significant conclusions are
drawn from the extensive analysis of experimental results:
(1) The SR and average CR were increased signifi-
cantly with an increase in spark energy and peak
current and decrease with the increase in spark
frequency.
(2) Machined surface’s morphology reveals the existence of
micro-voids, micro-globules and discharge craters,
whereas surface topography shows the formation of
fine and smoother surface with the shallow crater at
lower spark energy.
(3) A thinner recast layer with less transfer of foreign
atoms, namely, Mo, C, and O from dielectric fluid
and molybdenum wire was deposited on the outer
machining surface at lower spark energy as com-
pared to the higher value of spark energy.
(4) The investigation of XRD plot reveals the presence of
various compounds such as Fe1.2Ni0.8, Fe1.5Ni0.5,
 MATERIALS AND MANUFACTURING PROCESSES 9

Figure 11. XRD peaks of machined surface at (a) lower Es and (b) higher Es.

Table 5. Detail of identified peaks in XRD analysis.

Compound Ref Code Density (g/cm3) Crystal Structure Space group Lattice parameters
a/b/c (Å) α/β/ϒ (°)
Fe1.2Ni0.8 98–008-8175 8.02 Cubic Im-3m a = b = c = 2.869 α = β = ϒ = 90
Fe1.5Ni0.5 98–008-8167 7.69 Cubic Im-3m a = b = c = 2.868 α = β = ϒ = 90
Co0.06Fe0.94 98–009-9003 7.46 Cubic Fm-3m a = b = c = 3.618 α = β = ϒ = 90
Alo.29Ni0.27Ti0.44 98–011-7656 5.08 Hexagonal P63/mmc a = b = 5.013, α = β = 90
c = 8.073 ϒ = 120

Co0.06Fe0.94, and Alo.29Ni0.27Ti0.44 and also the existence
of tensile residual stress.
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