Key Engineering Materials Submitted: 2021-10-18

ISSN: 1662-9795, Vol. 948, pp 23-32 Revised: 2022-11-28

doi:10.4028/p-851078 Accepted: 2023-01-14
© 2023 Trans Tech Publications Ltd, Switzerland Online: 2023-06-06

Experimental Investigation on the Effect of EDM Wire Cut Parameters on

the formation of Cr23C6 in AISI 316 Steel
Muslimin1,a*, Muhammad Iqbal1,b, Sidiq Ruswanto1,c, Farid Triawan2,d
and Faisal Mahmuddin3,e
Department of Mechanical Engineering, Politeknik Negeri Jakarta, Jl. Prof. Dr. Siwabessy-
1

Kampus UI, Depok, Indonesia

2
Department of Mechanical Engineering, Faculty of Engineering and Technology, Sampoerna
University, Jakarta, 12780, Indonesia
Marine Engineering Department, Engineering Faculty, Hasanuddin University, Indonesia
3

a
muslimin@mesin.pnj.ac.id, bmuh.iqbal5g6@gmail.com, csidiq.ruswanto@mesin.pnj.ac.id,
d
farid.triawan@sampoernauniversity.ac.id, ef.mahmuddin@gmail.com

Keywords: Wire EDM, pulse on time, electrode wire, dies, Cr23C6

Abstract. Wirecut Electrical Discharge Machining (WEDM) is a manufacturing process typically

used to manufacture the machinery components in marine application with complex and challenging
shapes and profiles. This study aims to investigate the effect of the EDM wire cut parameters on AISI
316 steel by analyzing the formation of Cr23C6. Cr23C6 can be formed in the grain boundary if the
stainless steel is sensitized to a high temperature for too long. This compound becomes susceptible
to intergranular corrosion than can reduce structural strength. The formation of Cr23C6 is of interest
because this compound becomes vulnerable to intergranular corrosion than can reduce structural
strength. The experimental variables in this study are pulse on time (i.e., 8 μs and 12 μs), servo voltage
(i.e., 20 V and 30 V), and wire feed (i.e., 5 mm/min and 9 mm/min). The 0.2 mm brass wire is used
during the EDM process. The result is then analyzed by surface roughness test, scanning electron
microscope (SEM), and Energy-dispersive X-ray spectroscopy (EDS). As a result, the highest and
lowest surface roughness values are 2.526 μm 1.771 μm, respectively. SEM results are seen in the
pores of holes (craters) and fractures (microcracks). The result of EDS is the additions of elements
Carbon (C) and copper (Cu), Oxygen (O). Increased carbon Chrom in HAZ sections allows for
corrosion of grain limits.

Introduction
CNC wire cutting EDM (Electrical Discharge Machining) or WEDM is the most popular process
to cut metal workpieces with the following combination characteristics: high hardness, high
thickness, complicated shape with high precision, and good quality. WEDM machining is a
development of electrical discharge machining. Its development results from a search for a way to
develop the machining process using EDM due to the demands of component work with a high level
of precision [1]. The widespread use of WEDM covers the aerospace, marine, nuclear, automotive,
tooling, jewelry, mold, and dies industries. For example, the application of wire EDM in marine is to
cut workpieces with high thickness, a detailed profile, and high accuracy.
Wire EDM is a metal cutting process using the jump of electric sparks produced by wire electrodes
as Cathode to the workpiece as an anode that occurs periodically. Electric current arises because of
the potential difference between the workpiece and the electrode that results in the movement of
positive ions and electrons against opposite poles [1, 2].
WEDM uses electrode wire usually made of copper, brass, or tungsten with diameters varying
between 0.05 mm to 0.3 mm. The quality process on WEDM is similar to the EDM sinker process,
which uses the erosion effect produced by electric sparks. However, almost the same process, EDM
wire machining process variables with EDM sinking are not identical. In WEDM, the process of
scraping the workpiece is carried out by several electric sparks that occur between the workpiece gap

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24 Engineering Materials, Devices and Equipments

and the electrode wire. Electric sparks moving from the electrode wire to the workpiece will arise
periodically [2].
The marine device parts with very thick, challenging, and complex patterns have a lot to pay
attention to, such as the electrode material used and the level of roughness of the part surface. For
example, the marine construction material must be resistant to corrosion because corrosion will
reduce the material strength. In addition, the surface roughness level influences the fatigue strength
of the structure. Stainless steel is widely used in marine systems. AISI 316 is an austenitic stainless
steel with the addition of nickel and nitrogen. This type of stainless steel is suitable for use at low
temperatures due to the element nickel that makes this steel not brittle at that temperature. Austenitic
stainless steel has nonmagnetic properties and is resistant to low and high temperatures. It is also
strong, hard, shiny, resistant to oxidation, and has good manufacturability. Thus, the properties of this
material are very suitable for marine construction, such as ships, buildings, and other construction.
However, this type of steel has the disadvantage of being susceptible to corrosion of grain limits when
the process is high temperature, such as EDM Process and Welding. Grain boundary corrosion occurs
when the grain boundary area is affected by its deposits [3]. Weakening of grain boundaries is at the
temperature area (5000oC-9000oC), and at (6000oC-8000oC), precipitation values are highest [3].
Based on these considerations, the study of the effect of the parameters in wire EDM on the
formation of Cr23C6 compounds at the grain limit of AISI 316 material is conducted. In this study, the
electrode wire used is brass wire 0.2mm.

Literature Review
The WEDM process is a non-conventional machining process that converts the electrical energy
generated from the power supply into an electric spark that occurs between the electrode wire as an
anode and the workpiece as a cathode, then converts it into heat energy at temperatures of 8000oC to
10,000oC [1]. Electric current erodes the workpiece with a frequency that occurs in the range between
20,000 to 30,000 Hz so that the workpiece with electrode wire melts and evaporation occurs [1]. This
process will cause the air bubbles to continue to expand following the temperature changes that occur.
The melting and evaporation that occurs in the workpiece are much higher than the melting.
Evaporation occurs in electrodes. After an electric spark, the electricity flow from the power supply
will stop momentarily entering the off-time period (OFF). As a result of this, it will cause sudden
changes in temperature in the workpiece and electrodes. In addition, the gas bubbles that occur earlier
will explode and scatter out to leave smooth craters on the surface of the workpiece material [4]. The
dielectric fluid between the electrode wire and the workpiece serves to make the workpiece and the
melted electrode wire freeze quickly, and the dielectric fluid will rinse the result of the freezing. The
schematic process of wire EDM is shown in Fig. 1 and Fig. 2.
The process parameters determine the surface quality of the EDM wire machining. Research
researchers have previously researched using parameter parameters that affect the results of WEDM
work. Karsh and Singh compare surface roughness related to the free variables current, pulse on time,
and pulse off time [7]. The electrode wire used is a 0.25mm copper wire. The material used by Inconel
625. The study results obtained that the Surface Roughness value increases when there is an increase
in pulse on time value and decreases when there is an increase in pulse-off time value [1]. Shukla and
Yadav conducted a study to compare the value of Material Removal Rate (MRR) [8]. In this study,
Titanium Alloy (grade 5 6AL-4V) is the material used. Zinc coated with 0.25mm brass and kerosene
were used as wire and dielectric fluid, respectively. The free variables used are current, pulse-on time,
pulse-off time. The study results found that the value of Material Removal Rate (MRR) is directly
proportional to the increase in current and pulse on time value but inversely proportional to the rise
in pulse-off time value [8, 9].
 Key Engineering Materials Vol. 948 25

Fig. 1. Schematic diagram of wire EDM process [5]

Fig. 2. Schematic of cutting in wire EDM [6]

Ugrasen et al. compare Surface Roughness (SR), VMRR, and accuracy to HCHCr materials [10].
The electrode wire used is 0.18mm molybdenum wire. The free variables used are current, pulse on
time, pulse off time, bed speed. The study results obtained the factors that most influence the change
in surface roughness (SR), VMRR, and accuracy for HCHCr material, namely pulse on time [1, 10].
Kulkarni et al. compare Surface Roughness (SR) and Material Removal Rate (MRR). Nickel-
Titanium (NiTi) with a thickness of 2mm was analyzed [11]. The electrode wire used is a 0.25mm
brass wire. The free variables used are servo voltage, pulse on time, pulse off time. The study results
found that pulse on time and servo voltage are the most influential factors to get good Surface
Roughness results. Surface Roughness values increase when there is an increase in pulse on time
value and decrease when there is an increase in pulse off time and servo voltage values. The MRR
value is directly proportional to the rise in pulse value on time but inversely proportional to the
increase of the pulse value off-time. This yield shows that pulse on time and pulse off time are the
most influential factors for changes in MRR values [11]. Saini et al. compare Material Removal Rate
(MRR) [12]. The material used is Mild Steel. The electrode wire used is a 0.25mm molybdenum wire.
The free variable used is current, pulse on time, pulse off time, and wire feed and voltage. The study
results found that the change in MRR values is directly proportional to the increase in the pulse on-
time and current variables but is inversely proportional to the increase in pulse off time and voltage
values. The maximum value of MRR is optimum at pulse on time (115μs), pulse off time (50μs),
current (225A), voltage (70V) [12] .
Based on previous literature and research, pulse on-time parameters are the parameters that most
influence the results of the roughness of the wire EDM surface. Therefore, this study uses pulse on
time as a free variable with two other free variables: servo voltage and wire feed.
26 Engineering Materials, Devices and Equipments

Experimental Method
This research focuses on finding out the influence of the three parameters, namely pulse on time,
servo voltage, and wire feed, on the possibility of grain boundary corrosion. AISI 316 is analyzed; as
many as eight samples with a size of ø25mm x 19mm can be seen in Fig. 3. The material used was
stainless steel A316 food grade with a size of ø 25 mm x 19 mm for eight samples. The chemical
compositions of this material is 0.08 % C, 16-18% Cr, 0.1% Ni, 2-3 % Mo and 0.1%N (percentage
in weight). Varying variable in this research is the pulse on time (8μs and 12μs), servo voltage (20V
and 30V), and wire feed (5mm/ min and 9mm / min). The explanation of the varying variable is
explained in Table 1.

Fig. 3. Sample AISI 316

Table 1. Varying variable

No. Pulse on time Servo Voltage Wire Feed
(µs) (Volt) (mm/min)
1 8 20 5
2 12 20 5
3 8 30 5
4 12 30 5
5 8 20 9
6 12 20 9
7 8 30 9
8 12 30 9

Wire EDM Machine and Electrode

The wire electrodes used are brass wire with specifications, as shown in Table 2. The type of Wire
EDM Machine used in this research is wire EDM Fanuc Robocut α-C400iB Series is shown in Fig.
4.
Table 2. Brass wire Electrode Specifications
Properties Copper (99% pure)
Melting point (oC) 1130
Density (g/cm3) 7.20 – 8.86
Electrical resistivity (Ω-cm) 0.280
 Key Engineering Materials Vol. 948 27

Fig. 4. Wire EDM Machine

The fixed process parameters were pulse-off time, open voltage, wire tension, and dielectric fluids
of distilled water. The selected parameter set in this research is shown in Table 3.

Table 3. Fixed parameters of EDM

Open Voltage 1 (Volt)
Wire Tension 1300 (kgf)
Pulse off time 20 (µs)
Dielectric fluid Aqua destilata
Machine Type FANUC ROBOCUT seri α-CiB
Water flow 14 (kg/cm2)
Wire Electrode Brass wire

Each sample will be processed by the wire EDM machine and measured the surface roughness
level using a Surface Roughness Tester. Surface The smoothest surface roughness will be selected to
be tested Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) to see
changes in the composition of the material and the possibility of grain boundary corrosion.
Experiment schemes in this research were tested by Scanning Electron Microscope (SEM) to
analyze material microstructure. In contrast, Energy Dispersive Spectroscopy (EDS) was tested to
investigate the material's chemical composition before the wire EDM process and after the wire EDM
process. Fig. 5 shows a sample after the wire EDM process.

Fig. 5. Sample after wire EDM process

Results and Analysis

After the wire EDM process, the sample will be tested for surface roughness. The results of surface
roughness testing are shown in Table 4.
28 Engineering Materials, Devices and Equipments

Table 4. Result of surface roughness

No. Pulse on time Servo Voltage Wire Feed Roughness
(µs) (Volt) (mm/min) (µm)
1 8 20 5 2.179
2 12 20 5 2.322
3 8 30 5 1.771
4 12 30 5 1.826
5 8 20 9 2.436
6 12 20 9 2.476
7 8 30 9 2.354
8 12 30 9 2.526

Based on the surface roughness test results, a sample of 3 was selected for SEM and EDS testing
because it has the smoothest surface roughness level of 1.771 μm.
Fig. 6 shows the SEM image of the AISI316 before the EDM process. It shows that neither grain
boundary corrosion nor crack appears in this material. Figure 7 shows the EDS of the AISI316. Based
on the EDS result, the chemical composition of AISI316 is relatively the same as the catalog. Before
the EDM process, the chemical compositions on the surface are 0.60%Si, 15.13%Cr, 1.59%Mn,
9.28%Ni, and 1.55%Mo (percentage of weight).

Fig. 6. SEM image of A316 food-grade before Wire EDM process

Fig. 7. EDS of AISI316 food-grade before EDM process

 Key Engineering Materials Vol. 948 29

In the process of machining wire EDM, there will always be three layers, namely: recast layer,
HAZ, and base metal, as shown in Fig. 8. The recast layer is a layer that melts and then freezes back
to form a layer on the surface of the workpiece. While, the Heat Affected Zone is a layer of the parent
material that is affected by heat during the machining process. In this study, three layers: recast layer,
heat affected zone and base metal are formed as shown in Fig. 9.

Fig. 8. Schematic of recast layer, HAZ, base metal

Base Metal
Recast Layer HAZ Layer

Fig. 9. Structure after Wire EDM process

After EDM wire process, it will be seen the results of SEM and EDS tests on the recast and HAZ
sections to find out which parts are likely to occur corrosion of grain boundaries. Fig. 10 of SEM on
the recast layer and HAZ.
Based on Fig. 10, sample 3 with a variable pulse on-time variables 8 [μs], servo voltage 20 [V],
wire-feed 5 [mm/min] is visible that a significant number of pore pores are produced. There are also
holes (craters). In addition, there is a globule caused by the rest of the material that freezes rapidly
due to dielectric fluid. In addition, globule is caused by the current produced during the EDM wire
machining process. In the recast, the layer found a fault (microcracks). The flaw (microcrack) occurs
due to the fatigue voltage received by the workpiece [13]. Such defects can occur due to thermal
pressure caused by sudden cooling and non-uniform temperature distribution. SEM tests on this
material have not yet seen the formation of Cr23C6.
Fig. 11 shows the result EDS on the recast layer, and Fig. 12 shows EDS on HAZ.
30 Engineering Materials, Devices and Equipments

Recast Layer HAZ Layer

Micro crack

Crater

Pore
Globule

Fig. 10. SEM on recast layer and HAZ

Fig. 11. EDS on recast layer

Fig. 12. EDS on HAZ

 Key Engineering Materials Vol. 948 31

Fig. 11 is the result of energy dispersive spectroscopy (EDS) testing in the recast part of sample 3
with a variable pulse on-time 8 [μs], servo voltage 20 [V], wire feed 5 [mm/min]. In Fig. 11, the
energy dispersive spectroscopy (EDS) analysis results of chemical element composition are element
C 6.64%, element Cr 15.83%, element Fe 60.68%, element Ni 8.67%, element Cu 5.92%, and
component Mo 2.26%. Carbon (C) and Copper (Cu) are factors that add up in this recast layer.
Increasing carbon elements can increase hardness, but it can also form chrome carbide, so corrosion
resistance decreases. The addition of copper material because the rest of the brass wire electrodes,
which are a mixture of copper and zinc, melt and then freeze to attach to the recast layer of material.
The increase in the element Mo can increase the strength at high temperatures. Reduced elements Ni
and Cr can cause reduced corrosion resistance of the material and result in grain boundaries'
corrosion.
Fig. 12 is the result of energy dispersive spectroscopy (EDS) testing in HAZ layer of sample 3
with a variable pulse on-time 8 [μs], servo voltage 20 [V], wire-feed 5 [mm/min]. This EDS analysis
shows the chemical composition of HAZ layer 8.46 % C, element 2.18%O, element 20.08% Cr,
1.08% Mn, 47.72% Fe, 5.52 % Ni, 10.61 % Cu, 2.80% Zn, and 1.55% Mo. On the other hand, EDS
analysis of the chemical composition of based metal shows 17.87%Cr, 70.21% Fe, 9.79% Ni, and
2.13% Mo. Based on the comparison, C, Cr, Cu, and Zn significantly increase in this HAZ layer. The
additional elements Cu and Zn are caused by the remaining brass wire electrodes, which are a mixture
of Cu and Zn that melt and then freeze so that they still stick to the HAZ layer of the material. The
addition of element O to this HAZ division can cause corrosion, but the elemental content is still
relatively low, only 2.18%. Manganese (Mn) elements in the HAZ layer stabilize austenite at high
temperatures. On the other hand, the raised elements Cr and C are suggested considerably to allow
form Chromium Carbide (Cr23C6) in grain boundary corrosion in this HAZ section. The presence of
Cr23C6 indicated the corrosion process happening in this grain boundary. In this Research, Cr23C6
can not be directly seen because of several factors, such as the most influential variables. Pulse on
time only increases the duration of the length of electric sparks, not and when machining the material.
The workpiece is immediately cooled quickly / not slowly so that the material Cr does not have time
to settle in the recasting or HAZ to form Cr23C6 at the material grain limit AISI 316.

Conclusion
SEM results in specimen three are seen there are pore pores and also holes (crater). Based on the SEM
observation, globule caused by the rest of the material freezes rapidly due to dielectric fluid. In the
recast, the layer found a fault (microcracks). The results of EDS in the HAZ portion of the elements
that increase in this HAZ layer are Carbon (C), Copper (Cu), Oxygen(O), Zinc(Zn), and Manganese
(Mn). The presence of an increased C element can increase hardness, but it can also form chrome
carbide, so corrosion resistance decreases. The addition of element O to this HAZ division can cause
corrosion, but the elemental content is still relatively low, only 2.18%. In this layer, the elements Cr
and C increase significantly to allow the erosion of grain boundaries.

Acknowledgments
I would like to thank Pusat Penelitian dan Pengabdian Pada Masyarakat Politeknik Negeri Jakarta
(P3M PNJ), which supported and funded this research and PT. Sugimoto Presisi Teknologi place
machining wire EDM.
32 Engineering Materials, Devices and Equipments

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