Investigation of Al-Ti Nano Graphene Hybrid Approach in Power Mixed EDM: Advancing Electrical Conductivity, Stability, and Material Removal with Ceramic Integration

Authors

  • Hassan Karim Mohammed School of Mechanical Engineering, University Sains Malaysia, Malaysia.
  • Jamaluddin Abdullah School of Mechanical Engineering, University Sains Malaysia, Malaysia.
  • Muhammad Hafiz Bin Hassan School of Mechanical Engineering, University Sains Malaysia, Malaysia
  • Salah S. Abed AlKareem Department of Automated Manufacturing Engineering, Al-Khwarizmi College of Engineering, University of Baghdad, Iraq

DOI:

https://doi.org/10.63278/mme.v31i1.1232

Keywords:

Hybrid Al-Ti Nano Graphene, Power Mixed EDM, Ceramic Integration, Electrical Conductivity.

Abstract

The composite Al-Ti nano graphene alloy is efficient for industrial applications. Few research created nano graphene-aluminum composites. This research uses electrical arc machining to examine the effects of Al-Ti nano graphene composites on hardness, removal rate, roughness, resistance, and microstructure. The MIKROTOOLS DT- 110, with micromachining and high accuracy, was used for this work. Olympus SZX-12, Zeiss Supra 35 VP scanning electron microscope, and Energy Dispersive Spectroscopy were utilized to evaluate novel Al-Ti nano composites. Micro EDM, powder mixed micro-EDM, and die-sinker EDM were the major experimental methods. This study found steady improvement in corrected electrical conductivity, optimized machinery efficiency, Kojima and Pandey plasma channel radius approximations, and maximum heat flux approximations for the formulated new aluminum composites. The present study found successful machining with low material removal rate; cardon deposition controlled machining outputs (surface cracks and porosity); hybrid process achieved successful machining and removal rate; and high performance properties for the developed composites compared to conventional types. This research found the hybrid Al-Ti nano graphene method important for electric conductivity, stability, and material removal. This is the first research to examine power mixed EDM's advantages from ceramics with optimum performance.

References

Alam, M. N., Siddiquee, A. N., Khan, Z. A., & Khan, N. Z. (2022). A comprehensive review on wire EDM performance evaluation. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 236(4), 1724-1746.

Blanco, D., Rubio, E. M., Lorente-Pedreille, R. M., & Saenz-Nuno, M. A. (2021). Sustainable processes in aluminium, magnesium, and titanium alloys applied to the transport sector: a review. Metals, 12(1), 9.

Chen, X. Wang, Z. Xu, J. Wang, Y. Li, J. and Liu, H. (2018). Sustainable production of micro gears combining micro reciprocated wire electrical discharge machining and precision forging, J. Clean. Prod., vol. 188, pp. 1–11, Jul. 2018, doi: 10.1016/j.jclepro.2018.03.200.

Dhir, R. K. Ghataora, G. S. and Lynn, C. J. (2017). 6 - Ceramic Applications, in Sustainable Construction Materials, R. K. Dhir, G. S. Ghataora, and C. J. Lynn, Eds. Woodhead Publishing, 2017, pp. 159–183.

Farooqui M. N. and Patil, N. G. (2018). A perspective on shaping of advanced ceramics by electro discharge machining, Procedia Manuf., vol. 20, pp. 65–72, Jan. 2018, doi: 10.1016/j.promfg.2018.02.009.

Gupta K., and N. K. Jain, (2014). Analysis and optimization of micro-geometry of miniature spur gears manufactured by wire electric discharge machining, Precis. Eng., vol. 38, no. 4, pp. 728–737, Oct. 2014, doi: 10.1016/j.precisioneng.2014.03.009.

Ho, K. H., Newman, S. T., Rahimifard, S., & Allen, R. D. (2004). State of the art in wire electrical discharge machining (WEDM). International Journal of Machine Tools and Manufacture, 44(12-13), 1247-1259.

Joshi S. N. and Pande, S. S. (2010). Thermo-physical modeling of die-sinking EDM process, J. Manuf. Process., vol. 12, no. 1, pp. 45–56, Jan. 2010, doi: 10.1016/j.jmapro.2010.02.001.

Joshi, S. N., & Pande, S. S. (2009). Development of an intelligent process model for EDM. The International Journal of Advanced Manufacturing Technology, 45, 300-317.

Kumar C. S. and Patel, S. K. (2018). Effect of WEDM surface texturing on Al2O3/TiCN composite ceramic tools in dry cutting of hardened steel, Ceram. Int., vol. 44, no. 2, pp. 2510–2523, Feb. 2018, doi: 10.1016/j.ceramint.2017.10.236.

Mohri, N. Fukuzawa, Y. Tani, T. Saito, N. and Furutani, K. (1996). Assisting Electrode Method for Machining Insulating Ceramics, CIRP Ann., vol. 45, no. 1, pp. 201–204, 1996, doi: 10.1016/S0007-8506(07)63047-9.

Rajeevalochanam P. and Ganesh Banda B. V., (2017). Mechanical Design and Analysis of Ceramic Stator Blades for Gas Turbine Stage, Mater. Today Proc., vol. 4, no. 8, pp. 8613–8623, 2017, doi: 10.1016/j.matpr.2017.07.209.

Sandu, A. V., Achitei, D. C., Perju, M. C., & Burduhos-Nergis, D. D. (2024). Perspective Chapter: Titanium–A Versatile Metal in Modern Applications. Titanium- Based Alloys-Characteristics and Applications: Characteristics and Applications, 3.

Thoe, T. B. Aspinwall, D. K. and Killey, N. (1999). Combined ultrasonic and electrical discharge machining of ceramic coated nickel alloy, J. Mater. Process. Technol., vol. 92–93, pp. 323–328, Aug. 1999, doi: 10.1016/S0924-0136(99)00117-X

Uhlmann E. and D. C. Domingos, (2016). Investigations on Vibration-assisted EDM- machining of Seal Slots in High-Temperature Resistant Materials for Turbine Components –Part II, Procedia CIRP, vol. 42, pp. 334–339, Jan. 2016, doi: 10.1016/j.procir.2016.02.179.

Uhlmann E. and Domingos, D. C., (2013). Investigations on Vibration-Assisted EDM- Machining of Seal Slots in High-Temperature Resistant Materials for Turbine Components, Procedia CIRP, vol. 6, pp. 71–76, Jan. 2013, doi: 10.1016/j.procir.2013.03.019.

Xing, Y. Liu, L. Wu, Z. Wang, X. Huang, P. and Tang, L. (2018). Fabrication and characterization of micro-channels on Al2O3/TiC ceramic produced by nanosecond laser, Ceram. Int., vol. 44, no. 18, pp. 23035–23044, Dec. 2018, doi: 10.1016/j.ceramint.2018.09.106.

Zheng, Y., Zhang, K., Liu, T. T., W. H. Liao, C. D. Zhang, and H. Shao, (2019). Cracks of alumina ceramics by selective laser melting, Ceram. Int., vol. 45, no. 1, pp. 175– 184, Jan. 2019, doi: 10.1016/j.ceramint.2018.09.149.

Downloads

How to Cite

Hassan Karim Mohammed, Jamaluddin Abdullah, Muhammad Hafiz Bin Hassan, and Salah S. Abed AlKareem. 2025. “Investigation of Al-Ti Nano Graphene Hybrid Approach in Power Mixed EDM: Advancing Electrical Conductivity, Stability, and Material Removal With Ceramic Integration”. Metallurgical and Materials Engineering 31 (1):161-76. https://doi.org/10.63278/mme.v31i1.1232.

Issue

Vol. 31 No. 1 (2025)

Section

Research

License

Copyright (c) 2025 Hassan Karim Mohammed, Jamaluddin Abdullah, Muhammad Hafiz Bin Hassan, Salah S. Abed AlKareem

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

Authors who publish with this journal agree to the following terms:

  • Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgment of the work's authorship and initial publication in this journal.
  • Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgment of its initial publication in this journal.
  • Authors are permitted and encouraged to post their published articles online (e.g., in institutional repositories or on their website, social networks like ResearchGate or Academia), as it can lead to productive exchanges, as well as earlier and greater citation of published work (See The Effect of Open Access).

 

Creative Commons License
Except where otherwise noted, the content on this site is licensed under a Creative Commons Attribution 4.0 International License.