Microstructural Analysis of Recast Layer Thickness and Microcrack Formation During EDM of Hastelloy C-22 with Different Graphite Electrodes.
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| Title: | Microstructural Analysis of Recast Layer Thickness and Microcrack Formation During EDM of Hastelloy C-22 with Different Graphite Electrodes. |
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| Authors: | Nowicki, Rafał1 (AUTHOR) rafal.nowicki1@pw.edu.pl, Świercz, Rafał1 (AUTHOR) |
| Source: | Materials (1996-1944). Dec2025, Vol. 18 Issue 23, p5338. 18p. |
| Subjects: | Microcracks, Metallography, Electric metal-cutting, Nickel alloys, Carbon electrodes, Machining, Surface properties |
| Abstract: | Electrical discharge machining is a non-conventional shaping technique applied to electrically conductive, difficult-to-machine alloys, such as Hastelloy C-22. This study investigates the influence of graphite electrode properties and key machining parameters on the average thickness of the recast layer under positive polarity. Two POCO graphite electrodes with different grain sizes—AF-5 (1 μm) and S-180 (10 μm)—were used to examine the effects of discharge current, pulse duration, and interval on recast layer formation. Metallographic analyses measured layer thickness and observed microstructural defects, including microcracks. Results show that discharge current and pulse duration are the primary factors controlling recast layer thickness, with higher currents and longer pulses producing thicker layers due to resolidification of molten material remaining in the plasma-formed crater. The coarser S-180 electrode caused slightly higher microcrack density and greater thickness variations due to its lower electrical resistivity. Pulse interval mainly influenced discharge stability and debris removal, with minimal effect on average layer thickness. Statistical regression models were developed to quantify the relationships between machining parameters, electrode type, and recast layer thickness, providing predictive tools for selecting optimal conditions. These findings contribute to improving surface integrity and process control in electrical discharge machining of nickel-based alloys. [ABSTRACT FROM AUTHOR] |
| Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
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| Header | DbId: egs DbLabel: Engineering Source An: 190517487 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Microstructural Analysis of Recast Layer Thickness and Microcrack Formation During EDM of Hastelloy C-22 with Different Graphite Electrodes. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Nowicki%2C+Rafał%22">Nowicki, Rafał</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> rafal.nowicki1@pw.edu.pl</i><br /><searchLink fieldCode="AR" term="%22Świercz%2C+Rafał%22">Świercz, Rafał</searchLink><relatesTo>1</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Dec2025, Vol. 18 Issue 23, p5338. 18p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Microcracks%22">Microcracks</searchLink><br /><searchLink fieldCode="DE" term="%22Metallography%22">Metallography</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+metal-cutting%22">Electric metal-cutting</searchLink><br /><searchLink fieldCode="DE" term="%22Nickel+alloys%22">Nickel alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Carbon+electrodes%22">Carbon electrodes</searchLink><br /><searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+properties%22">Surface properties</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Electrical discharge machining is a non-conventional shaping technique applied to electrically conductive, difficult-to-machine alloys, such as Hastelloy C-22. This study investigates the influence of graphite electrode properties and key machining parameters on the average thickness of the recast layer under positive polarity. Two POCO graphite electrodes with different grain sizes—AF-5 (1 μm) and S-180 (10 μm)—were used to examine the effects of discharge current, pulse duration, and interval on recast layer formation. Metallographic analyses measured layer thickness and observed microstructural defects, including microcracks. Results show that discharge current and pulse duration are the primary factors controlling recast layer thickness, with higher currents and longer pulses producing thicker layers due to resolidification of molten material remaining in the plasma-formed crater. The coarser S-180 electrode caused slightly higher microcrack density and greater thickness variations due to its lower electrical resistivity. Pulse interval mainly influenced discharge stability and debris removal, with minimal effect on average layer thickness. Statistical regression models were developed to quantify the relationships between machining parameters, electrode type, and recast layer thickness, providing predictive tools for selecting optimal conditions. These findings contribute to improving surface integrity and process control in electrical discharge machining of nickel-based alloys. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.3390/ma18235338 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 18 StartPage: 5338 Subjects: – SubjectFull: Microcracks Type: general – SubjectFull: Metallography Type: general – SubjectFull: Electric metal-cutting Type: general – SubjectFull: Nickel alloys Type: general – SubjectFull: Carbon electrodes Type: general – SubjectFull: Machining Type: general – SubjectFull: Surface properties Type: general Titles: – TitleFull: Microstructural Analysis of Recast Layer Thickness and Microcrack Formation During EDM of Hastelloy C-22 with Different Graphite Electrodes. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Nowicki, Rafał – PersonEntity: Name: NameFull: Świercz, Rafał IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 12 Text: Dec2025 Type: published Y: 2025 Identifiers: – Type: issn-print Value: 19961944 Numbering: – Type: volume Value: 18 – Type: issue Value: 23 Titles: – TitleFull: Materials (1996-1944) Type: main |
| ResultId | 1 |
