Investigation of wire-EDM processing properties of different heat treatmented alsi10mg alloys manufactured by selective laser melting

This study investigates the machinability of AlSi10Mg alloy produced by Selective Laser Melting (SLM) using the Wire Electrical Discharge Machining (WEDM) process under three different conditions: as-built, heat-treated at 450 °C for 2 hours, and heat-treated at 550 °C for 2 hours. The aim of the study is to determine the effects of heat treatment on microstructure, material removal rate (MRR), and surface roughness (SR), and to identify the optimal WEDM process parameters using the Response Surface Methodology (RSM). The results revealed that heat treatment significantly improved the machinability of the AlSi10Mg material. The average MRR and SR values of the as-built samples were measured as 2.02 mm³/min and 3.26 µm, respectively. After heat treatment at 450 °C, the MRR increased by approximately 10% to 2.24 mm3/min, while SR decreased by 9% to 2.95 µm. The highest performance was achieved at 550 °C, where MRR reached 2.33 mm³/min and SR decreased to 2.70 µm, corresponding to an 11% increase and a 14% reduction compared to the as-built condition. The optimal process parameters obtained through RSM analysis were Ton = 117.5 µs, Toff = 56.5 µs, and WF = 5.5 m/s. The redistribution of Si particles and the densification of the Mg₂Si phase resulting from heat treatment enhanced the electrical conductivity and created a more stable material removal process in the discharge zone. The order of influence of the parameters (Ton>WF>Toff) remained constant under all conditions, indicating that heat treatment improved the material's response to discharge energy without altering the inherently energy-controlled nature of the WEDM process. The findings demonstrate that heat-treated AlSi10Mg alloys can be machined with higher productivity and superior surface quality using the WEDM method. These results contribute to energy-efficient and environmentally sustainable manufacturing approaches. Consequently, this study highlights the potential of SLM-based AlSi10Mg alloys for high-performance applications in aerospace, automotive, and defense industries where dimensional precision and surface integrity are critical.