Electrical Discharge Machining Process Research Articles

Growth of α-Al2O3 layer involving abnormal oxides in FeCrAl alloy tube fabricated by WEDM process and electrical insulating performance in fusion reactor blanket

The tubular specimens of FeCrAl alloy APMT (Fe-22Cr-5Al-3Mo) were fabricated by a wire electrical discharge machining (WEDM) process. The oxidation characteristics of the machined surface were investigated by means of the oxidation tests performed in air atmosphere at the temperatures of 1273 K and 1373 K up to 100 h. The abnormal oxides such as CuAl2O4 and ZnAl2O4 were grew on the recast layer which was locally remained on the machined surface even after the mechanical polishing procedure. The α-Al2O3 layer involving the abnormal oxides was formed on the machined surface in the oxidation treatment at 1273 K for 10 h. The apparent electrical conductivity of the layer involving the abnormal oxides was larger than that without the abnormal oxides. Thick Al-rich oxide layer was formed under the abnormal oxides when the oxidation treatment was performed at 1373 K. The apparent electrical conductivity of the oxide layer became lower due to the presence of the thick Al-rich oxide. This oxide layer formed at 1373 K could function as an electrical insulating layer to reduce the magnetohydrodynamic pressure drop in liquid breeder blanket systems of magnetic confinement fusion reactors.

Surface characteristics and machining rate of SS 316L coating developed using hydroxyapatite-mixed EDM process

Hydroxyapatite (HA) or bioceramic-based coatings on stainless steel (SS) 316L significantly enhance the biofunctionality of the base material's surface. However, HA's low thermal conductivity and brittleness limit its effectiveness as a coating material. This study investigates HA coating on SS 316L using electric discharge machining (EDM) with varying discharge energies and powder concentrations. Surface morphology, elemental composition, and phase analysis of untreated and coated samples were characterised using field emission scanning electron microscopy (FESEM), energy dispersive X-ray (EDX), and X-ray diffraction (XRD). The results demonstrate that the HA-assisted EDM process creates a coating comprising biocompatible oxides, phosphates, carbides, and intermetallic compounds. The coating exhibits a thin resolidified layer of 10.74 μm, characterised by redeposited spherical debris, shallow cavities, and a surface texture of 2.688 μm. The layer's hydrophilic nature is confirmed by a minimum contact angle of 47.68°. Taguchi analysis indicates that the machining rate is optimised at an HA powder concentration of 16 g/l, with peak current and HA powder concentration being the most influential parameters affecting resolidified layer thickness, surface texture, and wetting angle. The research intends to motivate SS 316L medical device manufacturers to implement the HA-assisted EDM process for bioimplant's dual machining and coating.

A REVIEW OF THE RECENT RESEARCH ACTIVITIES IN THE FILD OF ELECTRICAL DISCHARGE MACHINING

Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes being considered one of the most popular machining methods today. The EDM process basis on thermoelectric energy between the workpiece and an electrode, so that the discharge energy generated during the operation characterizes the productivity of the process. Due to the well-established machining options utilized in the industry of aerospace, automotive industry and surgical components for precision machining and making complex geometrical shapes in hard-to-cut materials, a significant amount of research interests has been created in this field. This paper provides a review of numerous academic research activities carried out in the previous years, as well as numerous developments in the field of EDM related to increased machining rates, improved performance, materials and dielectrics used, electrode design and manufacture.

Fabrication of microneedles using wire electric discharge machining and improving surface quality by electrochemical polishing

Microneedle (MN) arrays have many applications in biomedical engineering to deliver drugs transdermally or extract biomarkers from the interstitial fluid from the human skin. Several methods have been developed to fabricate different sizes and shapes of MN using polymers, ceramics and metals. However, most of these methods require expensive sophisticated machines and clean room facilities. So, it is difficult to fabricate microneedle arrays in large quantities at a reasonable cost. This study reports the fabrication of a high-quality stainless steel master pattern for an MN array using a wire-cut electric discharge machining process followed by electrochemical polishing (ECP). Different densities of a 5 × 5 array of microneedles with pyramidal shapes were fabricated by machining channels onto the workpiece surface in a criss-cross pattern. A systematic experimental study was carried out with reference to the offset between the two consecutive channel faces and the depth of channels. The output parameters are MN height (MNH), MN base (MNBW) and tip width (MNTW). The average needle tip width, base width, and height of microneedles were found to be 55.3 ± 5 µm, 679.8 ± 10 µm, and 914.7 ± 19 µm. Finally, the sharpness of the MN tips and the overall surface finish of the MN array were improved with ECP. The reductions in MNH, MNBW, and MNTW were reported to be −18.3%, −9.7%, and −95.4%, respectively, with a final tip width of 2.55 ± 1.62 µm. The MNs’ tip angle was reported to be 32.52° ± 1.56.

SURFACE MORPHOLOGY OF SILICON NITRIDE (Si3N4)-TITANIUM NITRIDE (TiN) COMPOSITES USING GRA-RSM STRATEGY ENCOMPASSED WITH EDMed PARAMETERS

This investigation explores the application of electrical discharge machining (EDM) to ceramic composites constructed from Si3N4–TiN (Syalon 501) by testing both square and cylindrical electrodes. Various experimental methods have been employed, including design-of-experiments (DoE), Grey relational analysis (GRA), analysis of variance (ANOVA), confirmation testing, and scanning electron microscopy (SEM), in an effort to optimize machining settings and comprehend their effect on performance. While ANOVA revealed crucial parameter levels influencing overall machining conditions as measured by the grey relational grade (GRG), the sophisticated method of GRA considerably improved the machining characteristics. Significant improvements in the EDM process were shown experimentally, resulting in outstanding results for material removal rate (MRR), surface roughness (SR), and electrode wear rate (EWR). In particular, numerous benefits of the square electrode layout over the more common cylindrical arrangement stood out. All of the aforementioned resulted in an impressively high MRR (measured at 0.0281[Formula: see text]gm/min), a low EWR (at 0.0020[Formula: see text]gm/min), and a significant improvement in SR (at 0.3150[Formula: see text][Formula: see text]m). The GRG value was 0.0163 for the square electrode design, which was excellent, and 0.0025 for the cylindrical electrode, which was significantly better. The optimized parameters were successfully used, especially with the square electrode arrangement, leading to significant improvements in MRR and decreases in EWR. On the other hand, surface quality was negatively affected by larger parameter values, which increased the development of microfractures, particularly when using the square electrode design. In any case, our study provides strong proof that adjusted settings can greatly improve EDM performance, allowing for accurate machining of Si3N4–TiN composites with increased MRR, great surface texture, and reduced electrode wear. In conclusion, our study provides useful information to improve EDM procedures for Si3N4–TiN ceramic composites, as well as practical insights into increasing the efficiency and quality of EDM operations in a variety of industrial sectors.

Development of optimum performance model during spark-eroded processing of rheocasted Al6061/Cenosphere MMCs

ABSTRACT In the present study, an improved wettability casting route was used to prepare lightweight structural materials. Using the compo casting process, an Al6061 alloy was created with cenosphere particles at various weight percentages (2, 4, 6, and 8 wt%). The molten aluminium slurry incorporated hollow alumina silicate particulates. X-ray diffraction (XRD) analysis of the aluminium matrix composites (AMCs) confirmed the presence of cenospheres without any intermetallic components. Further processing of the metal matrix composites (MMCs) was conducted using electric discharge machining (EDM) with a circular copper electrode. The EDM process parameters were controlled to measure response variables such as material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The effects of different combinations of machining parameters – including pulse current, pulse-on time, reinforcement percentage, and flushing pressure – on these performance characteristics were observed. Experimental trials were designed using the face-centred central composite design (CCD) of the response surface methodology (RSM). Optimal process variable conditions led to significant improvements in surface finish. Additionally, an artificial neural network (ANN) model was used to determine the best conditions for EDM processing. The ANN model demonstrated a strong correlation coefficient of 0.99 between the predicted and experimental values of MRR, TWR, and SR.

Machinability investigation and surface modification of nano-TiB2 and AlN grafted MWCNT hybridized Al 7075 matrix ternary composite through powder-mixed EDM

This paper accentuates powder-mixed electrical discharge machining (EDM) performance of a newly designed nano-TiB2 and AlN grafted multiwall carbon nano-tube (MWCNT) hybridized Al 7075 matrix ternary composite. The hybrid metal matrix composite (MMC) was fabricated through squeeze casting route, preceded by two-stage reinforcement addition, mechanical agitation, and ultrasonic treatment. EDM was carried out using cryogenic treated Cu electrode and Al2O3 particle-mixed dielectric medium. Influence of EDM process variables, that is, peak current ( I P), pulse-on time ( T ON), and powder concentration ( P C) on machinability of the hybrid MMC was studied considering material removal rate (MRR), tool wear rate (TWR), and average surface roughness ( Ra) as quality indicators. Effects of machining and Al2O3 particle addition on surface morphology of the hybrid MMC were also explored through scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), and elemental mapping. Results reveal elevation of MRR, reduction of TWR and improvement of surface finish during powder-mixed EDM in comparison to the non-mixed (conventional) EDM. Maximum traces of Al2O3 particle deposition was identified on the machined surfaces while using the powder concentration of 1.5 g/l within the dielectric.

Experimental investigations and process optimization of SKD61 for sinking EDM

ABSTRACT Electrical parameters are vital for electrical discharge machining (EDM) process performance. The study utilized the combination of Taguchi and grey relational analysis (GRA) to optimize sinking EDM. Optimization of peak current, pulse duration, duty ratio and electrode lifting time affecting material removal rate (MRR), relative electrode wear rate (REWR) and surface roughness (SR) in sinking EDM. Analysis of variance (ANOVA) shows that peak current and pulse duration significantly affect MRR and REWR, respectively. Peak current and pulse duration significantly affect SR. The optimized parameters were subjected to EDM experiments and the results are 8.54% increase in MRR, 11.11% decrease in REWR and 9.42% decrease in SR. It was found that at a peak current of 1A, the discharge pit not only depends on peak current and pulse duration but also on pulse off time. Compared to conventional optimization methods, this study analyzed the microstructure and recast layer of the workpieces.

Experimental Investigation on Wire Electric Erosion Behaviour of Silicon Dioxide Particulate Reinforced Composite

The intend of current study was focused on the prediction of material removal rate (MRR) and surface roughness (SR) for the AA7050-SiO2 composite during wire electric erosion or discharge machining (WEDM) process using a brass (Br) wire electrode. Here, stir casting process was employed to develop the AA7050 matrix composite with inclusion of 10wt.% SiO2 particle reinforcement. The multi-objective optimization method of Technique for order preference by similarity to ideal solution (TOPSIS) approach has been applied to find out the optimal setting of input machining parameters such as peak current (Ip), pulse-on time (Ton) and pulse-off time (Toff). Furthermore, the significant effects of parameters were identified by analysis of variance (ANOVA). Taguchi L9 (33) orthogonal design has been formulated to perform the experimental work. TOP SIS results stated that the optimal setting of Ip at 30 amps, Ton of 130 μs and Toff of 55 μs provide the better MRR with lesser SR. The ANOVA results noticed that Ip has the prime noteworthy parameter over the adopted responses having a contribution of 45.67%, followed by Ton (32.34%) and Toff (12.26%), respectively. The confirmation test was carried out by the optimal parameters setting to verify the predicted results. Finally, the scanning electron microscopy (SEM) test was carried out for the machined surface of the composite specimen and it was reveals that the formation of craters and recast layer thickness in the machined surfaces.

Parametric investigation of wire-EDM parameters for micro channel as a foundation of high-quality micro needle array fabrication

Micro channels are widely used in microfluidics, and medical science for the extraction of DNA, electrophoresis, and blood protein analysis. In the current work, the wire electrical discharge machining (WEDM) process was used to fabricate micro channels on the stainless steel 316 (SS316) substrate. To check the feasibility of fabricating high-quality micro channels and thereafter micro-scale structures with the WEDM process the effect of different process parameters such as pulse-off time, pulse-on time, servo gap reference voltage and wire feed rate were investigated. The quality attributes taken were namely surface roughness of the channel base, overcut, micro channel depth, and material removal rate (MRR). The pulse-on time significantly affects surface roughness and MRR. The servo gap reference voltage is the key process parameter affecting the overcut and micro channel depth. It was observed from the parametric study that 15 µs pulse-on time, 35 µs pulse-off time, 17 v servo gap reference voltage, and 8 m/min wire feed rate are the optimum levels for getting high MRR, low surface roughness, less overcut and high micro channel depth. Additionally, the topographical, morphological, surface, and sub-surface characterization were also carried out to assess the surface integrity and extent of thermal damage caused by the WEDM process. With the optimum combination of process parameters a 6 × 6 micro needle array was successfully fabricated on the same substrate using micro channels as a basis of the fabrication process for the first time using the WEDM process.

Multi Responses Optimization of Wire Electrical Discharge Machining (WEDM) Parameters of Tool Steel Using Grey Relation Analysis

The aim of this work is to study the effects of several wire electrical discharge machining (WEDM) process parameters, such as the servo voltage (SV), the pulse on time (TON), and the pulse off time (TOFF) on the surface finish (SR) and the kerf width (KW) of stainless steel 304 as a workpiece material. A multi-responses optimization approach based on Grey relational analysis has been designed, and it was discovered that the main affecting factor is the pulse on time followed by the servo voltage. According to the data, the grey relation analysis (GRA) grade for the second trial, including (a servo voltage of 14V, a pulse on time of 100µs, and a pulse off time of 45µs), was the optimum combination of settings that may concurrently optimize all of the specified response qualities. By utilizing the regression analysis, the mathematical equations illustrating the link between the input parameters and the responses have been established. In particular, the findings of this article will assist manufacturing engineers in selecting an optimal set of process parameters for machining stainless steel (SS304) grade.

Wire-cut electrical discharge machining of duplex stainless steel: a study

ABSTRACT In this study, the duplex stainless steel is machined using a wire-cut electrical discharge machining process to overcome the issues of poor finishing, lower dimensional accuracy, and rapid wear of cutting tools in conventional machining processes. The higher rate of material removal and superior finish on the machine surface is dependent on kerf loss, which is expressed as the mean kerf width assessed at certain locations. Nevertheless, this approach is typically not effective in explicating the intricacies of true kerf loss due to the random selection of distinctive points. This work proposes an area-based measuring approach to quantify the kerf loss by taking into account any imperfections on the kerf wall. At the pulse on time of 20 μs and current of 3 A, the machining appears not stable. The pulse on time, current, and voltage of 12 µs, 1 A, and 80 V proved suitable for obtaining excellent dimensional precision.

Performance evaluation in die-sinking EDM of polygonal micro cavities over EN-24 alloy steel using cylindrical electrode and polygon cycle approach

The integration of advanced Electrical Discharge Machining (EDM) technology, incorporating short and electronically pulsed discharges with precise circular electrode movements, has enabled the production of intricate 3D microstructures and cavities. This paper aims to investigate the machining performance of polygonal cavities—triangular, square, pentagon, and hexagon—fabricated on steel samples using a 400 µm cylindrical copper electrode within the polygon cycle approach of EDM. Experimental investigations were conducted to assess shape error, tool wear rate, recast layer formation, and elemental characterization. Various discharge patterns and side discharges were examined to understand their effects on spark gap uniformity, tool deflection, and discharge stability. The results revealed non-uniform spark gaps, tool deflection, and corner rounding due to varying discharge patterns and side discharges. Tool wear rate was found to be directly related to polygon complexity, with higher-order polygons leading to increased wear due to extended machining durations and heat accumulation. The maximum tool wear of 7.69 × 104 µm3/s occurred in case of hexagonal cavities while in case of triangular cavities, the tool wear rate was minimum having value of 5.77 × 104 µm3/s. Scanning Electron Microscopy (SEM) examinations showed the presence of recast layers and micro-cracks, particularly in cavities with higher shape complexities. Energy Dispersive X-ray Spectroscopy (EDS) analysis identified copper deposition, local material evaporation, and foreign element accumulation on the cavity surfaces. This study provides insights into the machining performance of polygonal cavities in EDM processes. The findings underscore the influence of discharge patterns, polygon complexity, and material interactions on tool wear, surface quality, and microstructure integrity. Understanding these factors can inform optimization strategies for EDM processes, leading to enhanced precision and efficiency in microstructure fabrication.

Enhancing cutting tool durability: Exploration of Al2O3-SiCw-graphene composites fabricated by SPS for improved mechanical and scratch resistance

This study focuses on the fabrication and characterisation of Al2O3-SiCw-rGO composites sintered by spark plasma sintering (SPS) technique. The research is mainly focused on understanding the impact of varying graphene content (0.5, 1.0 and 1.5 vol %) on nanomechanical properties and scratch resistance. Among the compositions investigated, the composite containing 0.5 vol% graphene showed superior mechanical properties. Specifically, it exhibited a hardness of ∼30 GPa, a fracture toughness of 10.5 MPa m1/2 and a flexural strength of ∼920 MPa. In addition, this composite showed remarkable scratch resistance compared to composites with a higher or lower graphene content. In addition to mechanical properties, the fabricated composites also exhibited high electrical conductivity. This characteristic is especially advantageous for electrical discharge machining (EDM) processes. The high electrical conductivity enables efficient machining of complex shapes by EDM, thereby reducing machining costs while ensuring accuracy and efficiency.

PERFORMANCE EVALUATION AND ECONOMIC ASSESSMENT IN ELECTRICAL DISCHARGE MACHINING OF SS316 USING GRAPHITE POWDER DISPERSED IN BIODEGRADABLE PALM OIL DIELECTRIC

In today’s rapidly evolving manufacturing industry, researchers and engineers are constantly seeking innovative methods to improve machining processes. One such area of interest is the use of electrical discharge machining (EDM) for difficult-to-machine metals like SS316. This research compares the performance and economic aspects of traditional EDM and powder-mixed EDM when machining SS316 using copper electrode. Graphite powder dispersed in biodegradable palm oil is investigated as a dielectric media with the aim of enhancing EDM performance. According to the findings, the analysis of the cutting performance of different machinability aspects revealed that using graphite powder mixed with palm oil as a dielectric in EDM outperformed conventional EDM relating to material removal, surface finish, surface hardness, electrode wear rate and hole overcut. The flushing condition and unique properties of graphite powder and palm oil, such as cooling, and thermal conductivity, contributed to the improved performance observed in EDM processes. These findings highlight the potential of graphite powder mixed with palm oil as a promising alternative dielectric in EDM, offering enhanced machining capabilities and improved surface quality. The total machining expenditure per part under PMEDM (INR 505.50) is lowered by 9.2% than expenditure under conventional EDM (INR 525). The surface microhardness of the machined component attained using graphite powder-mixed EDM is enhanced in comparison to that achieved using standard EDM due to the creation of a carbon-rich re-solidified layer.

Experimental Investigation on the Impact of Graphite Electrodes Grain Size on Technological Parameters and Surface Texture of Hastelloy C-22 after Electrical Discharge Machining with Negative Polarity.

Electrical discharge machining (EDM) is a rapidly evolving method in modern industry that manufactures highly complex components. The physical properties of a tool electrode material are significant factors in determining the effectiveness of the process, as well as the characteristics of the machined surfaces. The current trend of implementing graphite tool electrodes in manufacturing processes is observed. Innovative material engineering solutions enable graphite production with miniaturized grain size. However, the correlation between the graphite electrode grain size and the mechanism of the process removal in the EDM is a challenge for its widespread implementation in the industry. This research introduces a new method to evaluate the impact of the graphite electrode grain size and machining parameters on the material removal effectiveness, relative tool wear rate, and surface roughness (Ra) of Hastelloy C-22 following EDM with negative polarity. The study utilized new graphite materials with a grain size of 1 µm (POCO AF-5) and 10 µm (POCO EDM-180). An assessment of the impact of the EDM process parameters on the technological parameters and the development of the surface roughness was carried out. Electrical discharge machining with fine-grained graphite electrodes increases process efficiency and reduces tool wear. Graphite grains detached from the tool electrode affect the stability of electrical discharges and the efficiency of the process. Based on the experimental results, mathematical models were developed, enabling the prediction of machining effects to advance state-of-the-art manufacturing processes. The obtained mathematical models can be implemented in modern industrial EDM machines as guidelines for selecting adequate machining parameters depending on the desired process efficiency, tool wear rate, and surface roughness for advanced materials.

A comprehensive review of parametric optimization of electrical discharge machining processes using multi-criteria decision-making techniques

Optimization of electrical discharge machining (EDM) processes is a critical issue due to complex material removal mechanism, presence of multiple input parameters and responses (outputs) and interactions among them and varying interest of different stakeholders with respect to relative importance assigned to the considered responses. Multi-criteria decision making (MCDM) techniques have become potent tools in solving parametric optimization problems of the EDM processes. In this paper, more than 130 research articles from SCOPUS database published during 2013–22 are reviewed extracting information with respect to experimental design plans employed, materials machined, dielectrics used, process parameters and responses considered and MCDM tools applied along with their integration with other mathematical techniques. A detailed analysis of those reviewed articles reveals that the past researchers have mostly preferred Taguchi’s L9 orthogonal array as the experimental design plan; EDM oil as the dielectric fluid; medium and high carbon steels as the work materials; peak current and pulse-on time as the input parameters; material removal rate, tool wear rate and surface roughness as the responses; and grey relational analysis as the MCDM tool during conducting and optimizing EDM operations. This review paper would act as a data repository to the future researchers in understanding the stochastic behaviour of EDM processes and providing guidance in setting the tentative operating levels of varying input parameters along with achievable response values. The extracted dataset can be treated as an input to any of the machine learning algorithms for subsequent development of appropriate prediction models. This review also outlines potential future research avenues, emphasizing advancements in EDM technology and the integration of innovative multi-criteria decision-making tools.

Comprehensive Analysis of Heavy Metal Aerosol Emissions and Health Risk from the Electrical Discharge Machining Process: A Control and Mitigation Approach for Green Manufacturing

Comprehensive Analysis of Heavy Metal Aerosol Emissions and Health Risk from the Electrical Discharge Machining Process: A Control and Mitigation Approach for Green Manufacturing

Towards artificial intelligence empowered performance enhancement of EDM process using nano-graphene mixed bio-dielectric supporting the carbon neutrality and sustainable development

The growing population with every passing day sets an alarming situation with respect to the conservation climate protocols. The increasing needs of society also demand a significant enhancement in the manufacturing capacity to augment the situation. However, it's a stringent requirement of the hour to propose sustainable and clean manufacturing processes to realize the goal of carbon neutrality to support a healthy life on the earth. Specifically, the processes that are energy intensive like electric discharge machining (EDM) are of serious concern regarding sustainability viewpoint. The role of the said process cannot be essentially eliminated as advent of new materials of superior characteristics demand the application of EDM for accurate cutting of intricate profiles. Nevertheless, the commonly used oil-based dielectric (kerosene) in EDM releases aerosol, deposit particles, oxides of carbon (CO2 & CO), thus contributing to the environmental contamination. It is pertinent to mention that industries are compelled to tune their processes to achieve the goals of Net-Zero. Therefore, this study thoroughly investigates the potential of nano-graphene mixed rice bran oil to make the EDM process cleaner and sustainable which has never been investigated so far. Moreover, the process has been successfully modeled using artificial neural network (ANN) and optimized by non-dominated sorting genetic algorithm-II (NSGA-II) which is another novel aspect of this study as it eradicates the need of extensive experimentation. Experimentation has been performed via Taguchi's experimental strategy followed by a detailed explanation of the findings based on process physics. In comparison to the traditional dielectric an improvement of 98.8% in material removal rate (MRR) and 93.9% reduction in specific energy consumption (SEC) are realized if the said novel combination is applied without compromising the quality. CO2 emissions determined for both rice bran oil and kerosene oil have revealed that rice bran oil provides 99.96% lesser CO2 emission in comparison to its counterpart.

A study on die-sinking electrical discharge machining behaviour of friction stir processed AA5052/WS2 surface composite

In the present work, AA5052 alloy is reinforced with 6 vol.% of WS2 particles through friction stir process. Then, electrical discharge machining process is carried out on AA5052 alloy and friction stir processed AA5052/WS2 surface composite. The gap voltage, pulse current and pulse on time are selected as input process factors at three different levels. The material removal rate, tool wear rate and surface roughness have opted as output responses and experiments are conducted as per L27 orthogonal array. The electrical discharge machining results of AA5052 alloy revealed that the combined impact of pulse current and pulse on time exists at all gap voltages and affects significantly material removal rate compared to tool wear rate and surface roughness. The electrical discharge machining results of AA5052/WS2 surface composite revealed that the combined impact of pulse current and pulse on time is similar in material removal rate and surface roughness whereas, in tool wear rate, it is reversed. The TOPSIS technique-based optimal electrical discharge machining process factors for AA5052 alloy is Ton – 60 µs, Ip – 15 amps and Vg – 60 V and for friction stir processed AA5052/WS2 surface composite is Ton – 60 µs, Ip – 5 amps and Vg 60 V. The scanning electron microscope and energy dispersive X-ray analysis images of electrical discharge machining processed AA5052 alloy and AA5052/WS2 surface composite revealed the formation of larger and smaller craters, globules, recast layers, micro pits and cracks.