A morphological and textural analysis of Inconel-718 aerospace alloy processed through electrical discharging machining

Abstract The Inconel 718 has captured global attention for its huge applications in the aerospace and defense field. However, a limited approach is noticed to investigate this material's responses and morphological features after electrical discharge machining operation. This study wants to offer a more detailed investigating approach, including the analysis of morphological features, recast layer, microhardness, elemental composition, and several textural defects and basic responses. Scanning electron microscopy is used to investigate several textural features, defects, cracks, and recast layers. The findings claim 538 nm–2.168 µm and 14–41 µm variations in crack width and recast thickness, respectively, which increase with pulse current and pulse on-time. However, the low discharge energy can provide better micro-hardness than higher discharge conditions due to having sufficient time for flushing and heat dissipations. The recast surface and the interfaces are, respectively, 7.58%–13.16% and 22.75%–32.74% harder with low discharge condition than the intermediate and higher discharge condition. Moreover, the Energy Dispersive X-ray analysis reported the emigration of 17.81% of carbon and 0.33% of copper from the dielectric and tool during the machining.