Micro-Wire-EDM Machinability and Surface Study of the New Generation TNZT (Ti-35Nb-7Zr-5Ta) Alloy

Shahid Ali, Didier Talamona, Asma Perveen

2025

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DOI 10.1115/imece2025-166352
Data confidence 70 medium
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Abstract

Abstract Previously, titanium grade-V (Ti-6Al-4V) was considered the best biomedical, automotive, and aerospace alloy. However, researchers identified Aluminum and Vanadium toxicity in Ti-6Al-4V; moreover, it possesses a higher Young’s modulus than the new generation titanium (TNZT) alloys. Even though TNZT alloys offer lower modulus and good corrosion properties, the micromachining of these alloys with conventional methods remains a significant challenge. This study presents an experimental analysis of the μ-WEDM machinability of the Ti-35Nb-7Zr-5Ta alloy with tungsten wire of 50 μm diameter. μ-WEDM is a machining process that erodes the material from a workpiece, being electrically conductive, irrespective of its hardness. To evaluate machinability, the quality of the micro-features is assessed based on CA, KF, SR, and MH. The findings revealed that the micro-features on Ti-35Nb-7Zr-5Ta are slightly inferior at higher machining conditions, primarily due to significantly higher capacitance leading to larger spark width, increasing the size of the crater formation and surface hardness. In contrast, smoother surface finishes are achieved at lower machining conditions. At lower machining conditions, the CA, KF, SR, and MH are recorded as 18.9 μm2, 93.3 μm, 0.5 μm, and 310 HV, respectively. Furthermore, the optimal parameters are figured out by using grey relation grade (GRG) analysis post experimentation, the GRG analysis suggested that the lower capacitance (1nF) and voltage (80V) to be the optimal input parameters, and the parameters setting with higher capacitance and voltage 105 V to be the least optimal.