Investigation of Wear and Wire Electrical Discharge Machining Characteristics of Al-Mg-MoS2 Composites Using Response Surface Method

Abstract Aluminum metal matrix composites remain sophisticated materials with a broad series of applications because of their high strength-to-weight ratio, better resistance to wear and corrosion, improved high-temperature zone applications, and reasonable machinability. Furthermore, when manufactured through the powder metallurgy process, the tribological and machinability properties of aluminum-magnesium–based composites are found to be improved with the inclusion of molybdenum disulfide reinforcement. The response surface methodology technique was used for estimating the wear loss and coefficient of friction to study the tribological property. Also, it is employed in the wire electrical discharge machining (WEDM) technique, to predict material removal rate, surface roughness, and overcut. The projected values in both the wear and WEDM parameters are well within the minimal error value, according to the perturbation plot, and sufficient validation has been performed. The created model reveals that at 15 N, 2 m/s, 750 m, and 15 A, 90 µs, and 45 V, better tribology and WEDM characteristics are acquired.