This study shows improved machining efficiency and reduced surface defects in Inconel using nano-SiO2, suggesting significant potential for advanced manufacturing.
Nanopowder-mixed EDM was employed to machine metals that are challenging to machine by traditional processes. In this study, Inconel 718 was machined by adding nano-SiO2 to a soybean oil dielectric with the use of magnetic field to enhance the process’s functioning. The impact of machining factors (current, pulse on time, SiO2 concentration, and magnetic field) on white layer thickness (WLT), heat-affected zone (HAZ), surface roughness (Ra), material removal rate (MRR), tool wear rate (TWR), and surface crack density (SCD) were studied. The findings demonstrated that adding nano-SiO2 to the insulating fluid improved process’s functioning, whereas the WLT and HAZ were enhanced by 37.68% and 42.16%, respectively. Also, Ra, MRR, and TWR were improved by 9.59%, 50.93%, and 66.44%, respectively, as compared to machining without powder addition. The SEM micrographs revealed that fewer cracks were produced on the workpiece’s surface with 4 g/l of added SiO2, and the SCD improved by 12.81%.
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Ghulam et al. (2025) studied this question.
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