Wire electrical discharge machining of magnesium alloys for process optimization surface integrity and sustainable manufacturing

Over the period of time, wire electrical discharge machining (WEDM) has steadily emerged as one of the reliable non-contact thermo-electric machining techniques. It finds wide applications in producing precision components from electrically conductive materials. Unlike conventional cutting processes, WEDM removes material through controlled electrical discharges. Due to this, WEDM enables the fabrication of intricate geometries with minimal mechanical stresses. Over the past two decades, significant efforts have been taken by the WEDM researchers to improve machining performance through the various aspects, including machine configuration, electrode materials, and parameter optimization strategies. While extensive research exists on steels, titanium alloys, and nickel-based superalloys, comparatively limited attention has been given to magnesium alloys, particularly in the context of comprehensive modelling and multi-objective optimization. Nowadays, magnesium alloys such as AZ31B and AZ91D are increasingly attractive for aerospace and lightweight structural applications. However, these magnesium alloys possess a low melting point, high thermal conductivity, and a reactive nature which introduce distinct machining challenges during WEDM. The Current review critically examines the evolution of WEDM research, with particular attention to process parameters, performance metrics, modelling techniques, and optimization frameworks. Special focus is also given on artificial intelligence-based predictive models and multi-objective optimization algorithms. In addition, the discussion extends to sustainability considerations, highlighting the importance of energy efficiency and responsible manufacturing practices in alignment with the United Nations Sustainable Development Goals (SDGs). The study identifies existing research gaps and outlines future directions for advancing the WEDM of magnesium alloys.