investigation of the effects of additives kaolinite nanopowders and different gases in vegetable oil dielectric on ndpm-edm for msgnp/al-7075 composites

This study aims to investigate the influence of input parameters in wet-edm and near-dry powder mixing electrical discharge machining (nd-pmedm) on the performance of newly fabricated aluminum with microscopic slide glass nanoparticles (al-7075/msgnp) nanocomposites produced via stir-casting. the current study included air, argon, a mixture of argon and nitrogen, and freon gases, utilizing vegetable oil as the dielectric medium. kaolinite nano powders were used as an additive in nd-pmedm studies. minitab 18 software was employed to develop a mathematical model and predict the response of material removal rate, electrode wear ratio, surface roughness, and white layer thickness. the maximum material removal rates achieved in the nd-edm and ndpm-edm were 29.425 mm³/min and 15.468 mm³/min, respectively, when utilizing freon gas. the result exceeds the maximum value achieved with vegetable oil alone by 209.37%. the minimum electrode wear ratio achieved with freon gas was 0.003 when combined with vegetable oil, and 5% and 10% al2sio2(oh)4. the minimum sr recorded was 4.567 µm, achieved with the freon additive gas in the dielectric, utilizing 10a, ton of 800 µs, and vegetable oil with 0% cp. additionally, sr of 4.797 µm was noted when applying 5% al2sio2(oh)4. the sr values obtained are 19.88% and 14.13% lower than the minimum value achieved with sole vegetable oil. the sem analysis indicated a significant reduction in the average thickness of the recast white layer when employing nd-edm techniques in comparison to the conventional wet-edm method. the findings can be utilized to improve the performance and durability of components.