a comprehensive study on the effect of wire edm current intensity on the tribological behavior and energy efficiency in aluminum machining: a novel approach toward sustainable manufacturing

This study investigates the influence of discharge current variations in the wire electrical discharge machining (wedm) process on the surface properties and tribological behavior of aluminum components. five aluminum samples were machined at current levels ranging from 1 to 5 amperes, and their surface roughness, microhardness, wear resistance, and corrosion rate were evaluated. additionally, the energy consumption per unit volume of material removed was calculated. the results showed that as the current increased from 1 to 5 a, surface roughness initially rose from 1.8 µm for the reference sample to a maximum of 3.5 µm, then decreased to 2.5 µm at the highest current. surface microhardness increased from 49.8 hv in the reference sample to a maximum of 57 hv. wear and corrosion rates, key indicators of surface performance, were 9.2 mg and 0.008 mm/year under optimal conditions, compared to 18.4 mg and 0.001 mm/year in the reference sample. furthermore, specific energy consumption initially decreased but then increased at higher currents due to unstable sparks and re-melting effects. these findings provide valuable insights for optimizing electrical parameters in wedm parameters to improve the performance and sustainability of machined aluminum components.