Investigating the Surface Characteristics of Complex Geometrical Features on Ti-6Al-4V Alloy Processed through WEDM

Muhammad Umar Farooq; Muhammad Asad Ali; Saqib Anwar; Muhammad Usman; Zulfiqar Ali

doi:10.1007/s11665-025-11961-5

Investigating the Surface Characteristics of Complex Geometrical Features on Ti-6Al-4V Alloy Processed through WEDM

Muhammad Umar Farooq^* (Co-first Author)
, Muhammad Asad Ali (Co-first Author)
, Saqib Anwar (Co-first Author)
, Muhammad Usman (Co-first Author)
, Zulfiqar Ali (Co-first Author)

^*Corresponding author for this work

Department of Mechanical Engineering

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

2 Citations (Scopus)

2 Downloads (CityUHK Scholars)

Abstract

The present study focuses on producing an interface at micro- and nano-level on complex curved and plane features of Ti-6Al-4V (α + β) alloy through wire electric discharge machining (WEDM) which simultaneously does machining and surface modification. The process parameters such as servo voltage, pulse on-time, pulse off-time and wire speed are used as input controls to comprehend the surface attributes of complex curved features at different scales. A thorough statistical, parametric, surface integrity, modified layer, layer hardening, surface porosity and surface spectroscopical analyses are carried out for a comprehensive evaluation of surface properties. Multi-attribute optimization resulted in optimized process settings S_V (70 V), P_off (40 μs), P_on (8 μs) and W_S (6 mm/s) achieving 75.51% combined desirability of both responses. The predicted and experimental results are validated under a 95% confidence interval showing less than 5% error. The optimized parametric conditions show 3.58 μm surface roughness on curved features and 3.27 μm on plane features. ©The Author(s).

Original language	English
Pages (from-to)	29120-29134
Number of pages	15
Journal	Journal of Materials Engineering and Performance
Volume	34
Issue number	24
Online published	8 Oct 2025
DOIs	https://doi.org/10.1007/s11665-025-11961-5
Publication status	Published - Dec 2025

Funding

Ongoing Research Funding program, (ORF-2025-702), King Saud University, Riyadh, Saudi Arabia.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure

Research Keywords

machining
surface modification
sustainablility
Ti-6Al-4V

Publisher's Copyright Statement

This full text is made available under CC-BY 4.0. https://creativecommons.org/licenses/by/4.0/

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10.1007/s11665-025-11961-5

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abstract = "The present study focuses on producing an interface at micro- and nano-level on complex curved and plane features of Ti-6Al-4V (α + β) alloy through wire electric discharge machining (WEDM) which simultaneously does machining and surface modification. The process parameters such as servo voltage, pulse on-time, pulse off-time and wire speed are used as input controls to comprehend the surface attributes of complex curved features at different scales. A thorough statistical, parametric, surface integrity, modified layer, layer hardening, surface porosity and surface spectroscopical analyses are carried out for a comprehensive evaluation of surface properties. Multi-attribute optimization resulted in optimized process settings SV (70 V), Poff (40 μs), Pon (8 μs) and WS (6 mm/s) achieving 75.51\% combined desirability of both responses. The predicted and experimental results are validated under a 95\% confidence interval showing less than 5\% error. The optimized parametric conditions show 3.58 μm surface roughness on curved features and 3.27 μm on plane features. {\textcopyright}The Author(s).",

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Investigating the Surface Characteristics of Complex Geometrical Features on Ti-6Al-4V Alloy Processed through WEDM. / Farooq, Muhammad Umar (Co-first Author); Ali, Muhammad Asad (Co-first Author); Anwar, Saqib (Co-first Author) et al.
In: Journal of Materials Engineering and Performance, Vol. 34, No. 24, 12.2025, p. 29120-29134.

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

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T1 - Investigating the Surface Characteristics of Complex Geometrical Features on Ti-6Al-4V Alloy Processed through WEDM

AU - Farooq, Muhammad Umar

AU - Ali, Muhammad Asad

AU - Anwar, Saqib

AU - Usman, Muhammad

AU - Ali, Zulfiqar

PY - 2025/12

Y1 - 2025/12

N2 - The present study focuses on producing an interface at micro- and nano-level on complex curved and plane features of Ti-6Al-4V (α + β) alloy through wire electric discharge machining (WEDM) which simultaneously does machining and surface modification. The process parameters such as servo voltage, pulse on-time, pulse off-time and wire speed are used as input controls to comprehend the surface attributes of complex curved features at different scales. A thorough statistical, parametric, surface integrity, modified layer, layer hardening, surface porosity and surface spectroscopical analyses are carried out for a comprehensive evaluation of surface properties. Multi-attribute optimization resulted in optimized process settings SV (70 V), Poff (40 μs), Pon (8 μs) and WS (6 mm/s) achieving 75.51% combined desirability of both responses. The predicted and experimental results are validated under a 95% confidence interval showing less than 5% error. The optimized parametric conditions show 3.58 μm surface roughness on curved features and 3.27 μm on plane features. ©The Author(s).

AB - The present study focuses on producing an interface at micro- and nano-level on complex curved and plane features of Ti-6Al-4V (α + β) alloy through wire electric discharge machining (WEDM) which simultaneously does machining and surface modification. The process parameters such as servo voltage, pulse on-time, pulse off-time and wire speed are used as input controls to comprehend the surface attributes of complex curved features at different scales. A thorough statistical, parametric, surface integrity, modified layer, layer hardening, surface porosity and surface spectroscopical analyses are carried out for a comprehensive evaluation of surface properties. Multi-attribute optimization resulted in optimized process settings SV (70 V), Poff (40 μs), Pon (8 μs) and WS (6 mm/s) achieving 75.51% combined desirability of both responses. The predicted and experimental results are validated under a 95% confidence interval showing less than 5% error. The optimized parametric conditions show 3.58 μm surface roughness on curved features and 3.27 μm on plane features. ©The Author(s).

KW - machining

KW - surface modification

KW - sustainablility

KW - Ti-6Al-4V

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Investigating the Surface Characteristics of Complex Geometrical Features on Ti-6Al-4V Alloy Processed through WEDM

Abstract

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Research Keywords

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