Experimental investigation of WEDM process parameters for the machining of as-built and heat-treated SLM AlSi10Mg

Although additive manufacturing (AM) technology offers significant advantages in terms of geometric complexity and material efficiency, the lack of optimization in post-processing procedures of advanced alloys such as AlSi10Mg, which are widely used in high-precision sectors including aerospace, automotive, and defense, remains a major limitation for sustainable production. Despite the superior mechanical properties of AlSi10Mg alloys, such as their lightweight and high strength, their machinability is not compatible with all processing techniques. This limitation directly affects the surface quality, mechanical performance, and production efficiency of components fabricated by AM. Therefore, in the present study, we systematically investigate the effects of heat treatment and Wire Electrical Discharge Machining (WEDM) input parameters on AlSi10Mg alloys. The specimens, produced by selective laser melting (SLM) and heat-treated via furnace cooling (FC), were analyzed to evaluate the influence of WEDM process parameters. An L9 orthogonal array of the Taguchi method was utilized to model these effects. Pulse-on time, pulse-off time, and wire feed rate were considered as control parameters. Material removal rate (MRR) and Surface roughness (Ra) were evaluated as response variables. Microstructural and surface characteristics of the samples were examined to evaluate the effects of process parameters. The results indicated that FC heat treatment improved microstructural homogeneity, surface quality, and machinability. According to the ANOVA results, pulse-on time was identified as the dominant factor governing both MRR and Ra, while wire feed rate showed a secondary but consistent influence, particularly on MRR. This research provides experimental data for optimizing post-processing operations by revealing the combined effects of heat treatment and WEDM parameters on AlSi10Mg alloys.