Surface characterization of SAE 304 after WED cutting: an experimental investigation and optimization

Priyaranjan Sharma, Hargovind Soni, Sunita Sethy, Sudhansu Ranjan Das, Mohammed Y. Tharwan, Sharaf Al Sofyani, Abdel Hamid I. Mourad, Ammar Elsheikh

Research output: Contribution to journalArticlepeer-review

2 Citations (Scopus)


Stainless steel 304 is an iron-chromium-nickel-based alloy developed for structural applications. This alloy exhibits good mechanical strength along with excellent resistance to various atmospheric conditions. Due to the increasing demand for complex, precise, and high-quality structural components, the wire-electrical-discharge-cutting (WEDC) process is recommended as a powerful technique instead of conventional machine tools. The experimental layout is designed based on L27 Taguchi orthogonal array where pulse-on-time, pulse-off-time, servo voltage, and wire feed are selected as control variables. Post experimentation, roughness profile, topography, morphology, recast surface, and subsurface microhardness of the cut section of SAE 304 alloy were evaluated. Thereafter, the desirability function approach is used to find the optimum cutting conditions. The experimental investigation reveals lower profile roughness, smoother topography, no micro-cracks, least recast layer, and minimum hardness alteration under a trim-cut strategy which is found to be useful for safe, durable, and high–strength complex structural components.

Original languageEnglish
Pages (from-to)5723-5732
Number of pages10
JournalJournal of Materials Research and Technology
Publication statusPublished - Mar 1 2023


  • Morphology
  • Optimization
  • SAE 304 alloy
  • Surface roughness
  • WEDC

ASJC Scopus subject areas

  • Ceramics and Composites
  • Biomaterials
  • Surfaces, Coatings and Films
  • Metals and Alloys


Dive into the research topics of 'Surface characterization of SAE 304 after WED cutting: an experimental investigation and optimization'. Together they form a unique fingerprint.

Cite this