Abstract
Ti-3Al-2.5V superalloy is a highly structural and functional material predominantly used in hydraulic tubing for aircraft like Boeing and honeycomb structures in structural applications. In this study, the Wire Electrical Discharge Machining input parameters considered for observation were Pulse on time (T_on), Pulse off time (T_off), Wire Feed (WF), and Wire Tension (WT). The output responses analyzed were kerf width (KW) and Surface Roughness (SR). Taguchi’s L₁₆ orthogonal array was used for conducting experiments. The smallest and largest kerf width values observed were 0.311 and 0.344 mm, respectively. The lowest and highest surface roughness values observed were 1.530 and 2.649 μm, respectively. Signal-to-noise ratio response and Analysis of Variance revealed that Pulse on time (T_on) was the most influential parameter affecting kerf width and surface roughness. Microstructure analysis of machined samples and wire electrodes was carried out with a Scanning Electron Microscope.

Key words
surface roughness, scanning electron microscopy, surface characterization, titanium-based superalloy, Wire EDM, kerf width

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