Poroś, Dariusz; Wiśniewska, Magdalena
(Scientific Journals Maritime University of Szczecin, Zeszyty Naukowe Akademia Morska w Szczecinie,
)
We propose employing wire electrical discharge machining (WEDM) for shaping thin-walled, multidirectional,
carbon fiber reinforced silicon carbide (Cf-SiC) composite parts. Ceramic matrix composite Cf-SiC combines
the outstanding mechanical properties of the carbon fiber with oxidation, abrasive wear, corrosion resistance,
and high strength at the high temperature of the silicon carbide matrix. The impact of time-related electrical
discharge machining parameters (pulse ON-time and break OFF-time) on the material removal rate and surface roughness are analyzed. The material removal rate of the Cf-SiC is proved to be 36% lower than that for
machined steel grade 55. The high thermal stresses and interaction of the composite accompanying WEDM
are also discussed. Furthermore, an alternative mechanism to the WEDM of metals has been investigated and
confirmed by a scanning electron microscopy (SEM) analysis. The morphology of the machined Cf-SiC surface
demonstrates the dominance of the carbon fibers’ fracture mechanism, both the transverse and longitudinal
forms, with interphase detachment over craters and micro-cracks, pitting, and spalling on the SiC matrix. Satisfactory roughness indicators (Sa = 2 µm) are obtained in 3D topography measurements of the Cf-SiC surfaces.
Concluding, the WEDM should be considered a good alternative to Cf-SiC abrasive machining when cutting
holes, grooves, keyways, splines, and other complex shapes.