Abstract

High-entropy alloys (HEAs) have emerged as a novel class of materials exhibiting outstanding mechanical and thermal properties, making them attractive for advanced engineering applications. In this study, the machinability of the equiatomic CrCoNiFeMn HEA was investigated using Electrical Discharge Machining (EDM), with a particular focus on the effects of critical process parameters voltage, pulse-on time, discharge current and sintering temperature, the latter considered as a fabrication variable influencing material behavior. Specimens were synthesized via powder metallurgy and sintered at pressures of 40 MPa and temperatures of 800 °C and 1000 °C, respectively. A full factorial experimental design was employed to systematically analyze the influence of these parameters on material removal rate (MRR), tool wear, and surface roughness. Results indicated that Pulse-on time exhibited a direct correlation with all output metrics, leading to increased MRR, tool wear, and surface roughness. Discharge current significantly affected tool wear, with higher currents intensifying electrode degradation. Surface roughness was notably influenced by both pulse-on time and voltage. Interestingly, sintering temperature primarily affected tool wear, with samples sintered at 1000 °C demonstrating reduced wear.Quantitative analysis showed that discharge current was the most influential parameter on both material removal rate (MRR) and tool wear rate (TWR), while pulse-on time predominantly affected surface roughness.