Nickel-based alloys are finding a wide range of applications due to their superior properties of maintaining hardness at elevated temperatures, low thermal conductivity and resistance to corrosion. These materials are used in aircraft, power-generation turbines, rocket engines, automobiles, nuclear power and chemical processing plants. Machining of such alloys is difficult using conventional processes. Wire-cut electrical discharge machining is one of the advanced machining processes, which can cut any electrically conductive material irrespective of its hardness. One of the major disadvantages of this process is formation of recast layer as it affects the properties of the machined surfaces. In this study, experimental investigation has been carried out to study the effect of wire-cut electrical discharge machining process parameters on micro-hardness, surface roughness and recast layer while machining Inconel-690 material. Interestingly, hardness of the machined surface was found to be lower than that of the bulk material. The micro-hardness and recast layer thickness are inversely related to the variation of process parameters. Recast layer thickness, surface roughness and hardness of the wire-cut electrical discharge machined surfaces of Inconel-690 are found to be in the range of 10–50 µm, 0.276–3.253 µm and 122–171 HV, respectively, for different conditions. The research findings and the data generated for the first time on hardness and recast layer thickness for Inconel-690 will be useful to the industry.
