Investigation of Electrical Discharge Machining Micro Holes in CoCrFeNiZr_0.5 Eutectic High Entropy Alloys

As one of the most promising new materials in the field of materials science, high-entropy alloys (HEAs) have attracted widespread attention due to the unique structure, exceptional properties and engineering performance, and complex composition. The CoCrFeNiZr_0.5 eutectic high-entropy alloys (EHEAs) exhibits excellent high-temperature thermal stability, ductility, creep resistance, and corrosion resistance, demonstrating great potential for applications in marine equipment. This paper explores the engineering feasibility of electrical discharge machining (EDM) of CoCrFeNiZr_0.5 EHEAs and investigates the EDM of micro-holes using a hollow copper electrode on a CNC EDM drilling machine under various machining parameters, including different gap voltage, pulse-on time, pulse-off time, and pulse amplifier settings. The effects of these parameters on the inlet diameter, outlet diameter, and recast layer of the micro holes are analyzed. The optimal micro-hole machining parameters are determined by comprehensively considering machining efficiency and electrode wear: gap voltage of 33 V, pulse-on time of 3 μs, pulse-off time of 1 μs, and pulse amplifier output of 3 A. Adopting the parameters to process a button ingot sample with a depth of 5 mm, it was found that the machining speed is 7.79 mm/min and the electrode wear is 1 cm. This research renders the foundation for further development and engineering application of CoCrFeNiZr_0.5 EHEAs in the context of high-value material design and manufacturing.