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The surface preparation of shiny stainless steels is a must for applying esthetic paints, effective functional plasma spray coating, laser cladding, welding, etc., applications. The current work aims for effective surface roughening and erosion MRR of SS 304 work surface using SiC abrasive jet erosion and optimization of the process parameters. The response surface approach is used to design and conduct the studies using the Box–Behnken design method. The surface topography of the eroded surfaces is examined by a 2D profilometer, 3D profilometer, and scanning electron microscope (SEM). The abrasive grit size and working gas pressure greatly affect the surface roughness of SS 304 samples. The influence of the process parameters on the variation of these topographical features is analyzed and confirmed. The working jet pressure is seen to significantly impact erosion MRR. The lower working gas pressure shows a typical influence on Ra (surface preparation) and as pressure increases, erosion MRR rises, and the surface preparation mode shifts to the erosion metal removal/cutting zone. The quality of SS 304 surface prepared from SiC abrasive jet impact is characterized by 3D profilometry.

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